New Holland Skid Steer Compact Track Loader 200 Series Tier 4B (final) Service Manual (47683911) by www.heydownloads.com

SERVICE MANUAL L221 / L228 Tier 4B (final) and Stage IV 200 Series Skid Steer Loader

SERVICE MANUAL L221 / L228 Tier 4B (final) and Stage IV 200 Series Skid Steer Loader L221 PIN NEM479941 and above; L228 PIN NFM401134 and above

L221 PIN NEM479941 and above; L228 PIN NFM401134 and above

C227 / C232 Tier 4B (final) and Stage IV 200 Series Compact Track Loader C227 PIN NDM471837 and above; C232 PIN NFM402195 and above

1/2 Part number 47683911

Part number 47683911 1st edition English August 2016

SERVICE MANUAL C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

47683911 27/02/2015 EN

Link Product / Engine Product C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

Market Product Europe

Engine F5HFL463A*F001

Europe

F5HFL463A*F001

Europe

F5HFL463A*F001

Europe

F5HFL463A*F001

47683911 27/02/2015

Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.501] Exhaust Gas Recirculation (EGR) exhaust treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6

Power coupling........................................................................... 19 [19.121] Pump-drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1

Front axle system ....................................................................... 25 [25.450] Chain drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1

Rear axle system........................................................................ 27 [27.650] Chain drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1

Hydrostatic drive......................................................................... 29 [29.200] Mechanical control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.1 [29.218] Pump and motor components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.2 [29.202] Hydrostatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.3 [29.134] Two-speed assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.4

Brakes and controls .................................................................... 33 [33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1

Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 47683911 27/02/2015

[35.525] Auxiliary hydraulic valves and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5 [35.600] High flow hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6 [35.724] Front loader hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7 [35.701] Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8 [35.734] Tool quick coupler hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9

Frames and ballasting ................................................................. 39 [39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1

Wheels ...................................................................................... 44 [44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1 [44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2

Tracks and track suspension ........................................................ 48 [48.130] Track frame and driving wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.1 [48.100] Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.2 [48.134] Track tension units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.3 [48.138] Track rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.4

Cab climate control ..................................................................... 50 [50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1 [50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2

Electrical systems ....................................................................... 55 [55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.011] Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.019] Hydrostatic drive control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.036] Hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.051] Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls. . . . . . . . . . . . . . . . . . . 55.7 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 47683911 27/02/2015

[55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11 [55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.12 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.13 [55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.14 [55.518] Wiper and washer system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.15 [55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.16 [55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.17

Front loader and bucket............................................................... 82 [82.100] Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.1 [82.300] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.2

Platform, cab, bodywork, and decals ............................................. 90 [90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.154] Cab doors and hatches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3 [90.124] Pneumatically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4

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INTRODUCTION

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Contents INTRODUCTION Foreword - Important notice regarding equipment servicing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety rules - Ecology and the environment (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety rules (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety rules (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Safety rules - Personal safety (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Basic instructions - Loader arm lock and cab tilt procedure - radial lift machines (*) . . . . . . . . . . . 8 Basic instructions - Loader arm lock and cab tilt procedure - vertical lift machines (*) . . . . . . . 12 Torque - Standard torque data for hydraulics (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Basic instructions - Shop and assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Torque - Minimum tightening torques for normal assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Basic instructions - Video links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 General specification - Biodiesel fuels (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Fluids and lubricants (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 General specification - Engine oil viscosity (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Product identification - Machine orientation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

(*) See content for specific models 47683911 27/02/2015

INTRODUCTION

Foreword - Important notice regarding equipment servicing C227 C232 L221 L228

WE WE WE WE

All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel, strictly complying with the instructions given, and using, whenever possible, the special tools. Anyone who performs repair and maintenance operations without complying with the procedures provided herein shall be responsible for any subsequent damages. The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manufacturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer. In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case of damages caused by parts and/or components not approved by the manufacturer. The manufacturer reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at time of publication but are subject to change without notice. In case of questions, refer to your NEW HOLLAND CONSTRUCTION Sales and Service Networks.

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INTRODUCTION

Safety rules - Ecology and the environment WE WE WE WE

C227 C232 L221 L228

Soil, air, and water quality is important for all industries and life in general. When legislation does not yet rule the treatment of some of the substances that advanced technology requires, sound judgment should govern the use and disposal of products of a chemical and petrochemical nature. Familiarize yourself with the relative legislation applicable to your country, and make sure that you understand this legislation. Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, anti-freeze, cleaning agents, etc., with regard to the effect of these substances on man and nature and how to safely store, use, and dispose of these substances.

Helpful hints • Avoid the use of cans or other inappropriate pressurized fuel delivery systems to fill tanks. Such delivery systems may cause considerable spillage. • In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of these products contain substances that may be harmful to your health. • Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems. • Avoid spillage when you drain fluids such as used engine coolant mixtures, engine oil, hydraulic fluid, brake fluid, etc. Do not mix drained brake fluids or fuels with lubricants. Store all drained fluids safely until you can dispose of the fluids in a proper way that complies with all local legislation and available resources. • Do not allow coolant mixtures to get into the soil. Collect and dispose of coolant mixtures properly. • The air-conditioning system contains gases that should not be released into the atmosphere. Consult an air-conditioning specialist or use a special extractor to recharge the system properly. • Repair any leaks or defects in the engine cooling system or hydraulic system immediately. • Do not increase the pressure in a pressurized circuit as this may lead to a component failure. • Protect hoses during welding. Penetrating weld splatter may burn a hole or weaken hoses, allowing the loss of oils, coolant, etc.

Battery recycling Batteries and electric accumulators contain several substances that can have a harmful effect on the environment if the batteries are not properly recycled after use. Improper disposal of batteries can contaminate the soil, groundwater, and waterways. NEW HOLLAND CONSTRUCTION strongly recommends that you return all used batteries to a NEW HOLLAND CONSTRUCTION dealer, who will dispose of the used batteries or recycle the used batteries properly. In some countries, this is a legal requirement.

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

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INTRODUCTION

Safety rules WE WE WE WE

C227 C232 L221 L228

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

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

DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury. CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

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

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

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INTRODUCTION

Safety rules C232 L228

WE WE

BT09A213

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Safety rules - Personal safety WE WE WE WE

C227 C232 L221 L228

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

Thoroughly read and understand this manual and the attachment Operator’s Manual before operating this or any other equipment.

Be sure all people and pets are clear of the machine before starting. Sound the horn, if equipped, three times before starting engine.

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.

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.

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

• Disengage all clutching levers or switches. • Lower the attachment, if equipped, to the ground or raise the attachment completely and engage the cylinder safety locks. Completing these actions will prevent the attachment from lowering unexpectedly. • Engage the parking brake. • Shut off the engine and remove the key. • Wait for all machine movement to stop before leaving the operators platform. 6.

Always keep the machine in gear while travelling downhill.

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

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.

Always lower the attachment, shut off the engine, set the parking brake, engage the transmission gears, remove the key and wait for all machine movement to stop before leaving the operators platform.

10. If the attachment or machine should become obstructed or plugged; set the parking brake, shut off the engine and remove the key, engage the transmission gears, wait for all machine or attachment motion to come to a stop, before leaving the operators platform to removing the obstruction or plug. 11. Never disconnect or make any adjustments to the hydraulic system unless the machine and/or the attachment is lowered to the ground or the safety lock(s) is in the engaged position. 12. Use of the flashing lights is highly recommended when operating on a public road. 13. When transporting on a road or highway, use accessory lights and devices for adequate warning to the operators of other vehicles. In this regard, check local government regulations. Various safety lights and devices are available from your 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.

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INTRODUCTION

Basic instructions - Loader arm lock and cab tilt procedure - radial lift machines WE WE WE

C227 TIER 4B (FINAL) [NDM471837 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

DANGER Crushing hazard! Do not enter or exit the operator's compartment while the loader arms are raised or unsupported. Rest the loader arms on the ground or verify that loader arm is being supported by the loader arm strut or loader arm lock pin before entering or exiting the operator's compartment. Failure to comply will result in death or serious injury. D0168A

WARNING Crushing hazard! Loader arms are unsupported during support strut removal. Do not enter or exit the operator's compartment with an unsupported loader arm. Two persons are required during storage. One person should remove and store the support strut while the operator remains in the operator's compartment. Failure to comply could result in death or serious injury. W0077B

Raise and lock the loader arm for machine service NOTE: An instructional decal on the inside of the righthand loader arm, just above the support strut is also available. Understand the loader arm lock procedure before continuing. 1. Sit in the operator's seat, fasten the seat belt, and start the engine. 2. Press the OPERATE button to enable the hydraulics. 3. Remove the bucket or attachment from the mounting plate. 4. Park the machine on firm and level surface. 5. If an assistant is not available, turn off the engine and exit the machine. 20092924

6. Remove the support strut pin (A) and let the support strut (B) rest on the lift cylinder barrel (C).

93106848A

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INTRODUCTION

Slowly raise the loader arm until the support strut (B) falls onto the cylinder rod (D).

Stop the engine.

Pull up on the override control knob (red control knob near the right-hand side of the operator’s seat). The support strut (B) will brace against the top of the cylinder barrel (C)..

10. Ask an assistant to insert the pin (A) into the support strut (B). If an assistant is not available visually confirm that the support strut is braced against the top of the cylinder barrel before exiting the machine. 93106854A

RAIL14SSL0418AA

Tilt and lock the cab forward for machine service 1. Remove the two, rear retaining nuts, located at the rear of the cab.

931001633

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2. Pull on the hand holds at the front of the machine until the cab is completely tilted forward.

93107498

3. Confirm that the red lock tube has lowered over the cab pivot linkage. If it has the cab tilt position is now secure.

RAPH12SSL0420BA

Tilt and secure the cab for machine operation 1. Raise the red lock tube exposing the cab pivot linkage. 2. Push the cab backward into the operation position.

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3. Install the retaining nuts. Torque the nuts to 170 N·m (125 lb ft).

931001633

Unlock and lower the loader arm for machine operation WARNING Crushing hazard! Loader arms are unsupported during support strut removal. Do not enter or exit the operator's compartment with an unsupported loader arm. Two persons are required during storage. One person should remove and store the support strut while the operator remains in the operator's compartment. Failure to comply could result in death or serious injury. W0077B

NOTE: An instructional decal on the inside of the righthand loader arm, just above the support strut is also available. Understand the loader arm unlock procedure before continuing.

RAIL14SSL0418AA

Placing the support strut in the storage position requires a second person. The operator must remain in the seat during this procedure. 1. Sit in the operator's seat, fasten the seat belt, and start the engine. 2. Press the operate button to enable the hydraulics. 3. Raise the loader arm until the support strut (B) is not resting on the end of the cylinder barrel (C).

93106854A

93106848A

4. Instruct the second person to remove the support strut pin (A) and place the support strut in the stowed position and reinstall the support strut pin (A). When the second person has cleared the area, the operator may now lower the loader arm. 5. Commence work operations or park the machine and stop the engine.

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INTRODUCTION

Basic instructions - Loader arm lock and cab tilt procedure vertical lift machines WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

WARNING Crushing hazard! Do not enter or exit the operator's compartment while the loader arms are raised or unsupported. Rest the loader arms on the ground or verify that loader arm is being supported by the loader arm strut or loader arm lock pin before entering or exiting the operator's compartment. Failure to comply could result in death or serious injury. W1365A

Raise and lock the loader arm for machine service 1. Sit in the operator's seat, fasten the seat belt, and start the engine. 2. Press the operate button to enable the hydraulics. 3. Remove the bucket or attachment from the mounting plate. 4. Park the machine on a level surface.

20092924

5. Fully raise the loader arm.

RAPH14SSL0351BA

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6. Locate the loader arm lock lever on the left-hand side of the operator’s seat. 7. Rotate the lock lever toward the operator’s seat (clockwise) to engage the lock support pin(s). 8. Stop the engine.

RAIL14SSL0426AA

9. Pull up on the override control knob (red control knob near the right-hand side of the operator’s seat). The loader will brace against the lock support pin and keep the loader arm in a raised position. NOTE: Only use the override control knob to lower the loader arm in emergency situations when engine power is not available or to lower it onto the lock support pin for servicing the machine.

93107457

931001633

Tilt and lock the cab forward for machine service 1. Remove the two, rear retaining nuts, located at the rear of the cab.

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INTRODUCTION

2. Pull on the hand holds at the front of the machine until the cab is completely tilted forward.

RAPH11SSL0016BA

RAPH12SSL0420BA

3. Confirm that the red lock tube has lowered over the cab pivot linkage. If it has the cab tilt position is now secure.

Tilt and secure the cab for machine operation 1. Raise the red lock tube exposing the cab pivot linkage. 2. Push the cab backward into the operation position.

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3. Install the retaining nuts. Torque the nuts to 170 N·m (125 lb ft).

931001633

Unlock and lower the loader arm for machine operation 1. Sit in the operator's seat, fasten the seat belt, and start the engine. 2. Press the operate button to enable the hydraulics. 3. Fully raise the loader arm.

RAPH14SSL0351BA

RAIL14SSL0426AA

4. Rotate the lock lever away from the seat (counter clockwise) to retract the lock pin(s). 5. Lower the loader arm. 6. Commence work operations or park the machine and stop the engine.

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INTRODUCTION

Torque - Standard torque data for hydraulics WE WE WE WE

C227 C232 L221 L228

INSTALLATION OF ADJUSTABLE FITTINGS IN STRAIGHT THREAD O RING BOSSES 1. Lubricate the O-ring by coating it with a light oil or petroleum. Install the O-ring in the groove adjacent to the metal backup washer which is assembled at the extreme end of the groove (4). 2. Install the fitting into the SAE straight thread boss until the metal backup washer contacts the face of the boss (5). NOTE: Do not over tighten and distort the metal backup washer.

23085659

3. Position the fitting by turning out (counterclockwise) up to a maximum of one turn. Holding the pad of the fitting with a wrench, tighten the locknut and washer against the face of the boss (6).

STANDARD TORQUE DATA FOR HYDRAULIC TUBES AND FITTINGS TUBE NUTS FOR 37° FLARED FITTINGS

SIZE

TUBING OD

THREAD SIZE

TORQUE

O-RING BOSS PLUGS ADJUSTABLE FITTING LOCKNUTS, SWIVEL JIC- 37° SEATS TORQUE

4 5 6 8 10 12 14 16 20 24 32

6.4 mm (1/4 in) 7.9 mm (5/16 in) 9.5 mm (3/8 in) 12.7 mm (1/2 in) 15.9 mm (5/8 in) 19.1 mm (3/4 in) 22.2 mm (7/8 in) 25.4 mm (1 in) 31.8 mm (1-1/4 in) 38.1 mm (1-1/2 in) 50.8 mm (2 in)

7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1-1/16-12 1-3/16-12 1-5/16-12 1-5/8-12 1-7/8-12 2-1/2-12

12 - 16 N·m (9 - 12 lb ft) 16 - 20 N·m (12 - 15 lb ft) 29 - 33 N·m (21 - 24 lb ft) 47 - 54 N·m (35 - 40 lb ft) 72 - 79 N·m (53 - 58 lb ft) 104 - 111 N·m (77 - 82 lb ft) 122 - 136 N·m (90 - 100 lb ft) 149 - 163 N·m (110 - 120 lb ft) 190 - 204 N·m (140 - 150 lb ft) 217 - 237 N·m (160 - 175 lb ft) 305 - 325 N·m (225 - 240 lb ft)

8 - 14 N·m (6 - 10 lb ft) 14 - 20 N·m (10 - 15 lb ft) 20 - 27 N·m (15 - 20 lb ft) 34 - 41 N·m (25 - 30 lb ft) 47 - 54 N·m (35 - 40 lb ft) 81 - 95 N·m (60 - 70 lb ft) 95 - 109 N·m (70 - 80 lb ft) 108 - 122 N·m (80 - 90 lb ft) 129 - 158 N·m (95 - 115 lb ft) 163 - 190 N·m (120 - 140 lb ft) 339 - 407 N·m (250 - 300 lb ft)

These torques are not recommended for tubes of 12.7 mm (1/2 in) OD and larger with wall thickness of 0.889 mm (0.035 in) or less. The torque is specified for 0.889 mm (0.035 in) wall tubes on each application individually. Before installing and torquing 37 ° flared fittings, clean the face of the flare and threads with a clean solvent or Loctite cleaner and apply hydraulic sealant LOCTITE® 569 to the 37 ° flare and the threads. Install fitting and torque to specified torque, loosen fitting and retorque to specifications.

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INTRODUCTION

PIPE THREAD FITTING TORQUE

PIPE THREAD FITTING

Before installing and tightening pipe fittings, clean the threads with a clean solvent or Loctite cleaner and apply sealant LOCTITE® 567 PST PIPE SEALANT for all fittings including stainless steel or LOCTITE® 565 PST for most metal fittings. For high filtration/zero contamination systems use LOCTITE® 545.

Torque (Maximum) 13 N·m (10 lb ft) 16 N·m (12 lb ft) 22 N·m (16 lb ft) 41 N·m (30 lb ft) 54 N·m (40 lb ft)

Thread Size 1/8-27 1/4-18 3/8-18 1/2-14 3/4-14

INSTALLATION OF ORFS (O-RING FLAT FACED) FITTINGS When installing ORFS fittings thoroughly clean both flat surfaces of the fittings (1) and lubricate the O-ring (2) with light oil. Make sure both surfaces are aligned properly. Torque the fitting to specified torque listed throughout the repair manual. NOTICE: If the fitting surfaces are not properly cleaned, the O-ring will not seal properly. If the fitting surfaces are not properly aligned, the fittings may be damaged and will not seal properly. NOTICE: Always use genuine factory replacement oils and filters to ensure proper lubrication and filtration of engine and hydraulic system oils. The use of proper oils, grease, and keeping the hydraulic system clean will extend machine and component life.

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INTRODUCTION

Basic instructions - Shop and assembly C227 C232 L221 L228

WE WE WE WE

Shimming For each adjustment operation, select adjusting shims and measure the adjusting shims individually using a micrometer, then add up the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or the rated value shown on each shim.

Rotating shaft seals For correct rotating shaft seal installation, proceed as follows: 1. Before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes. 2. Thoroughly clean the shaft and check that the working surface on the shaft is not damaged. 3. Position the sealing lip facing the fluid. NOTE: With hydrodynamic lips, take into consideration the shaft rotation direction and position the grooves so that they will move the fluid towards the inner side of the seal. 4. Coat the sealing lip with a thin layer of lubricant (use oil rather than grease). Fill the gap between the sealing lip and the dust lip on double lip seals with grease. 5. Insert the seal in its seat and press down using a flat punch or seal installation tool. Do not tap the seal with a hammer or mallet. 6. While you insert the seal, check that the seal is perpendicular to the seat. When the seal settles, make sure that the seal makes contact with the thrust element, if required. 7. To prevent damage to the seal lip on the shaft, position a protective guard during installation operations.

O-ring seals Lubricate the O-ring seals before you insert them in the seats. This will prevent the O-ring seals from overturning and twisting, which would jeopardize sealing efficiency.

Sealing compounds Apply a sealing compound on the mating surfaces when specified by the procedure. Before you apply the sealing compound, prepare the surfaces as directed by the product container.

Spare parts Only use CNH Original Parts or NEW HOLLAND CONSTRUCTION Original Parts. Only genuine spare parts guarantee the same quality, duration, and safety as original parts, as they are the same parts that are assembled during standard production. Only CNH Original Parts or NEW HOLLAND CONSTRUCTION Original Parts can offer this guarantee. When ordering spare parts, always provide the following information: • Machine model (commercial name) and Product Identification Number (PIN) • Part number of the ordered part, which can be found in the parts catalog

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Protecting the electronic and/or electrical systems during charging and welding To avoid damage to the electronic and/or electrical systems, always observe the following practices: 1. Never make or break any of the charging circuit connections when the engine is running, including the battery connections. 2. Never short any of the charging components to ground. 3. Always disconnect the ground cable from the battery before arc welding on the machine or on any machine attachment. • Position the welder ground clamp as close to the welding area as possible. • If you weld in close proximity to a computer module, then you should remove the module from the machine. • Never allow welding cables to lie on, near, or across any electrical wiring or electronic component while you weld. 4. Always disconnect the negative cable from the battery when charging the battery in the machine with a battery charger. NOTICE: If you must weld on the unit, you must disconnect the battery ground cable from the machine battery. The electronic monitoring system and charging system will be damaged if this is not done. 5. Remove the battery ground cable. Reconnect the cable when you complete welding.

WARNING Battery acid causes burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately. Failure to comply could result in death or serious injury. W0111A

Special tools The special tools that NEW HOLLAND CONSTRUCTION suggests and illustrate in this manual have been specifically researched and designed for use with NEW HOLLAND CONSTRUCTION machines. The special tools are essential for reliable repair operations. The special tools are accurately built and rigorously tested to offer efficient and longlasting operation. By using these tools, repair personnel will benefit from: • Operating in optimal technical conditions • Obtaining the best results • Saving time and effort • Working in safe conditions

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Torque - Minimum tightening torques for normal assembly WE WE WE WE

C227 C232 L221 L228

METRIC NON-FLANGED HARDWARE NOM. SIZE

M4 M5 M6 M8

CLASS 8.8 BOLT and CLASS 8 NUT PLATED UNPLATED W/ZnCr

CLASS 10.9 BOLT and CLASS 10 NUT PLATED UNPLATED W/ZnCr

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

3.2 N·m (28 lb in) 6.4 N·m (57 lb in) 11 N·m (96 lb in) 26 N·m (234 lb in)

M10

37 N·m (27 lb ft)

M12

64 N·m (47 lb ft)

M16 M20 M24

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

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

52 N·m (38 lb ft) 91 N·m (67 lb ft) 225 N·m (166 lb ft) 440 N·m (325 lb ft) 762 N·m (560 lb ft)

4.2 N·m (37 lb in) 8.5 N·m (75 lb in) 15 N·m (128 lb in) 35 N·m (311 lb in) 70 N·m (51 lb ft) 121 N·m (90 lb ft) 301 N·m (222 lb ft) 587 N·m (433 lb ft) 1016 N·m (750 lb ft)

LOCKNUT CL.8 W/CL8.8 BOLT

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

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

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

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METRIC FLANGED HARDWARE NOM. SIZE

CLASS 8.8 BOLT and CLASS 8 NUT PLATED W/ZnCr

UNPLATED M4 M5 M6 M8

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

M10

40 N·m (30 lb ft)

M12

70 N·m (52 lb ft)

M16 M20 M24

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

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

CLASS 10.9 BOLT and CLASS 10 NUT

UNPLATED 3.5 N·m (31 lb in) 7.0 N·m (62 lb in) 12 N·m (105 lb in) 29 N·m (257 lb in) 57 N·m (42 lb ft) 100 N·m (74 lb ft) 248 N·m (183 lb ft) 484 N·m (357 lb ft) 838 N·m (618 lb ft)

4.6 N·m (41 lb in) 9.4 N·m (83 lb in) 16 N·m (141 lb in) 39 N·m (343 lb in) 77 N·m (56 lb ft) 134 N·m (98 lb ft) 331 N·m (244 lb ft) 645 N·m (476 lb ft) 1118 N·m (824 lb ft)

Metric Hex head and carriage bolts, classes 5.6 and up

1. Manufacturer's Identification 2. Property Class

Metric Hex nuts and locknuts, classes 05 and up

20083681

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LOCKNUT CL.10 W/CL10.9 BOLT

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

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

PLATED W/ZnCr

IDENTIFICATION

20083680

LOCKNUT CL.8 W/CL8.8 BOLT

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

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

INTRODUCTION

1. Manufacturer's Identification 2. Property Class 3. Clock Marking of Property Class and Manufacturer's Identification (Optional), i.e. marks 60 ° apart indicate Class 10 properties, and marks 120 ° apart indicate Class 8.

INCH NON-FLANGED HARDWARE NOMINAL SIZE

SAE GRADE 5 BOLT and NUT UNPLATED or PLATED SILVER

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

SAE GRADE 8 BOLT and NUT

UNPLATED PLATED W/ZnCr or PLATED GOLD SILVER

LOCKNUT GrB W/ Gr5 BOLT

LOCKNUT GrC W/ Gr8 BOLT

PLATED W/ZnCr GOLD

12 N·m 16 N·m 8 N·m (71 lb 11 N·m (97 lb (106 lb in) (142 lb in) in) in) 17 N·m 23 N·m 24 N·m 32 N·m (150 lb in) (204 lb in) (212 lb in) (283 lb in) 40 N·m 43 N·m (31 lb 57 N·m (42 lb 30 N·m (22 lb (30 lb ft) ft) ft) ft) 65 N·m 48 N·m (36 lb 68 N·m (50 lb 91 N·m (67 lb (48 lb ft) ft) ft) ft) 98 N·m 104 N·m 139 N·m 74 N·m (54 lb (73 lb ft) (77 lb ft) (103 lb ft) ft) 107 N·m 142 N·m 150 N·m 201 N·m (79 lb ft) (105 lb ft) (111 lb ft) (148 lb ft) 147 N·m 196 N·m 208 N·m 277 N·m (108 lb ft) (145 lb ft) (153 lb ft) (204 lb ft) 261 N·m 348 N·m 369 N·m 491 N·m (193 lb ft) (257 lb ft) (272 lb ft) (362 lb ft) 420 N·m 561 N·m 594 N·m 791 N·m (310 lb ft) (413 lb ft) (438 lb ft) (584 lb ft) 630 N·m 841 N·m 890 N·m 1187 N·m (465 lb ft) (620 lb ft) (656 lb ft) (875 lb ft)

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

8.5 N·m (75 lb in)

31 N·m (23 lb ft) 44 N·m (33 lb ft) 50 N·m (37 lb ft) 71 N·m (53 lb ft) 108 N·m (80 lb ft) 156 N·m (115 lb 111 N·m (82 lb ft) ft) 153 N·m (113 lb 215 N·m (159 lb ft) ft) 271 N·m (200 lb 383 N·m (282 lb ft) ft) 437 N·m (323 lb 617 N·m (455 lb ft) ft) 654 N·m (483 lb 924 N·m (681 lb ft) ft) 76 N·m (56 lb ft)

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

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INTRODUCTION

INCH FLANGED HARDWARE NOMSAE GRADE 5 BOLT and SAE GRADE 8 BOLT and INAL NUT NUT SIZE PLATED UNPLATED PLATED UNPLATED W/ZnCr or PLATED W/ZnCr or PLATED GOLD SILVER GOLD SILVER 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

9 N·m (80 lb in) 19 N·m (168 lb in) 33 N·m (25 lb ft) 53 N·m (39 lb ft) 81 N·m (60 lb ft) 117 N·m (86 lb ft) 162 N·m (119 lb ft) 287 N·m (212 lb ft) 462 N·m (341 lb ft) 693 N·m (512 lb ft)

LOCKNUT GrF W/ Gr5 BOLT

12 N·m (106 lb 13 N·m (115 lb 17 N·m (150 lb 8 N·m (71 lb in) in) in) in) 25 N·m (221 lb 26 N·m (230 lb 35 N·m (310 lb 17 N·m (150 lb in) in) in) in) 44 N·m (33 lb 47 N·m (35 lb 63 N·m (46 lb 30 N·m (22 lb ft) ft) ft) ft) 71 N·m (52 lb 75 N·m (55 lb 100 N·m (74 lb 48 N·m (35 lb ft) ft) ft) ft) 153 N·m 108 N·m (80 lb 115 N·m (85 lb 74 N·m (55 lb ft) (113 lb ft) ft) ft) 156 N·m 165 N·m 221 N·m 106 N·m (78 lb ft) (115 lb ft) (122 lb ft) (163 lb ft) 216 N·m 228 N·m 304 N·m 147 N·m (108 lb (159 lb ft) (168 lb ft) (225 lb ft) ft) 383 N·m 405 N·m 541 N·m 261 N·m (193 lb (282 lb ft) (299 lb ft) (399 lb ft) ft) 617 N·m 653 N·m 871 N·m 421 N·m (311 lb (455 lb ft) (482 lb ft) (642 lb ft) ft) 925 N·m 979 N·m 1305 N·m 631 N·m (465 lb (682 lb ft) (722 lb ft) (963 lb ft) ft)

LOCKNUT GrG W/ Gr8 BOLT

12 N·m (106 lb in) 24 N·m (212 lb in) 43 N·m (32 lb ft) 68 N·m (50 lb ft) 104 N·m (77 lb ft) 157 N·m (116 lb ft) 207 N·m (153 lb ft) 369 N·m (272 lb ft) 594 N·m (438 lb ft) 890 N·m (656 lb ft)

IDENTIFICATION Inch Bolts and free-spinning nuts

20083682

Grade Marking Examples 1 2 3

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

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

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INTRODUCTION

Inch Lock Nuts, All Metal (Three optional methods)

20090268

Grade Identification Grade Grade A Grade B Grade C

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

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

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

INTRODUCTION

Basic instructions - Video links This service manual contains video links that are viewable through the eTim service or through the Dealer Portal. Video links are denoted by the YouTube struction or through the Dealer Portal.

icon within the document, and can be viewed in the eTim service in-

The Dealer Portal video location is located under the <Service> <Training> <Tech Knowledge Program> tabs.

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General specification - Biodiesel fuels WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Biodiesel usage in NEW HOLLAND CONSTRUCTION products Introduction to Fatty Acid Methyl Ester (FAME) biodiesel FAME biodiesel, called biodiesel fuel in the following section, consists of a family of fuels derived from vegetable oils treated with methyl esters. There are two main biodiesel fuel types: Rapeseed Methyl Ester (RME) and Soybean Methyl Ester (SME). RME is a blend of rapeseed and sunflower methyl ester, and is the preferred crop in Europe. SME is the preferred crop in the United States. Biodiesel fuel is a renewable alternative fuel source. Its use and development is promoted worldwide, especially in Europe and in the United States. NOTICE: Your Selective Catalytic Reduction (SCR) system is compatible with up to 20 % biodiesel fuel (B20). Be aware that the use of biodiesel fuel that does not comply with the standards mentioned in this section could lead to severe damage to the engine, fuel system or aftertreatment system of your machine. The use of non-approved fuels may void NEW HOLLAND CONSTRUCTION Warranty coverage. Biodiesel fuel can be used to run diesel engines as pure biodiesel fuel or when blended with standard diesel fuel: • B5: indicates the blend of 5 % biodiesel and 95 % diesel fuels. • B7: indicates the blend of 7 % biodiesel and 93 % diesel fuels. • B20: indicates the blend of 20 % biodiesel and 80 % diesel fuels. • B100: indicates pure biodiesel, or 100 % biodiesel fuel. Do not use. Biodiesel fuel has several positive features in comparison with diesel fuel: • Biodiesel fuel adds lubricity to the fuel, which is beneficial in many circumstances, particularly as sulfur and aromatics are removed from the fuel. • Biodiesel has a greater cetane number and burns cleaner. • Biodiesel produces less particulate matter and reduces smoke emissions. • Biodiesel is fully biodegradable and non-toxic.

Diesel and biodiesel fuel specifications Tier 4a diesel fuel specifications are covered by the following: • ASTM D975-10, Standard Specification for Diesel Fuel Oils. (15 ppm sulfur maximum.) Biodiesel blends are covered by: • United States Diesel Fuel Specification ASTM D6751-09A allows up to 5 % biodiesel since 2009. United States fuel suppliers are allowed to use up to 5 % biodiesel fuel (B5) to supply the network. • United States Biodiesel Fuel Specification ASTM D7467-09A provides specifications for diesel and biodiesel blends from B5 to B20. Pure biodiesel (B100) specification is covered by the following requirements: • ASTM D6751-09A - Standard specification for biodiesel fuel blend stock (B100) for middle distillate fuels. NOTE: ASTM D6751 specification has been updated to improve the quality of biodiesel in the market place. Before raw oil can be converted into usable biodiesel fuel, it must undergo transesterification to remove glycerides. During the transesterification process, the oil reacts with an alcohol to separate the glycerine from the fat or vegetable oil. This process leaves behind two products: methyl ester (the chemical name for biodiesel) and glycerine (a byproduct usually sold for use in soaps or other products). 47683911 27/02/2015

INTRODUCTION

NOTICE: Biodiesel fuels approved for use in the NEW HOLLAND CONSTRUCTION equipment must be transesterified and comply with the North America Standard ASTM D6751. NOTICE: Cold Pressed Biodiesel, Cold Pressed Oil, Straight Vegetable Oil (SVO), or more generally unrefined vegetable oils used as motor fuel, are fuels that are normally made from Rapeseed oil or similar high oil content crops. These kinds of fuel are not transesterified, so they do not fulfil the ASTM D6751 requirements. There is no recognized quality standard available for these types of fuel. Therefore the use of Cold Pressed Biodiesel, Cold Pressed Oil, Straight Vegetable Oil (SVO), or more generally unrefined vegetable oils used as motor fuel are NOT APPROVED at any blend in any NEW HOLLAND CONSTRUCTION product. NOTICE: Any engine and fuel injection equipment fitted to a NEW HOLLAND CONSTRUCTION vehicle found to have run with any blend of NON-APPROVED fuel (fuel not fulfilling the specification described in the requirement ASTM D6751) will no longer be covered for Warranty by NEW HOLLAND CONSTRUCTION.

Biodiesel fuel usage conditions You must stringently follow the biodiesel fuel usage conditions. Incorrect application of the biodiesel fuel usage conditions could lead to severe damage to the engine, fuel injection equipment and aftertreatment system. The main concerns related to operation with biodiesel fuels are: • Filters and injector blockage caused by poor fuel quality. • Wear and corrosion of internal components due to water content, which affects lubricity. • Deterioration of some rubber sealing compounds in the fuel system. • Biodiesel oxidation, which can lead to the formation of deposits that can harm the fuel injection system. NOTICE: Any problem in the engine fuel injection equipment associated with non-compliance to the following conditions for biodiesel fuel handling and maintenance will not be covered for Warranty by NEW HOLLAND CONSTRUCTION. Purchase biodiesel fuel from a trusted supplier who understands the product and maintains acceptable fuel quality. It is highly recommended that you use biodiesel from BQ 9000 accredited suppliers to maintain the quality and consistency of the fuel. The BQ 9000 Quality Management Program is accredited by the National Biodiesel Board for producers and marketers of biodiesel fuel. See the National Biodiesel Board website at www.biodiesel.org for more information. The use of biodiesel blends above B5 through B20 will not void the NEW HOLLAND CONSTRUCTION warranty as long as the following conditions for biodiesel fuel handling and maintenance are stringently followed: Biodiesel fuel must be pre-blended by the supplier. Mixing biodiesel fuels on-site can result in an incorrect mixture that could damage the engine and/or fuel system. For machines using Tier 4a engines with SCR aftertreatment: 1. If the biodiesel blend stock to ASTM D6751-09A is used, special precautions need to be taken to insure that it fully complies with the following special requirements: • Group I Metals content (Sodium + Potassium) is ≤ 5 mg/kg per EN14538 as specified in the biodiesel spec. • Group II Metals content (Calcium + Magnesium) is ≤ 5 mg/kg per EN14538 as specified in the biodiesel spec. • Phosphorus content lower than specified is a mandatory requirement. Phosphorus must not exceed 4 mg/kg per ASTM D4951. 2. The resulting greater than B5 through B20 blend must not exceed 1 mg/kg for Group I Metals (Sodium + Potassium) and for Group II Metals (Calcium + Magnesium). NOTICE: For machines using Tier 4a engines with SCR aftertreatment in regions where the biodiesel blend stock is supplied to the ASTM D6751-09A standard, it is essential that evidence of compliance to the special limits for Group I Metals, Group II Metals and the reduced phosphorus content specified above be obtained on every delivery of fuel from the fuel supplier. Failure to comply with this requirement can result in damage to the SCR system which will not be covered under warranty.

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INTRODUCTION

NOTICE: NEW HOLLAND CONSTRUCTION may void your warranty if the problem is associated with poor fuel quality due to improper blending. It is the responsibility of the fuel supplier and/or yourself to ensure the right type of fuel and blend is delivered and used.

Maintenance intervals For machines using the all electronic engines with a high pressure common rail fuel system, the engine oil and filter change interval is reduced down to 50% of the standard value when using biodiesel blends greater than B5 up to B20. Please refer to the maintenance intervals specified in the Operator Manual for all engines. Check all hoses, connections and gaskets to ensure integrity and cleanliness every 3 months or 150 hours of operation, whichever comes first. Regular oil sampling is highly recommended to monitor for oil and engine deterioration. NOTE: Oil sampling kits are available from your authorized NEW HOLLAND CONSTRUCTION dealer. When switching back from biodiesel to regular #2 diesel, all fuel filter, oil and oil filter should be changed even if this falls between routine service intervals.

Storage The machine should not be stored for more than three months with biodiesel in the fuel system. For longer storage time, it is strongly suggested that only regular #2 diesel fuel is used. NOTE: If storage for longer than 3 months is necessary, the engine must be run on regular #2 diesel for a minimum of 20 h to flush the biodiesel fuel out of the fuel system prior to storage. Biodiesel is highly hygroscopic and tends to collect water more than diesel fuel. This increases the risk of algae and bacteria growth which can cause severe damage to the fuel injection system. Keep the machine fuel tanks and on-site storage tanks as full as possible to limit the amount of air and water vapors inside the tank. Drain water from the tanks at least once a week. NOTICE: Do not use biocide additives on Tier 4a engines with an exhaust aftertreatment system.

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INTRODUCTION

Fluids and lubricants C227 TIER 4B (FINAL) [NDM471837 - ] C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE WE

Fuel tank Capacity L213, L216 L218, L220, L221, C227 L228, C232 Specifications

60.5 L (16.0 US gal) 75.5 L (20.0 US gal) 95.5 L (25.5 US gal) #1 or #2 Diesel ultra-low sulfur

Cooling system Capacity L213 L216 L218, L220 L221, C227 L228, C232 Specifications

15.0 L (4.0 US gal) 15.6 L (4.2 US gal) 17.0 L (4.5 US gal) 19.0 L (5.0 US gal) NEW HOLLAND AMBRA ACTIFULL™ OT EXTENDED LIFE COOLANT

Hydraulic system Reservoir capacity System capacity: L213, L216 L218, L220, L221, C227 L228, C232 Specifications

15.0 L (3.96 US gal) 29.9 L (7.9 US gal) 38.1 L (10.0 US gal) 45.4 L (12.0 US gal) TUTELA AUTO SUPREME™ ENGINE OIL SAE 10W-30

Chain compartments Capacity - each side L213, L216 L218, L220 L221 L228 Specifications

6.25 L (6.6 US qt) 7.4 L (7.9 US qt) 26.0 L (27.5 US qt) 22.2 L (23.5 US qt) TUTELA AUTO SUPREME™ ENGINE OIL SAE 10W-30

Grease fittings As required TUTELA MOLY GREASE GR-75 (Molydisulfide)

Quantity Specifications

Engine crank case oil Capacity - with filter change L213, L216, L218, L220 L221, L228, C227, C232 Specifications

7.0 L (7.5 US qt) 8.5 L (9.0 US qt) NEW HOLLAND AMBRA UNITEK MASTERGOLD SBL CJ-4

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INTRODUCTION

Final track drive Capacity - each side Specifications

1.0 l (1.06 US qt) +/- 0.1 l (0.1 US qt) TUTELA HYPOIDE EP GEAR LUBE SAE 80W-90

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INTRODUCTION

General specification - Engine oil viscosity WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

NEW HOLLAND AMBRA UNITEK MASTERGOLD SBL CJ-4 is recommended for use in this engine. See the chart below for the recommended viscosity at ambient temperature ranges. NOTICE: DO NOT put performance additives or other oil additive products in the engine crankcase.

RAPH12SSL0417FA

(H) = Engine oil pan or coolant block heater recommended in this range.

Block

Viscosity

Temperature range

(1) (2) (3) (4) (5) (6)

API CJ–4 20W-50 10W-40 CJ–4 UNITEK to CNH MAT3521 10W-30 CJ–4 UNITEK to CNH MAT3521 API CJ–4 5W-30 0W-40 CJ–4 UNITEK to CNH MAT3521 API CJ-4 0W-40

0 - 50 °C (32 - 122 °F) -15 - 40 °C (5 - 104 °F) -15 - 30 °C (5 - 86 °F) -25 - 30 °C (-13 - 86 °F) -40 - 40 °C (-40 - 104 °F) -40 - 40 °C (-40 - 104 °F)

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INTRODUCTION

Product identification Product Identification Number (PIN). • Outside right-hand side of chassis - vertical lift

9310748611

931002296A

931007505A

• Inside left-hand side loader arm tower - radial lift

Roll Over Protective Structure (ROPS) certification plate. • Front edge (lower) inside cab.

Engine serial number plate location for Models L213 and L216 • On the fuel injection pump.

76075756

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INTRODUCTION

Engine serial number plate location for Models L218 and L220 • On the right-hand side of the engine.

RAPH12SSL0406AA

Engine serial number plate location for Models L221, L228, C227, and C232 • On the side of the Exhaust Gas Recirculation (EGR) cooler. • On top of the valve cover. • The serial number is also stamped on the engine front cover.

23119866

Bucket identification plate

BT04F026-01

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INTRODUCTION

Product identification - Machine orientation C227 C232 L221 L228

WE WE WE WE

RAPH12SSL0057BA

The terms front (1), right (2), rear (3), and left (4) are used in this manual to indicate the direction as seen from the operator's seat.

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SERVICE MANUAL Engine C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Engine - 10

[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.501] Exhaust Gas Recirculation (EGR) exhaust treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6

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Engine - 10 Engine and crankcase - 001

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Engine - 10 Engine and crankcase - 001

SERVICE Engine Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Filling (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

(*) See content for specific models 47683911 27/02/2015

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Engine - Engine and crankcase

Engine - Drain fluid WE WE WE WE

C227 TIER 4B (FINAL) [NDM471837 - ] C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

1. Remove the access cover at the rear, lower left of the machine, exposing the engine oil drain hose and remote oil filter. 2. Remove the drain plug to drain the oil. 3. When the oil has completely drained, reinstall the drain plug and torque to 68 - 82 N·m (50 - 61 lb ft).

63109370

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Engine - Engine and crankcase

Engine - Remove WE WE WE WE

C227 TIER 4B (FINAL) [NDM471837 - ] C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

The following procedure has been performed on a radial lift machine. Engine removal for vertical lift machines is very similar. Prior operation: Tilt the cab. Please see Cab tilting system - Tilt (90.150). Prior operation: Disconnect the battery. See Battery - Disconnect (55.302). Prior operation: Drain the engine oil. Please see Engine - Drain fluid (10.001). Prior operation: Drain the coolant. Please see Radiator - Drain fluid (10.400). Prior operation: Discharge the A/C system (if equipped). See Air conditioning - Discharging (50.200). 1. Remove access plate (1) for the engine oil pan from the chassis.

RAPH12SSL0233AA

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Engine - Engine and crankcase

2. Disconnect the hose (1) for the oil drain plug from the engine oil pan.

RAPH12SSL0232AA

RAIL14SSL0845BA

RAPH12SSL0075AA

3. Remove the mounting bolts for the overflow bottle. 4. Remove the overflow bottle from the chassis.

5. If equipped with A/C, disconnect the A/C lines (1) from the condenser. 6. Disconnect the fan motor (2) from the wiring harness.

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Engine - Engine and crankcase

7. Support the engine hood with a suitable lifting device. 8. Disconnect the engine hood strut (1) from the engine hood.

RAPH12SSL0074AA

RAPH12SSL0073AA

931001899

9. Remove the mounting hardware (2) from the engine hood. 10. Remove the engine hood (1) from the chassis.

11. Remove the engine cover (1) from the chassis.

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Engine - Engine and crankcase

12. Remove the air cooler (1) from the shroud.

RAPH12SSL0067AA

RAPH12SSL0065AA

13. Disconnect the upper radiator hose (1) from the radiator.

14. Disconnect the lower radiator hose (1) from the radiator. NOTE: The rear access door has been removed for picture clarity.

RAPH12SSL0083AA

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Engine - Engine and crankcase

15. Remove the radiator (2) from the shroud. 16.

RAPH12SSL0066AA

RAPH12SSL0062AA

RAPH12SSL0264AA

17. Remove the radiator fan (1) from the engine.

18. Unbolt and remove the shroud (1).

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Engine - Engine and crankcase

19. Remove the oil cooler (1).

931001884

931001896

931001895

931002030

20. Remove the mounting bolts (1) retaining the mounting flange for the muffler inlet pipe to the turbocharger.

21. Remove the retaining bolts (1) from the muffler support. 22. Remove the muffler.

23. Disconnect the air restriction sensor (1) from the wiring harness.

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Engine - Engine and crankcase

24. Loosen the hose clamps on the intake tube at both ends. 25. Remove the tube (1) for the air cleaner and turbocharger.

931001898

931001900

931001908

931001909

26. Remove the air cleaner housing (1) from the chassis.

27. Disconnect the alternator (1) from the wiring harness.

28. Disconnect the starter (1) from the wiring harness.

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Engine - Engine and crankcase

29. Disconnect the ground connection (1) below the starter (2).

931001910

RAPH12SSL0266AA

RAPH12SSL0053AA

30. Remove the oil filler neck (1) from the engine. 31. If equipped with A/C, disconnect the low pressure line (2) on the A/C compressor.

32. Disconnect the fuel return line (1) on the tank.

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Engine - Engine and crankcase

33. Disconnect the fuel feed line (1) on the fuel filter housing.

RAPH12SSL0054AA

RAPH12SSL0052AA

RAPH12SSL0055AA

34. Disconnect the engine harness connectors (1).

35. Disconnect the fuel temperature sensor (1) from the wiring harness. 36. Disconnect the fuel feed line (2) from the engine.

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Engine - Engine and crankcase

37. Place a suitable container under the remote engine oil filter lines (1). 38. Label and disconnect oil filter lines (1).

931001923

931001929

931001928

931001936

39. Place a suitable support beam (1) across the skid steer frame. 40. Tie a suitable strap (2) around the pump (3) and secure to the support beam.

41. Remove the pump mounting bolts (1).

42. Disengage the pump assembly (1) from the engine housing (2).

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Engine - Engine and crankcase

43.

DANGER Heavy parts! Support designated component(s) with adequate lifting equipment. Failure to comply will result in death or serious injury. D0018A

Attach proper lifting equipment (1) to support the engine (2).

931001944

931001933

931001943

931002114

44. Remove the front and rear engine mounts bolts (1).

45. Remove heater hose clamp (1).

46. Remove upper heater hose (1).

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Engine - Engine and crankcase

47. Remove the lower heater hose (1).

48.

931001940

931001946

WARNING Heavy object! ALWAYS use adequate lifting equipment (heavy-duty hoist, loader, or forklift) to lift the component. Failure to comply could result in death or serious injury. W0101A

Remove engine (1) from the chassis.

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Engine - Engine and crankcase

Engine - Install WE WE WE WE

C227 TIER 4B (FINAL) [NDM471837 - ] C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

The following procedure has been performed on a radial lift machine. Engine installation for vertical lift machines is very similar. 1. Attach proper lifting equipment to the front and rear of the engine, and carefully lower the engine into the chassis.

931001946

931001936

931001928

2. Orient the hydraulic pump coupler to the adapter on the engine, ensuring the attachment of the engine plate to the flywheel housing.

3. Apply LOCTITE® 243™ to the threads of the mounting bolts (1) for the hydrostatic drive assembly. 4. Install the mounting bolts and washers (1) into pump housing. Torque the mounting bolts (1) for the hydrostatic drive assembly to 87 - 117 N·m (64 - 86 lb ft).

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Engine - Engine and crankcase

5. Apply LOCTITE® 243™ to the threads of the rear mounting bolts (3) for the engine. 6. Install the two rear mounting bolts (3) and bushings for the engine. Torque the rear mounting bolt (3) to a torque of 163 - 176 N·m (120 - 130 lb ft).

931002047

931001933

931001929

931001940

7. Apply LOCTITE® 243™ to the threads of the front mounting bolts (2) for the engine. 8. Install the two front mounting bolts (2) and bushings for the engine. Torque the front mounting bolts (2) to 163 - 176 N·m (120 - 130 lb ft).

9. Verify that the mounting bolts for the pump are secure, and carefully remove support brace (4) and straps (5) from pump.

10. Connect the lower heater hose (6) to the engine.

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Engine - Engine and crankcase

11. Connect the upper heater hose (7) to the engine.

931002114

931001923

12. Connect the two remote lines (12), (13) for the oil filter.

13. Connect the fuel temperature sensor (1) to the wiring harness. 14. Connect the fuel feed line (2) to the engine.

RAPH12SSL0055AA

RAPH12SSL0052AA

15. Connect the engine harness connectors (1) to the engine.

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Engine - Engine and crankcase

16. Connect the fuel feed line (1) to the fuel filter housing.

RAPH12SSL0054AA

RAPH12SSL0053AA

RAPH12SSL0266AA

17. Connect the fuel return line (1) to the tank.

18. Install the oil filler neck (1) onto the engine. 19. If equipped with A/C, connect the low pressure line (2) onto the A/C compressor.

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Engine - Engine and crankcase

20. Connect the ground connection (1) to the mounting location located below the starter (2).

931001910

931001909

931001908

931001900

21. Connect the starter (1) to the wiring harness.

22. Connect the alternator (1) to the wiring harness.

23. Install the air cleaner housing (1) onto the chassis. Torque the bolts to 27 - 31 N·m (20 - 23 lb ft).

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Engine - Engine and crankcase

24. Install the intake tube (1) for the air cleaner and turbocharger. Torque the clamp to 3 - 4 N·m (27 - 35 lb in).

931001898

931002030

931001895

931001896

25. Connect the air restriction sensor (1) to the wiring harness.

26. Install the muffler and retaining bolts (1). Torque the mounting bolts to 27 - 31 N·m (20 - 23 lb ft).

27. Install the mounting bolts (1) retaining the mounting flange to the muffler inlet pipe and to the turbocharger. Torque the mounting bolts to 27 - 31 N·m (20 - 23 lb ft).

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Engine - Engine and crankcase

28. Install the oil cooler (1).

931001884

RAPH12SSL0264AA

RAPH12SSL0062AA

29. Install the shroud (1).

30. Apply LOCTITE® 243™ to the threads of the bolts , and install the fan (1).

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Engine - Engine and crankcase

31. Readjust the shroud if there is not 13 mm (1/2 in) of clearance (A) between the fan blades and the shroud.

RAPH14SSL0776BA

RAPH12SSL0066AA

RAPH12SSL0067AA

32. Install the radiator (1) into the shroud. Torque the bolts to 27 - 37 N·m (20 - 27 lb ft). 33. Attach the clamps to the radiator. Torque the hose clamps to 3 - 4 N·m (27 - 35 lb in).

34. Install the air cooler (1) into the shroud. Torque the bolts to 27 - 37 N·m (20 - 27 lb ft).

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Engine - Engine and crankcase

35. Install the engine cover (1) onto the chassis.

931001899

RAPH12SSL0073AA

RAPH12SSL0074AA

36. Install the engine hood (1) onto the chassis.

37. Connect the engine hood strut (1) to the engine hood.

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Engine - Engine and crankcase

38. If equipped with A/C, connect the A/C lines (1) to the condenser. 39. Connect the fan motor (2) to the wiring harness.

RAPH12SSL0075AA

RAIL14SSL0845BA

RAPH12SSL0232AA

40. Install the overflow bottle onto the chassis.

41. Connect the hose (1) for the oil drain plug to the engine oil pan.

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Engine - Engine and crankcase

42. Install access plate (1) for the engine oil pan to the chassis, and torque to 42 - 58 N·m (31 - 43 lb ft).

RAPH12SSL0233AA

Next operation: Add fluids. Please see Capacities (). Next operation: Charge the A/C system (if equipped). Please see Air conditioning - Charging (50.200).

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Engine - Engine and crankcase

Engine - Filling WE WE WE WE

C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

1. Remove the engine oil dipstick (1) to provide crankcase ventilation. NOTICE: Slowly fill to avoid flooding valve cover with oil. 2. Use an oil spout that is smaller than the engine oil fill neck (2), allowing air to pass around the oil fill neck. NOTE: Keep the oil fill spout in the upper half of the oil fill neck. 3. Slowly add the correct type and quantity of oil. Please see Capacities () for specifications. 4. Start the engine and run at low idle.

RAIL13SSL0608AA

5. Check the engine oil filter and drain plug for leaks. After 2 min, stop the engine, wait for 2 - 3 min and check the engine oil level.

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Index Engine - 10 Engine and crankcase - 001 Engine - Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - Filling (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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Engine - 10 Fuel tanks - 216

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Engine - 10 Fuel tanks - 216

SERVICE Fuel tank Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

(*) See content for specific models 47683911 27/02/2015

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Engine - Fuel tanks

Fuel tank - Drain fluid WE WE

C232 L228

1. Remove the access plate (1) for the engine oil pan.

RAPH12SSL0233AA

RAPH12SSL0344AA

2. Locate the petcock. NOTE: Engine has been removed for picture clarity. 3. Loosen the petcock, and drain the fluid into a suitable container. 4. When the tank is empty, tighten the petcock.

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Engine - Fuel tanks

5. Center and attach the access plate (1) for the engine oil pan. Torque the bolts (2) to 42 - 58 N·m (31 - 43 lb ft).

RAPH12SSL0233AA

Next operation: Clean the inside area the frame to remove any spilled fuel.

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Engine - Fuel tanks

Fuel tank - Remove WE WE

C232 L228

WARNING Fire hazard! When handling diesel fuel, observe the following precautions: 1. Do not smoke. 2. Never fill the tank when the engine is running. 3. Wipe up spilled fuel immediately. Failure to comply could result in death or serious injury. W0099A

Prior operation: Remove the engine. See Engine - Remove (10.001) Prior operation: Remove the oil cooler. See Oil cooler/Heat exchanger - Remove (35.300) 1. Drain the tank.

RAPH12SSL0344AA

RAPH12SSL0042AA

2. Disconnect the fuel level sensor (1). 3. Disconnect the fuel outlet line (2).

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Engine - Fuel tanks

4. Remove the right-hand side fuel tank bracket (1).

931002100B

RAIL15SSL0013BA

931002102B

5. Remove the left-hand side fuel tank bracket (1).

6. Carefully remove the fuel tank.

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Engine - Fuel tanks

Fuel tank - Install WE WE

C232 L228

1. Carefully install the fuel tank.

931002102B

RAIL15SSL0013BA

2. Install the left-hand side fuel tank bracket (1).

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Engine - Fuel tanks

3. Install the right-hand side fuel tank bracket (1).

931002100B

RAPH12SSL0042AA

4. Connect the fuel level sensor (1). 5. Connect the fuel outlet line (2).

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Index Engine - 10 Fuel tanks - 216 Fuel tank - Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel tank - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel tank - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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Engine - 10 Exhaust Gas Recirculation (EGR) exhaust treatment - 501

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Engine - 10 Exhaust Gas Recirculation (EGR) exhaust treatment - 501

FUNCTIONAL DATA Diesel Oxidation Catalyst (DOC) Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - Exhaust Gas Recirculation (EGR) exhaust treatment

Diesel Oxidation Catalyst (DOC) - Dynamic description C227 TIER 4B (FINAL) [NDM471837 - ] C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE WE

During normal operation, the diesel engine generates certain pollutants. Federal law regulates the levels of exhaust pollutants that a vehicle is allowed to emit. Pollutants generated in the normal operation of these engines require after-treatment. The Diesel Oxidant Catalyst (DOC) and a Particulate Matter Catalyst (PM-Catalyst) emissions system controls these pollutants. The DOC and PM-Catalyst system is an opened passage, non-serviceable, particulate filter system that allow exhaust gasses to freely flow, thus decreasing exhaust pressure and increasing engine performance. The DOC oxidizes carbon monoxide and hydrocarbons into carbon dioxide and water, and the PM-Catalyst traps particulate matter. The Engine Control Unit (ECU) monitors the inlet temperature sensor (2) and the outlet temperature sensor (3) to determine DOC efficiency. During normal operations, the DOC outlet temperature is higher than the DOC inlet temperature because of the chemical reactions inside the DOC. The ECU estimates soot accumulation in the PM-Catalyst by monitoring and recording the lambda sensor (1). The ECU also monitors the outlet temperature sensor (3) during PM-Catalyst regeneration; extreme temperatures will damage the PM-Catalyst. As soot content and exhaust temperature information are being observed and recorded, the ECU calibrates machine operation to regenerate the PM-Catalyst. Nothing is needed from the operator to perform a regeneration to the PM-Catalyst. To effectively regenerate the PM-Catalyst, the ECU must calculate a NOx to particulate matter ratio of twelve to one or higher and the exhaust temperature at the inlet of the DOC must be between 250.0 - 400.0 °C (482 - 752 °F). The PM-Catalyst does not require replacement or service after four thousand hours of usage unlike the Diesel Particulate Filter (DPF) system. The DOC and PM-Catalyst needs to be replaced when the customer notices excessive regenerations of the PM-Catalyst as well as a decrease in fuel economy.

RAPH14SSL0016FA

DOC/PM-Catalyst DOC/PM-Catalyst components (1) DOC (2) PM-Catalyst

(3) DOC outlet temperature sensor (4) DOC inlet temperature sensor

(5) Lambda sensor

dPF ON or REGEN ACTIVE notification on the instrument cluster The DOC and PM-Catalyst emissions system does not have a DPF. Fiat Power Train (FPT) added an observable regeneration process to the PM-Catalyst system to improve PM-Catalyst performance. Like other tier four, New Holland models, the operator is notified by a single audible beep and dPF ON or REGEN ACTIVE appears on the instrument cluster when the regeneration process has started. The audible beep and the dPF ON or REGEN ACTIVE notification disappears and reappears during this process. When the regeneration process is complete, dPF OFF or REGEN OFF will appear on the instrument cluster. 47683911 27/02/2015

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Engine - Exhaust Gas Recirculation (EGR) exhaust treatment

After Treatment System (ATS) Failure If the DOC and PM-Catalyst and/or Exhaust Gas Recirculation (EGR) system detects a malfunction, the ECU derates the engine output and prompts the operator to seek service for the machine by displaying ATS FAIL on the instrument cluster. The instrument cluster warning is also accompanied by a red, flashing light and an audible alarm. An ATS failure triggers one or more fault codes. Please use the Electronic Service Tool (EST) to diagnose the fault(s). Once the fault is corrected and the code is cleared, ATS FAIL, the alarm, and warning light will disappear from the instrument cluster and the machine will return to normal operations.

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RAPH13SSL0576AA

Index Engine - 10 Exhaust Gas Recirculation (EGR) exhaust treatment - 501 Diesel Oxidation Catalyst (DOC) - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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Engine - 10 Engine cooling system - 400

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Engine - 10 Engine cooling system - 400

SERVICE Radiator Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Filling (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

(*) See content for specific models 47683911 27/02/2015

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Engine - Engine cooling system

Radiator - Drain fluid WE WE WE WE

C227 TIER 4B (FINAL) [NDM471837 - ] C232 L221 L228

1. Remove the radiator cap (1).

RAIL13SSL0142AA

RAPH12SSL0083AA

2. Drain the engine coolant system by loosening the drain valve (1), and drain the coolant into a suitable container. When the radiator is empty, tighten the drain valve NOTE: Rear access door removed for picture clarity.

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Engine - Engine cooling system

Radiator - Remove WE WE WE WE

C227 TIER 4B (FINAL) [NDM471837 - ] C232 L221 L228

WARNING Burn hazard! Be very careful to avoid contact with hot fluids. If fluid is extremely hot, allow it to cool to a moderately warm temperature before proceeding. Failure to comply could result in death or serious injury. W0362A

Prior operation: Drain the coolant system. See Radiator - Drain fluid (10.400) Prior operation: Remove the air cooler. 1. Disconnect the upper radiator hose (1).

RAPH12SSL0065AA

RAPH12SSL0083AA

2. Disconnect the lower radiator hose (1). NOTE: Rear access door removed for picture clarity.

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Engine - Engine cooling system

3. Remove the 45 ° overflow hose elbow (1). NOTE: Engine hood removed for picture clarity. 4. Remove the radiator hold-down bolts (3), and remove the radiator (2).

RAPH12SSL0066AA

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Engine - Engine cooling system

Radiator - Install WE WE WE WE

C227 TIER 4B (FINAL) [NDM471837 - ] C232 L221 L228

1. Place the radiator (2) above the hydraulic oil cooler. Install the radiator hold-down bolts (3). Tighten the bolts to a torque of 27 - 37 N·m (20 - 27 lb ft). NOTE: Engine hood and rear access door removed for picture clarity. 2. Apply LOCTITE® 567™ PST PIPE SEALANT to the treads of the 45 ° overflow hose elbow (1) and install the elbow into the side of the radiator. Tighten the 45 ° overflow hose elbow (1) two to three turns past finger tight. NOTE: 45 ° overflow hose elbow (1) is to be positioned with the spout facing downward.

RAPH12SSL0066AA

RAPH12SSL0083AA

RAPH12SSL0065AA

3. Connect the lower radiator hose (1). Tighten the clamp to a torque of 3 - 4 N·m (27 - 35 lb in).

4. Connect the upper radiator hose (1). Tighten the clamp to a torque of 3 - 4 N·m (27 - 35 lb in).

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Engine - Engine cooling system

Radiator - Filling WE WE WE WE

C227 TIER 4B (FINAL) [NDM471837 - ] C232 L221 L228

1. Tighten the drain valve (1). NOTE: Rear access door removed for picture clarity.

RAPH12SSL0083AA

RAIL13SSL0142AA

RAPH12SSL0414BA

2. Remove the radiator cap (1), and add a coolant solution of 50% NEW HOLLAND AMBRA ACTIFULL™ OT EXTENDED LIFE COOLANT and 50% distilled water. 3. Install the radiator cap (1).

4. Start and run the engine until it reaches operating temperature. 5. Stop the engine and check the level of the coolant in the reservoir bottle. The coolant level must be at the cold minimum or hot maximum mark which is stamped on the reservoir bottle. 6. If the coolant level falls below the cold minimum mark, add the proper coolant solution of 50% NEW HOLLAND AMBRA ACTIFULL™ OT EXTENDED LIFE COOLANT and 50% distilled water.

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Index Engine - 10 Engine cooling system - 400 Radiator - Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator - Filling (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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Engine - 10 Fan and drive - 414

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Engine - 10 Fan and drive - 414

SERVICE Belt Tension adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(*) See content for specific models 47683911 27/02/2015

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Engine - Fan and drive

Belt - Tension adjust WE WE WE WE

C227 C232 L221 L228

NOTE: The serpentine belt does not have a tensioning procedure. Adjust the adjusting bolt to the stop on the bracket. 1. Loosen the upper and lower mounting bolts (1) on the alternator. 2. Loosen the adjusting bracket bolt (2). 3. Loosen the jam nut on the adjusting bolt, and turn the adjusting bolt (3) until bracket (4) is adjusted to the stop (as shown). 4. Torque the adjusting bracket bolt (2) to 50 N·m (37 lb ft). 5. Torque the jam nut for the adjusting bolt to 30 N·m (22 lb ft). 6. Torque the mounting bolts (1) to 50 N·m (37 lb ft).

RCPH11SSL038AAP

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Index Engine - 10 Fan and drive - 414 Belt - Tension adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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Engine - 10 Engine lubrication system - 304

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Engine - 10 Engine lubrication system - 304

SERVICE Engine oil filter Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - Engine lubrication system

Engine oil filter - Replace 1. Remove the battery cover hardware (1) and the battery cover (2).

931001637

RAIL15SSL0051AA

2. Turn the engine oil filter (1) counterclockwise to remove. 3. Turn the new oil filter (1) clockwise onto the base until the gasket makes contact with the base. Continue to tighten the filter one full turn or apply a torque of 35 N·m (26 lb ft) to the engine oil filter. NOTICE: Do not use a filter strap wrench to install the oil filter.

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Index Engine - 10 Engine lubrication system - 304 Engine oil filter - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

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.

47683911 27/02/2015 EN

SERVICE MANUAL Power coupling C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Power coupling - 19

[19.121] Pump-drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1

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Power coupling - 19 Pump-drive assembly - 121

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Power coupling - 19 Pump-drive assembly - 121

TECHNICAL DATA Pump-drive coupling Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(*) See content for specific models 47683911 27/02/2015

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Power coupling - Pump-drive assembly

Pump-drive coupling - Torque WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Component Flange bolt (1)

Toque Consumable 30 - 33 N·m LOCTITE® 243™ (266 - 292 lb in)

identification

RAPH14SSL0302BA

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Index Power coupling - 19 Pump-drive assembly - 121 Pump-drive coupling - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

47683911 27/02/2015 EN

SERVICE MANUAL Front axle system C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Front axle system - 25

[25.450] Chain drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1

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Front axle system - 25 Chain drive system - 450

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Front axle system - 25 Chain drive system - 450

SERVICE Chain drive system Change fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Axle Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Chain drive Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Measure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

(*) See content for specific models 47683911 27/02/2015

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Front axle system - Chain drive system

Chain drive system - Change fluid WE WE

L221 TIER 4B (FINAL) [NEM479941 - ] L228

1. Park the machine on a level surface. 2. Remove the fill plug (1),

RAIL13SSL0560AA

RAIL13SSL0382BA

RAIL13SSL0560AA

3. Remove the drain plug, and drain the fluid into a suitable container. 4. When the tank is empty, apply LOCTITE® 545™ to the threads of the drain plug, then install the drain plug.

5. Fill the chain tank by pouring oil into the fill plug hole. Please see Capacities () for specifications and capacities. 6. Apply LOCTITE® 545™ to the threads of the fill plug (1), then install the fill plug (1).

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Front axle system - Chain drive system

Axle - Remove L221 L228

WE WE

WARNING Jack stands can slip or fall over. Dropping, tipping, or slipping of machine or its components is possible. DO NOT work under a vehicle supported by jack stands only. Park machine on a level surface. Block wheels. Support machine with safety stands. Failure to comply could result in death or serious injury. W0069A

NOTE: The following procedure has been performed on the right, front axle. All axles are similar. 1. Drain the chain tank.

RAIL13SSL0382BA

RAIL13SSL0383BA

2. Lift the of the machine off of the ground, and support the machine with adequate equipment. 3. Remove the tire.

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Front axle system - Chain drive system

4. Support the axle with suitable lifting device. Remove the nuts (1).

RAIL13SSL0562BA

RAIL13SSL0384BA

5. Disconnect the axle from the sprocket.

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Front axle system - Chain drive system

Axle - Disassemble L221 L228

WE WE

1. Remove the snap ring.

RAIL13SSL0388BA

RAIL13SSL0387BA

RAIL13SSL0386BA

2. Remove the shim.

3. Remove the spacer.

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Front axle system - Chain drive system

4. Press the axle shaft out of the axle housing.

RAIL13SSL0389BA

RAIL13SSL0391BA

RAIL13SSL0392BA

5. Remove the inner bearing.

6. Remove the outer bearing.

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Front axle system - Chain drive system

7. Remove the seal.

RAIL13SSL0393BA

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Front axle system - Chain drive system

Axle - Assemble L221 L228

WE WE

CAUTION Burn hazard! Always wear heat-resistant protective gloves when handling heated parts. Failure to comply could result in minor or moderate injury. C0047A

Prior operation: Properly grease all bearings with NEW HOLLAND AMBRA GR-9 MULTI-PURPOSE GREASE 1. Before assembling, inspect the disc (1) and bearing cups (2) for damage. Replace if necessary.

RAIL14SSL0738BA

RAIL13SSL0396BA

2. Heat the outer bearing to 60 °C (140 °F).

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Front axle system - Chain drive system

CAUTION Hot area! Use care when working near hot components. Wear protective gloves. Failure to comply could result in minor or moderate injury. C0034A

Carefully place the outer bearing in the bearing cup.

RAIL13SSL0394BA

RAIL13SSL0395BA

RAIL13SSL0397BA

4. Install the seal.

5. Slowly drop the axle shaft into the axle housing. NOTE: The axle will easily slide through the bearing if the bearing has been heated to 60 °C (140 °F).

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Front axle system - Chain drive system

6. Press the inner bearing onto the shaft and into the housing. NOTE: The maximum pressure allowed on the bearing is 40000 N (9000 lb). 7. Do not release the pressure from the press. 8. Rotate the axle assembly three times. The axle should easily rotate with a maximum pressure of 40000 N (9000 lb) applied to the bearings. If the axle does not rotate easily, please repeat the disassembly and assembly procedure on this axle. 9. Remove the axle assembly from the press.

RAIL13SSL0385BA

RAPH14SSL0732BA

RAPH14SSL0733BA

10. Temporarily install the snap ring.

11. Measure the distance (A) between the inner face of the snap ring and the top of the bearing cone. 12. Using your measurement from step 11, select the correctly sized shim and spacer by using the table below.

Sizing table

Gap (mm) 6.84 - 6.93 6.94 - 7.03 7.04 - 7.13 7.14 - 7.23

Spacer size * #1 #2 5.3 Lg 5.8 Lg 1 1 1 1

#3 6.3 Lg

#4 6.8 Lg

Shim size ** A B 1.6 T 1.7 T 1

C 1.8 T

D 1.9 T

E 2.0 T

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Front axle system - Chain drive system

7.24 - 7.33 7.34 - 7.43 7.44 - 7.53 7.54 - 7.63 7.64 - 7.73 7.74 - 7.83 7.84 - 7.93 7.94 - 8.03 8.04 - 8.13 8.14 - 8.23 8.24 - 8.33 8.34 - 8.43 8.44 - 8.53 8.54 - 8.63

1 1 1 1 1

1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1

1 1 1 1 * Spacer length has a tolerance of +/- 0.02mm ** Shim length has a tolerance of +0.00mm / -0.04mm

13. Remove the snap ring.

RAPH14SSL0732BA

14. Install the new spacer.

RAIL13SSL0386BA

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Front axle system - Chain drive system

15. Install the new shim.

RAIL13SSL0387BA

RAIL13SSL0388BA

RAPH14SSL0734BA

16. Install the snap ring.

17. Verity that end play (A) does not exist between the spacer, shim, and snap ring. 18. If you do not find end play, please proceed to step 19. If you find end play between the spacer, shim, and snap ring, please repeat steps 11 – 17.

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Front axle system - Chain drive system

19. Measure the rolling torque of the axle by using the rolling torque tool, part number 380003339. The specification for the rolling torque is 10 - 16 N·m (7 - 12 lb ft) 14 - 26 N·m (10 - 19 lb ft). 20. If the rolling torque of the axle is not within specification, please repeat the disassembly and assembly procedure for this axle.

RAPH14SSL0735BA

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Front axle system - Chain drive system

Axle - Install L221 L228

WE WE

NOTE: The following procedure has been performed on the right, front axle. All axles are similar. 1. Insert the axle shaft into the sprocket, and position the axle assembly on the mounting bolts.

RAIL13SSL0384BA

RAIL13SSL0562BA

2. Install the nuts (1), but do not tighten.

3. Remove the lifting equipment.

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Front axle system - Chain drive system

4. The drive chain will need adjustment. Either remove the chain tank cover and proceed to step 5 or see Chain drive - Check (25.450) for alternative adjustment procedures.

RAIL13SSL0561BA

96091469

RAPH13SSL0563BA

5. Adjust the axle so the chain has 10 - 15.0 mm (13/32 19/32 in) of slack at the center (1) of the chain.

6. Apply a bead of LOCTITE® RTV SILICONE CLEAR to the bolt holes and to the chain tank opening. 7. Install the chain tank cover (1).

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Front axle system - Chain drive system

8. After adjusting the chain play, torque the nuts (1) to 224 - 264 N·m (165 - 195 lb ft).

RAIL13SSL0562BA

RAIL13SSL0383BA

RAIL13SSL0560AA

9. Install the tire. For flange nuts, torque the nuts (1) to 203.5 N·m (150 lb ft) For tapered nuts, torque the nuts (1) to 169.5 N·m (125 lb ft).

10. Fill the chain tank by remove the fill plug (1). 11. Apply LOCTITE® 545™ to the threads of the fill plug (1) before reinstalling the fill plug (1).

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Front axle system - Chain drive system

Chain drive - Check L221 L228

WE WE

Check the tension of the four drive chains after the first 250 hours of operation on a new machine or if new chains have been installed and every 500 hours of operation. 1. With the machine blocked up, rotate each tire and check for allowable movement. 0.5 - 1.5 ° or 6 - 12 mm (15/64 - 15/32 in) of movement is the acceptable range.

63107489

931002280

93109317

Drive chain adjustment 2. To adjust the final drive chains, jack up and block the complete skid steer securely off the ground.

3. Each axle drive chain is adjustable by loosening the retaining nuts (1) (left front shown) and sliding the axlehub assembly to remove the excessive slack. To tighten the chains slide the front axle-hubs forward and rear axle-hubs rearward. Torque the axle retaining hardware to 224 - 264 N·m (165 - 195 lb ft).

4. Repeat step 1.

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Front axle system - Chain drive system

Chain drive - Measure L221 L228

WE WE

1. The individual joints in a roller chain articulate as they enter and leave the sprockets. This articulation results in wear on the pins and bushings. Material that is worn away from these surfaces will cause the chain to gradually elongate. Chains do not stretch. Material is worn from pin and bushing. Critical dimensions of the chain are as follows: 1.

2X pitch

Wear plus 2X pitch

Elongation due to pin and bushing wear

96091478

96091469

Elongation is normal and may be minimized by proper lubrication and drive maintenance. The rate of wear is dependent upon: the relationship between the load and the amount of bearing area between pin and bushing, the material and surface condition of the bearing surfaces, the adequacy of lubrication, and the frequency and degree of articulation between pins and bushings. The latter is determined by the quantity of sprockets in the drive, their speeds, the number of teeth and the length of the chain in pitches. An accurate wear measurement (1) can be made by using the above illustration. Measure as closely as possible from the center of one pin to the center of another. The more pitches (pins) contained within the measurement increase the accuracy. If the measured value exceeds the nominal by more than the allowable percentage the chain should be replaced. The maximum allowable wear elongation is approximately 3 % for most industrial applications, based upon sprocket design. The allowable chain wear in percent can be calculated using the relationship: 200/ (N), where (N) is the number of teeth in the large sprocket. This relationship is often useful since the normal maximum allowable chain wear elongation of 3 % is valid only up to 67 teeth in the large sprocket. In drives having fixed center distances, chains running in parallel or where smoother operation is required, wear should be limited to approximately 1.5 %. For example, if 12 pitches (12 pins) of a #80 chain were measured and the result was 313.944 mm (12.360 in) or greater (using 3 % as the maximum allowable wear), the chain should be replaced. Anything less than 313.944 mm (12.360 in) would still be acceptable by most industrial standards.

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Index Front axle system - 25 Chain drive system - 450 Axle - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chain drive - Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chain drive - Measure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chain drive system - Change fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

47683911 27/02/2015 EN

SERVICE MANUAL Rear axle system C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Rear axle system - 27

[27.650] Chain drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1

47683911 27/02/2015

Rear axle system - 27 Chain drive system - 650

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Rear axle system - 27 Chain drive system - 650

SERVICE Chain drive system Change fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Rear axle system - Chain drive system

Chain drive system - Change fluid L221 L228

WE WE

1. Park the machine on a level surface. 2. Remove the fill plug (1),

RAIL13SSL0560AA

RAIL13SSL0382BA

RAIL13SSL0560AA

3. Remove the drain plug, and drain the fluid into a suitable container. 4. When the tank is empty, apply LOCTITE® 545™ to the threads of the drain plug, then install the drain plug.

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Rear axle system - Chain drive system

Axle - Remove L221 L228

WE WE

NOTE: The following procedure has been performed on the right, front axle. All axles are similar. 1. Drain the chain tank.

RAIL13SSL0382BA

RAIL13SSL0383BA

2. Lift the of the machine off of the ground, and support the machine with adequate equipment. 3. Remove the tire.

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Rear axle system - Chain drive system

4. Support the axle with suitable lifting device. Remove the nuts (1).

RAIL13SSL0562BA

RAIL13SSL0384BA

5. Disconnect the axle from the sprocket.

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Rear axle system - Chain drive system

Axle - Disassemble L221 L228

WE WE

1. Remove the snap ring.

RAIL13SSL0388BA

RAIL13SSL0387BA

RAIL13SSL0386BA

2. Remove the shim.

3. Remove the spacer.

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Rear axle system - Chain drive system

4. Press the axle shaft out of the axle housing.

RAIL13SSL0389BA

RAIL13SSL0391BA

RAIL13SSL0392BA

5. Remove the inner bearing.

6. Remove the outer bearing.

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Rear axle system - Chain drive system

7. Remove the seal.

RAIL13SSL0393BA

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Rear axle system - Chain drive system

Axle - Assemble L221 L228

WE WE

CAUTION Burn hazard! Always wear heat-resistant protective gloves when handling heated parts. Failure to comply could result in minor or moderate injury. C0047A

Prior operation: Properly grease all bearings with NEW HOLLAND AMBRA GR-9 MULTI-PURPOSE GREASE 1. Before assembling, inspect the disc (1) and bearing cups (2) for damage. Replace if necessary.

RAIL14SSL0738BA

RAIL13SSL0396BA

2. Heat the outer bearing to 60 °C (140 °F).

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CAUTION Hot area! Use care when working near hot components. Wear protective gloves. Failure to comply could result in minor or moderate injury. C0034A

Carefully place the outer bearing in the bearing cup.

RAIL13SSL0394BA

RAIL13SSL0395BA

RAIL13SSL0397BA

4. Install the seal.

5. Slowly drop the axle shaft into the axle housing. NOTE: The axle will easily slide through the bearing if the bearing has been heated to 60 °C (140 °F).

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Rear axle system - Chain drive system

RAIL13SSL0385BA

RAPH14SSL0732BA

RAPH14SSL0733BA

10. Temporarily install the snap ring.

Sizing table

Gap (mm) 6.84 - 6.93 6.94 - 7.03 7.04 - 7.13 7.14 - 7.23

Spacer size * #1 #2 5.3 Lg 5.8 Lg 1 1 1 1

#3 6.3 Lg

#4 6.8 Lg

Shim size ** A B 1.6 T 1.7 T 1

C 1.8 T

D 1.9 T

E 2.0 T

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Rear axle system - Chain drive system

7.24 - 7.33 7.34 - 7.43 7.44 - 7.53 7.54 - 7.63 7.64 - 7.73 7.74 - 7.83 7.84 - 7.93 7.94 - 8.03 8.04 - 8.13 8.14 - 8.23 8.24 - 8.33 8.34 - 8.43 8.44 - 8.53 8.54 - 8.63

1 1 1 1 1

1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1

1 1 1 1 * Spacer length has a tolerance of +/- 0.02mm ** Shim length has a tolerance of +0.00mm / -0.04mm

13. Remove the snap ring.

RAPH14SSL0732BA

14. Install the new spacer.

RAIL13SSL0386BA

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15. Install the new shim.

RAIL13SSL0387BA

RAIL13SSL0388BA

RAPH14SSL0734BA

16. Install the snap ring.

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Rear axle system - Chain drive system

RAPH14SSL0735BA

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Rear axle system - Chain drive system

Axle - Install L221 L228

WE WE

NOTE: The following procedure has been performed on the right, front axle. All axles are similar. 1. Insert the axle shaft into the sprocket, and position the axle assembly on the mounting bolts.

RAIL13SSL0384BA

RAIL13SSL0562BA

2. Install the nuts (1), but do not tighten.

3. Remove the lifting equipment.

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Rear axle system - Chain drive system

4. The drive chain will need adjustment. Either remove the chain tank cover and proceed to step 5 or see Chain drive - Check (25.450) for alternative adjustment procedures.

RAIL13SSL0561BA

96091469

RAPH13SSL0563BA

5. Adjust the axle so the chain has 10 - 15.0 mm (13/32 19/32 in) of slack at the center (1) of the chain.

6. Apply a bead of LOCTITE® RTV SILICONE CLEAR to the bolt holes and to the chain tank opening. 7. Install the chain tank cover (1).

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Rear axle system - Chain drive system

8. After adjusting the chain play, torque the nuts (1) to 224 - 264 N·m (165 - 195 lb ft).

RAIL13SSL0562BA

RAIL13SSL0383BA

RAIL13SSL0560AA

9. Install the tire. For flange nuts, torque the nuts (1) to 203.5 N·m (150 lb ft) For tapered nuts, torque the nuts (1) to 169.5 N·m (125 lb ft).

10. Fill the chain tank by remove the fill plug (1). 11. Apply LOCTITE® 545™ to the threads of the fill plug (1) before reinstalling the fill plug (1).

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Rear axle system - Chain drive system

Chain drive - Check L221 L228

WE WE

63107489

931002280

93109317

Drive chain adjustment 2. To adjust the final drive chains, jack up and block the complete skid steer securely off the ground.

4. Repeat step 1.

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Rear axle system - Chain drive system

Chain drive - Measure L221 L228

WE WE

2X pitch

Wear plus 2X pitch

Elongation due to pin and bushing wear

96091478

96091469

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Index Rear axle system - 27 Chain drive system - 650 Axle - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chain drive - Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chain drive - Measure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chain drive system - Change fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

47683911 27/02/2015 EN

SERVICE MANUAL Hydrostatic drive C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Hydrostatic drive - 29

[29.200] Mechanical control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.1 [29.218] Pump and motor components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.2 [29.202] Hydrostatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.3 [29.134] Two-speed assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.4

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Hydrostatic drive - 29 Mechanical control - 200

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Hydrostatic drive - 29 Mechanical control - 200

SERVICE Mechanical control Adjust - Machines with only hand controls (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Adjust - Machines with foot controls (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Hydrostatic drive - Mechanical control

Mechanical control - Adjust - Machines with only hand controls WE WE WE WE

C227 C232 L221 L228

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

NOTE: Inspect the linkage and linkage components for wear and damage before performing the following steps. Replace all worn and/or damaged parts. 1. Loosen the bolts (1) that attach the self centering dampeners. 2. Loosen the jam nuts (3), (4). 3. Rotate the rod (2) until the handles are in the correct position of 75 ° (see image 2). 4. Tighten the jam nuts (2), (3). 5. Tighten the bolts (1) that attach the self centering dampeners. 6. Repeat steps 1 – 5 on the other pump.

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23112921

23112922

Hydrostatic drive - Mechanical control

Adjust the stop bolts NOTE: The following images may or may not represent your exact machine configuration. This procedure is the same for all mechanically operated machines in any configuration. 7. Turn the stop bolt (1) out several turns. 8. Push the handle (2) forward until the pump is fully stroked. Hold the handle in this position and turn stop bolt in until it touches the casting. 9. Repeat steps 7 and 8 on the other side. 10. Start the machine, and test drive. Record the drift. NOTE: The machine should not steer in either direction more than 1.8 m (6 ft) from the centerline after traveling 30.5 m (100 ft) forward or 15.2 m (50 ft) backward. 11. If the machine does steer beyond the specifications in step 10, please repeat steps 7 – 10.

23112915

23112916

NOTE: The stop bolt should touch the casting when the pump is at full stroke.

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Hydrostatic drive - Mechanical control

Mechanical control - Adjust - Machines with foot controls WE WE WE WE

C227 C232 L221 L228

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

NOTE: Inspect the linkage and linkage components for wear and damage before performing the following steps. Replace all worn and/or damaged parts. 1. Remove the tag along the springs (1) (both sides).

23112920

23112919A

23112922

2. Loosen the jam nuts (2), (3). Rotate the control rods (6) until the handles are in the correct position of 75 ° (see image 3), then tighten the jam nuts (2), (3).

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Hydrostatic drive - Mechanical control

3. Loosen the roller (4) and position the roller (4) in the center of the cam (5). Tighten the roller (4). 4. Reinstall the tag along springs that was removed in step 1. 5. Repeat steps 2, 3 for the other pump.

23112920

RAPH12UTL0663AA

RAIL14SSL0856AA

6. Loosen the nuts (1) on the rods for the foot controls. 7. Turn the couplings (2) until you have reached a pedal angle of 17 ° (R). Please see image 6 for details. 8. Tighten the nuts (1).

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Hydrostatic drive - Mechanical control

Adjust the stop bolts NOTE: The following images may or may not represent your exact machine configuration. This procedure is the same for all mechanically operated machines in any configuration. 9. Turn the stop bolt (1) out several turns. 10. Push the handle (2) forward until the pump is fully stroked. Hold the handle in this position and turn stop bolt in until it touches the casting. 11. Repeat steps 9 and 10 on the other side. 12. Start the machine, and test drive. Record the drift. NOTE: The machine should not steer in either direction more than 1.8 m (6 ft) from the centerline after traveling 30.5 m (100 ft) forward or 15.2 m (50 ft) backward. 13. If the machine does steer beyond the specifications in step 12, please repeat steps 9 – 12.

23112915

23112916

NOTE: The stop bolt should touch the casting when the pump is at full stroke.

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Index Hydrostatic drive - 29 Mechanical control - 200 Mechanical control - Adjust - Machines with foot controls (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical control - Adjust - Machines with only hand controls (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Hydrostatic drive - 29 Pump and motor components - 218

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Hydrostatic drive - 29 Pump and motor components - 218

TECHNICAL DATA Pump General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Charge pressure relief valve - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Pressure limiter valve - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Motor General specification - Single speed motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 General specification - Two-speed motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

FUNCTIONAL DATA Pump Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Motor Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SERVICE Pump Charge pressure relief valve - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Pressure limiter valve - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Measure - Piston travel (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Motor Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

(*) See content for specific models 47683911 27/02/2015

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Disassemble - Single speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Assemble - Single speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Disassemble - Two speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Assemble - Two speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Filling (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Servo control Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

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Hydrostatic drive - Pump and motor components

Pump - General specification C227 C232 L221 L228

WE WE WE WE

Mechanical Mechanical Mechanical Mechanical

RAPH12SSL0359GA

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Hydrostatic pump Manufacturer Pump displacement Charge pump displacement Charge pump flow at 1800 RPM Charge pressure relief valve (3) Pressure limiter valve

Sauer-Danfoss 46 cm³ (2.8 in³) 22.9 cm³ (1.4 in³) 30 l (8 US gal) 24 - 25 bar (350 - 370 psi) at 1800 RPM Left-hand, forward, drive circuit (1). 360 - 378 bar (5220 - 5481 psi) Rright-hand, reverse, drive circuit (2). 360 - 378 bar (5220 - 5481 psi) Right-hand, forward, drive circuit (4). 360 - 378 bar (5220 - 5481 psi) Left-hand, reverse, drive circuit (5). 360 - 378 bar (5220 - 5481 psi)

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A - Reverse port B - Forward port T - Case drain X1 - Control Pressure, before the orifice X2 - Control Pressure, before the orifice R - Air bleed Ma - Operating pressure A Mb - Operating pressure B G - Pressure for auxiliary circuit G2 - Pressure for auxiliary circuit S - Boost suction Mg - Operating pressure G Yst - Control pressure

Port identification

Pump Charge pressure relief valve - Torque WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

Component Charge pressure relief valve (1)

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Torque Consumable 109 N·m (80 lb None ft)

Identification

23111054

Pump - Torque WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Torque Consumable 176 N·m (130 lb None ft)

Component Identification Pressure limiter valve (1)

RAPH12SSL0359GA

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Pump - General specification C227 C232 L221 L228

WE WE WE WE

RAPH13SSL0964FA

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Hydrostatic pump Manufacturer Pump displacement Charge pump displacement Charge pump flow Charge pressure relief valve (5) Pressure limiter valve identification

Bosch Rexroth 35 cm³ (2.1 in³) 14.9 cm³ (0.9 in³) 40 l (10.5 US gal) 24 - 26 bar (347 - 377 psi) Right-hand, forward, drive circuit (1). 350 - 370 bar (5075 - 5365 psi) Left-hand, forward, drive circuit (2). 350 - 370 bar (5075 - 5365 psi) Left-hand, reverse, drive circuit (3). 350 - 370 bar (5075 - 5365 psi) Right- hand, reverse, drive circuit (4). 350 - 370 bar (5075 - 5365 psi)

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A - Reverse port B - Forward port T - Case drain port X1 - Control Pressure, before the orifice X2 - Control Pressure, before the orifice R - Air bleed Ma - Operating pressure for port A Mb - Operating pressure for port B G - Pressure for auxiliary circuit G2 - Pressure for auxiliary circuit S - Boost suction Mg - Operating pressure for port G Yst - Control pressure

Port identification

Pump - Torque WE WE WE WE

C227 C232 L221 L228 TIER 4B (FINAL) [NFM401134 - ]

Component Charge pressure relief valve (1)

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Torque 69 N·m (51 lb ft)

Identification

RAPH13SSL0964FA

Pump Pressure limiter valve - Torque C227 C232 L221 L228 TIER 4B (FINAL) [NFM401134 - ]

WE WE WE WE

Electro Electro Electro Electro

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hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Consumable None

Hydrostatic drive - Pump and motor components

Torque Consumable 249 N·m (184 lb None ft)

Component Identification Pressure limiter valve (1)

RAPH13SSL0964FA

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Motor - General specification - Single speed motor 200 Series Compact Track Loaders 200 Series Skid Steer Loaders

WE WE

RAPH14SSL0039FA

Motor Manufacturer Displacement Brake release pressure Flushing valve setting Port identification

Bosch-Rexroth 325 cm³ (20 in³) 11 - 15 bar (160 - 218 psi) 19.0 - 21.0 bar (276 - 305 psi) A - Main port B - Main port L - Case drain Z - Brake release

Motor - General specification - Two-speed motor L221 L228

WE WE

RAPH14SSL0041JA

Motor Manufacturer Displacement Brake release pressure Flushing valve setting

Bosch-Rexroth 325 cm³ (20 in³) 11 - 15 bar (160 - 218 psi) 19.0 - 21.0 bar (276 - 305 psi)

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A - Main port B - Main port L - Case drain Z - Brake release X - Two-speed port

Port identification

Motor - General specification C227 C232

WE WE

RAPH14SSL0033EA

Motor Manufacturer Displacement Brake release pressure Fluid specification for the planetary gear case Port identification

Bonfiglioli 33.1 - 50.8 cm³ (2.0 - 3.1 in³) 13 bar (189 psi) 1.3 L (1.4 US qt) of TUTELA HYPOIDE EP GEAR LUBE SAE 80W-90 oil 1 – Oil filling and draining plug 2 – Oil level plug P1 – Service P2 – Service Ps – Two-speed control Pp – Mechanical brake pilot Dr – Drain

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Pump - Dynamic description WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

The hydrostatic pump is an axial piston pump with the ability to vary the rate and the direction of the oil flow. The change of flow is accomplished by changing the position of the hydrostatic pump's swash plate (2). The angle of the swash plate (2) causes the pistons (1) to stroke in and out of the cylinder block bores as the swash plate (2) rotates. Changing the angle of the swash plate (2) varies the piston stroke and the amount of oil being pumped to the drive motor. Tilting the swash plate (2) in the opposite direction reverses the flow to the drive motor which changes the direction of drive motor’s rotation.

RAIL14SSL0010BA

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Motor - Dynamic description WE WE

L221 TIER 4B (FINAL) [NEM479941 - ] L228

The drive motor is actually a radial piston pump. There are two main parts within a radial piston pump: The rollers (A) and the stationary cam ring (B). As displayed in image 1, high pressure oil from the hydrostatic pump enters port 1 of the drive motor. This oil enters a cavity above the rollers. As the cavities fill with oil, the rollers are forced to move down the cam ring. The rollers are connected to an assembly, and this roller assembly is attached to the output shaft, so spinning the roller assembly spins the output shaft. As the rollers travel up the cam ring, oil is sent back to the hydrostatic pump though port 2. Changing the direction of the oil being sent to the motor, i.e., sending oil to port 2 instead of port 1 changes the rotational direction of the roller assembly, which changes the direction of the output shaft.

RAPH14SSL0034BA

RAPH14SSL0035AA

The drive motor is available in one-speed or two-speed. Image 2 is an example of the two-speed functionality. In image 1, the high pressure oil from the hydrostatic pump enters every roller, giving that motor a low speed and maximum torque. In image 2, the high pressure oil enters every other roller. Because the hydrostatic pump sends the same amount of oil to half of the rollers during two-speed travel, the roller assembly spins twice as fast, but because half of the rollers are receiving oil, the motor also has half of the torque.

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Motor - Dynamic description WE WE

C227 C232

The motor is a fixed displacement pump with axial pistons. Inside the pump are a number of pistons (2) connected to a rotating cylinder block (3). The base of the pistons (2) sit diagonally on the fixed cam plate (1). When high pressure oil enters the pump, the piston (2) is at top dead center. The high pressure oil pushes the piston (2) and fills the cylinder. As oil fills the cylinder, the piston (2) descends the plane of the fixed cam plate (1), which spins the rotating cylinder block (3) and the output shaft. This process is called the reciprocation cycle. As the rotating cylinder block (3) continues to spin, the piston (2) ascends the plane of the fixed cam plate (1) and pushes oil out of the pump. This process is called the discharge cycle. RAPH14SSL0332BA

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Pump Charge pressure relief valve - Pressure test WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Hydraulic fluid can also infect a minor cut or opening in the skin. Serious infection or reaction can result without immediate medical treatment. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0358A

DANGER Crushing hazard! Always install the safety lock before working under the raised attachment. Failure to comply will result in death or serious injury. D0075A

RAPH12SSL0392AA

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3. Connect a 41 bar (600 psi) pressure gauge, part number 380500129, to the test port for charge pressure, or connect a T-fitting (1) to an outlet hose for the charge pump and attach a 41 bar (600 psi) pressure gauge , part number 380500129, to the T-fitting. Please see the table below for recommended testing areas or see Pump - General specification (29.218) for specifications about the pumps. Recommended testing areas for charge pressure Models (mechanically controlled): L213, L215, L216, 218, L220

RAPH12SSL0420AA

RAPH12SSL0421AA

RAPH12SSL0424AA

Models (mechanically controlled): L221, L223, L225, L228, L230, C227, C232, C238

Models (electro-hydraulic controlled): All models

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4. Start the machine and run at high idle.

931007504

RAPH12SSL0422AA

5. Read the pressure gauge and record the charge pressure reading. Stop the engine. NOTE: Image 6 is an example of a pressure reading. Image 6 may not match your reading. 6. The pressure reading must be approximately 24 bar (350 psi). Please see Pump - General specification (29.218) for general specifications about the hydrostatic pumps.

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Pump Pressure limiter valve - Pressure test WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

DANGER Crushing hazard! Always install the safety lock before working under the raised attachment. Failure to comply will result in death or serious injury. D0075A

NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: You will need two people to perform this test. NOTE: An error code may appear on the instrument cluster during this test. When the unit is shut down and all connections are returned to normal, the fault code will be stored as inactive. This fault can be cleared by using the Electronic Service Tool (EST). 1. Raise the machine off of the floor until the tires/tracks are not touching. Support the machine with proper lifting equipment. NOTICE: This is a safety precaution if the parking brakes fail to hold. 2. Connect a 690 bar (10000 psi) pressure gauge, part number 380500129, to the test port of the circuit you wish to test. Please see the chart below for port identification, or see Pump - General specification (29.218) for specifications on the hydrostatic pumps. NOTE: Not all pressure test ports on the hydrostatic drive assembly are easily accessible. Remember, you can test all four pressure limiter valves by plugging a pressure gauge into the most available pressure test port and exchanging pressure limiter valves. Test port identification for the pressure limiter valves Mechanical controls Models: L213, L215, L216, L218, L220 Pressure port M3 (1) for port C Pressure port M2 (2) for port B NOTE: Port M2 located under the pump assembly. Pressure port M4 (3) for port D Pressure port M1 (4) for port A

RAPH12SSL0357HA

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Mechanical controls Models: L221, L223, L225, L228, L230, C227, C232, C238 Pressure port (1) for port C Pressure port (2) for port D Pressure port (3) for port A Pressure port (4) for port B

RAPH12SSL0359GA

RAPH15SSL0110BA

Electro Hydraulic (EH) controls Models: All models Pressure port MB (1) for port B Pressure port MB (1) for port B Pressure port MA (2) for port A Pressure port MA (2) for port A NOTE: Ports MA are located under the pump assembly.

3. Disconnect and cap the brake lines and fittings. NOTE: Image 4 may not match your machine. Please see Parking brake control valve or manifold - General specification (33.110) for specifications on the parking brake control valve.

RAPH12SSL0392AA

931007504

4. Start the machine and adjust the throttle to high idle. NOTE: If equipped with two speed drive motors, press the two speed button to activate the two speed option.

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5. Slowly move the correct control lever for the corresponding hydrostatic pump in the correct position. 6. Watch the pressure gauge until the pressure stops increasing. When the pressure gauge stops increasing, record the value on the pressure gauge and move the control lever to neutral. NOTE: To prevent overheating, do not pressurize the system for an extended period of time. 7. Refer to Pump - General specification (29.218) for specifications on the hydrostatic pumps. 8. Retest the circuit after repair.

RAPH12SSL0407AA

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Pump - Test WE WE WE WE

C227 C232 L221 L228

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

DANGER Crushing hazard! Always install the safety lock before working under the raised attachment. Failure to comply will result in death or serious injury. D0075A

Checking the charge pressure NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: You will need two people to perform this test. NOTE: An error code may appear on the Instrument Cluster during this test. When the unit is shut down and all connections are returned to normal, the fault code will be stored as inactive. This fault can be cleared using the Electronic Service Tool (EST). 1. Raise the machine off of the floor until the tires are not touching. Support the machine with proper lifting equipment. NOTICE: This is a safety precaution if the parking brakes fail to hold. 2. Disconnect and cap the brake lines and fittings. NOTE: Image 1 may not match your machine. Please see Parking brake control valve or manifold - General specification (33.110) for specifications on the parking brake control valve.

RAPH12SSL0392AA

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3. Install a T-fitting (1) at the charge pump outlet. NOTE: Image 2 is an example of a pressure reading. Image 2 may not match your reading. 4. Disconnect and cap the servo inlet line. 5. Connect a hose with a 41 bar (600 psi) pressure gauge (2), part number 380500128, from the T-fitting outlet (1) to the servo inlet (3).

RAPH12SSL0423AA

RAPH12SSL0422AA

6. Start the machine and run at high idle. NOTE: If equipped with two-speed drive motors, press and hold the two-speed button. 7. Record the charge pressure with the control levers in the neutral position on the data collection sheet located on the following page. NOTE: Image 3 is an example of a pressure reading. Image 3 may not match your reading. 8. Gently move one control lever in the forward position. Watch for the pressure drop on the pressure gauge. Record the pressure drop on the data collection sheet located on the following page. Return the control lever to the neutral position. NOTE: Always maintain the engine RPM for this test. Do not move the control levers to a point where a load is put on the engine. A load on the engine will lower the engine speed and create a difference in pump flow. A difference in pump flow will effect your readings and the accuracy of this test. 9. Gently move the same control lever in the reverse position. Watch for the pressure drop on the pressure gauge. Record the pressure drop on the data collection sheet located on the following page. Return the control lever to the neutral position. 10. Repeat steps 8 and 9 on the other pump and control lever.

Results Review the recorded results on the data collection sheet located on the following page. With the engine speed set and maintained at a high idle, the maximum pressure drop between the system in neutral and the system in forward or reverse must be 2.1 bar (30 psi) or less. Any pressure drop greater than 2.1 bar (30 psi) could indicate an excessive leak in the hydrostatic system, which will require more diagnosis of the hydrostatic system.

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Data collection sheet Front pump bar (psi)

Neutral ___________ Forward __________ Reverse __________

Rear pump bar (psi)

Neutral ___________ Forward __________ Reverse __________

Notes:

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Pump - Disassemble WE WE WE WE

C227 C232 L221 L228

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Some types of failures will require the disassembly of the tandem pump for cleaning and inspection. If there is failure in the drive motors or tandem pump, disassemble both the rear and front pumps, the drive motors, and all hoses between the pumps and drive motors. 1. Remove the bolts that fasten the pumps together.

83111565

83111566

83111567

2. Remove the nut and bracket from the stud.

3. Separate the pumps (1).

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4. Remove the two O-rings (1) and back-up ring (2).

83111568

83111569

83111570

83111571

5. Remove the charge pump cover. Note the position of the charge pump cover pin (1) for use during assembly.

6. Remove the coupling from the inner gear.

7. Remove the inner gear from the outer gear.

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8. Remove the outer gear from the charge pump cover.

83111572

83111573

9. Remove the bolt stud.

10. Remove the special bolts from the cover.

83111574

83111575

11. Remove the cover, the gasket, and the shaft assembly.

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12. Remove the swash plate.

83111576

83111577

83111578

83111579

13. Remove the retainer and the pistons.

14. Remove the guide.

15. Remove the cylinder block. NOTE: Do not disassemble the cylinder block.

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16. Do not lose the three pins (1) that are inserted into the cylinder block. They must stay in position.

83111580

83111581

83111582

83111583

17. Remove the wear plate.

18. Remove the gasket.

19. Remove the snap ring from the seal.

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20. Fasten the cover in a vise with soft jaws. Use a prybar to remove the seal.

83111584

83111585

83111586

83111587

21. Remove the snap ring from the groove, just above the ball bearing.

22. Push the shaft out of the cover. Inspect the bearing on the shaft. Replace if necessary.

23. Inspect the bearings (1) on the cover. If the tan surface has worn through to the dark base, use new bearings.

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24. Remove the screws from the cover.

83111588

83111589

83111590

83111591

25. Pull out the piston assembly from the housing.

26. Remove and discard the gasket.

27. Fasten the piston assembly in a vise with soft jaws. Hold the special bolt in place. Remove the special nut. Ensure that the special bolt does not turn while removing the special nut.

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28. Measure the distance between the top of the special bolt and the cover. Record that measurement.

83111592

83111593

83111594

83111595

29. Thread the cover counterclockwise until it is removed from the special bolt. 30. Fasten the piston in a vise with soft jaws. Hold the adjusting nut in place. Loosen the jam nut.

31. Hold the special bolt in place. Tighten the adjusting nut to push the outer spring guide down, and away from the retaining ring.

32. Remove the retaining ring. NOTE: The retaining ring will be difficult to remove.

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33. Hold onto the end of the special bolt and pull out the spring assembly.

83111596

83111597

83111598

83111599

34. Thread the jam nut (1) and the adjusting nut (2) counterclockwise until they are removed from the special bolt. Separate the outer spring guide (3), spring (4), sleeve, and inner spring guide (5) from the special bolt.

35. Remove the piston from the housing. Remove and discard the O-rings, and the piston rings from each end of the piston (1).

36. Remove the screws from the cover.

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37. Remove the cover and discard the gasket.

83111600

83111601

83111602

83111603A

38. Go to the spool assembly. Mark the position of where the stop bracket is bolted. Repeat for the other side.

39. Remove the bolts and the spool assembly from the housing.

40. Remove the sleeve from the housing.

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41. Remove the lock nut and washer from the spool.

83111604

83111605

83111606

83111607

42. Remove and discard the backup ring (1) and O-ring (2) from the spool.

43. Remove and discard the backup ring (1) and O-ring (2) from the sleeve.

44. Remove the hex plug and shims for the charge pressure relief valve.

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45. Remove the shims from the hex plug. Save the shims for later use.

83111608

83111609

83111610

83111611

46. Remove the spring.

47. Remove the valve poppet with a slide hammer.

48. Mark the hex plug that is used for the circuit reliefcheck valve.

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49. Remove the hex plug.

83445485

83111612A

83111613A

83111614B

50. Remove the spring.

51. Remove the circuit relief-check valve.

52. Loosen the bypass valve.

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53. Thread the bypass valve counterclockwise until it is removed.

83111615C

83115460

83115461

54. Remove and discard the O-ring (1) and backup ring (2).

55. Remove the plug.

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Pump - Measure - Piston travel WE WE WE WE

C227 C232 L221 L228

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

1. Measure the free travel between the shoes and the pistons. If all of the measurements are not equal to approximately 0.13 mm ( 0.005 in), use a new cylinder assembly.

83115462

83115463

2. Measure the thickness of each shoe. If the measurements are not equal to approximately 0.02 mm ( 0.0001 in), use a new cylinder assembly.

3. Check the fit of the pistons in the bores. The piston must move freely with minimum clearance. Use a new cylinder assembly as necessary. 4. Measure the gear tip clearance between the inner gear and the outer gear. Clearance must not be more than 0.13 mm ( 0.005 in). 5. Measure the width of the inner gear and the outer gear. The width of each gear must be equal to within 0.05 0.06 mm ( 0.002 - 0.003 in).

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Hydrostatic drive - Pump and motor components

Pump - Assemble WE WE WE WE

C227 C232 L221 L228

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

NOTE: Some of the photos in the following procedure may appear slightly different than the model you are repairing. The procedure is the same. 1. Install the plug. Tighten the plug to a torque of 0.9 1.3 Nm (8 - 12 lb in).

83115461Z

83115460Z

83111615L

2. Slide a new backup ring (2) and O-ring (1) into the grooves of the bypass valve.

3. Thread the bypass valve into the housing.

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4. Tighten the bypass valve to a torque of 9 - 13 Nm (84 - 120 lb in)

83111614Q

83111613H

83111612T

83445485V

5. Thread the circuit relief-check valve into the housing.

6. Insert the spring on top of the circuit relief-check valve.

7. Thread the plug on top of the spring. Tighten the plug to a torque of 115 - 230 Nm ( 85 - 170 lb ft).

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8. Use a slide hammer to insert the valve poppet into the housing for the charge pressure relief valve.

83111610T

83111609S

9. Insert the spring on top of the valve poppet.

10. Insert the necessary quantity of shims into the hex plug. Thread the hex plug on top of the spring. Tighten but do not overtighten.

83111607-

83111606H

11. Slide a new O-ring (2) and backup ring (1) into the grooves of the sleeve.

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12. Slide a new O-ring (2) and backup ring (1) into the grooves of the spool.

83111605S

83115464G

83111604P

83111603PNA55

13. Insert the spool into and through the stop bracket.

14. Slide the washer and nut onto the protruding threads of the spool. Hold the spool assembly in place. Tighten the nut, but do not overtighten.

15. Lubricate the sleeve. Insert the sleeve into the housing. Ensure that the notch on the end of the sleeve is properly aligned with the notch inside housing.

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16. Lubricate the spool. Insert the spool inside the sleeve.

83115465H0

83111602AS

83111600HJ

83111599FUG

17. Ensure the marks are in alignment. Secure the spool assembly with two bolts.

18. Place the new gasket and cover onto the rim of the housing.

19. Secure the cover with screws.

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20. Slide the inner spring guide (5), sleeve, spring (4), outer spring guide (3), the adjusting nut (2), and the jam nut (1) onto the special bolt.

83111597I

83115466GH

83111598P

83111596RQWE

21. Hold the bolt assembly in place. Tighten the adjusting nut to begin compression of the spring.

22. Insert one new ring (2) and one O-ring (1) into the grooves on each end of the piston.

23. Fasten the piston in a vise with soft jaws. Hold onto the end of the of the special bolt to insert the spring assembly into the piston.

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24. Hold the special bolt in place. Tighten the adjusting nut until the outer spring guide is below the groove. This will allow space for the retaining ring.

83111594FHJ

83115467DB

83111594G

83115468KIJ

25. Install the retaining ring onto the spring assembly.

26. Slightly loosen the special bolt. Ensure that the spring and adjusting nut do not become loose.

27. Hold the adjusting nut and special bolt in place. Tighten the jam nut. Recheck the special bolt and spring. Verify that the spring did not become loose.

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28. Lubricate the piston with clean oil. Slide the piston into the housing.

83115469HY

83115470TRY

83115471GH

83111588SD

29. Slide a new gasket and cover onto the special bolt.

30. During disassembly, the measured distance between the top of the special bolt and cover. Thread the cover up or down the special bolt until the distance is equal to that recorded measurement.

31. Secure the cover with four screws. Tighten the screws to the torque of 11 - 15 Nm ( 96 - 132 lb in).

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Hydrostatic drive - Pump and motor components

32. Hold the special bolt in place. Slide the special nut (with the sealing surface side down) onto the special bolt. Tighten the special nut, but do not overtighten.

83115472DFH

83115473MIO

83115474KO

83115475DR

33. During disassembly, the bearings on the cover were inspected. If one of the bearings need to be replaced, align and insert the cover roll pin into the hole of the bearing. This will ensure proper placement. NOTE: If a new cover is being used, install new roll pins so the distance between the tops of the roll pins and the face cover are 2.3 - 2.8 mm ( 0.090 - 0.110 in).

34. During disassembly, the ball bearing for the shaft was inspected. If the ball bearing for the shaft has been replaced, install one snap ring on each side of the ball bearing.

35. Fasten the cover in a vice with soft jaws. Firmly press the ball bearing and the shaft into the cover.

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36. Install the snap ring into the groove, just above the ball bearing.

83111585DFDFHFH

83115476ASDFG

83111583F

83111581DFF

37. Lubricate the lip of the seal with clean oil. Carefully press the new seal with the lip down, into the cover.

38. Install the snap ring into the seal.

39. Lubricate the wear plate with clean oil. Align the notch on the wear plate with the roll pin that is located inside the cylinder port. Insert the wear plate with the bronze surface side up, into the cylinder port.

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40. Ensure that the three pins are still inserted in the cylinder block.

83111580DFFG

83115477WEED

83111579CVBNJ

83115480SDF

41. Hook the retaining collar and slide it up the splines until it reaches the top.

42. Insert the cylinder block into the pump.

43. Align and install the guide on top of the pins.

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Hydrostatic drive - Pump and motor components

44. Slide the retainer on top the guide. Ensure that the holes of the retainer are properly aligned with the holes of the cylinder block

83115479ASD

83115480SDF

83115481X

83115482MKP

45. Lubricate the pistons with clean oil. Insert one piston into each aligned hole of the retainer and cylinder block. Ensure that the guide is still properly positioned on top of the three pins.

46. If a new swash plate or pin is being used, go to the underside of the swash plate. Insert the pin into the top, center slot. Press down on the pin until the distance between the top of the pin and the swash plate is 8.4 - 8.9 mm ( 0.33 - 0.35 in).

47. Slide the guide (1) onto the pin located on the side of the swash plate.

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Hydrostatic drive - Pump and motor components

48. Install the swash plate. The pin must engage the slot in the body of the control valve. The retainer must engage the groove in the piston.

83111576CV

83115483FN

83115484I

83111574WER

49. Place a new gasket on the outside rim.

50. Carefully place the cover and the shaft assembly onto the gasket. Rotate the shaft to align the support with the cylinder block.

51. Secure the cover with special bolts. Use the bolts to evenly draw the cover to the housing. Tighten the 3/8 in special bolt to a torque of 53 - 64 Nm 39 - 47 lb ft. Tighten the 7/16 in special bolts to a torque of 81 100 Nm ( 60 - 74 lb ft).

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Hydrostatic drive - Pump and motor components

52. Insert the bolt stud into the housing.

83111573CFF

83111572HJU

83111571BL

83111570DF

53. Slide the outer gear into the charge pump cover.

54. Slide the inner gear into the outer gear.

55. Align the coupling pin with the inner gear slot. Slide the coupling into the inner gear.

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56. Lubricate the charge pump cover with clean oil. Align the cover pin (1) with the hole found at the top of the housing. Slide the cover onto the cylinder block and into the housing.

83111569FTR

83111568

83111567

83111566

57. Install new O-rings and back-up ring.

58. Install bracket and nut. Connect the front and rear pump together.

59. Torque the retaining nut to 102 N·m (75.2 lb ft)

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60. Install the bolts that fasten the front and rear pumps together. Torque the bolts to 91 - 111 Nm ( 67 - 82 lb ft

83111565

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Hydrostatic drive - Pump and motor components

Pump - Remove WE WE WE WE

C227 C232 L221 L228

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Prior operation: Tilt the ROPS NOTE: Some of the photos in the following procedure may appear slightly different than the model you are repairing. The procedure is the same. 1. Label and disconnect control wires (1) on bottom of pumps

931001961

20111248

2. Label and disconnect the two front (1) and two rear (2) pump control connections.

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Hydrostatic drive - Pump and motor components

3. Label and disconnect the hydraulic oil temperature sender (1).

931001963

931001964

931001965

931001966

4. Label and disconnect the right hand side hydraulic hose (1).

5. Label and disconnect the oil supply hose (1) by loosening the hose clamp and cap ports.

6. Label and disconnect the top hydraulic tube (1) and cap open ports.

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7. Label and disconnect right hand side drive motor hoses (1) and cap open ports.

931001970

931001971

931001972

8. Label and disconnect left hand side drive motor hoses (1) and cap open ports.

9. Label and disconnect hydraulic hose (1) and cap open ports.

10. Label and disconnect case drain hose (1) and cap open ports.

931001963

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Hydrostatic drive - Pump and motor components

11. Label and disconnect gear pump supply hose (1) and cap open ports.

931001955

931001956

931001974

931001928

12. Label and disconnect gear pump hydraulic tubes (1) and cap open ports.

13.

Place a lifting strap around the pump and using a hoist support the pump, as shown. 14. Remove the two mounting bolts and washers (1) from the pump.

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Hydrostatic drive - Pump and motor components

15. Using the hoist, carefully remove pumps.

931001976

Next operation: Pump - Install (29.218)

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Pump - Install WE WE WE WE

C227 C232 L221 L228

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Prior operation: Inspect the O-ring on the hydrostatic pump, and replace if necessary. Prior operation: Lubricate the O-ring with clean hydraulic oil. Prior operation: Fill the hydrostatic pump with clean hydraulic oil. Prior operation: Apply NEW HOLLAND AMBRA GR 75 MD to the coupler. NOTE: Some of the photos in the following procedure may appear slightly different than the model you are repairing. The procedure is the same. 1. Mount the coupler (1) to pump shaft with the supplier logo facing out, toward the engine. 2. Align the coupler on the pump shaft. The distance (A) should be 49 mm (1 29/32 in). 3. Torque the set screws to 25.7 - 28.3 N·m (19.0 - 20.9 lb ft).

93111555A

931001928

4. Move the pump inward until the mounting flange is flush with the mounting surface of the hydrostatic pump. 5. Apply LOCTITE® 243™ to the pump mounting bolts (1). Install washers on the bolts and install the bolts into the pump mounting flange. Torque the mounting bolts to 86 - 117 N·m (63.4 - 86.3 lb ft).

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6. Connect gear pump hydraulic hoses (1) as shown.

931001956

931001955

931001963

931001972

7. Connect the gear pump supply hose (1), and tighten the hose clamp.

8. Connect the case drain hose (1), and secure with the clamp.

9. Connect the hydraulic hose (1), as shown.

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10. Connect the hoses (1) for the left-hand side of the drive motor.

931001971

931001970

931001966

11. Connect the hoses (1) for the right-hand side of the drive motor.

12. Connect the top hydraulic hose (1).

13. Connect the oil supply hose (1), and tighten the hose clamp.

931001965

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14. Connect the hose (1) for the right-hand side.

931001964

931001963

20111248

931001961

15. Connect the hydraulic oil, temperature sender (1), and secure with the nut.

16. Connect the electrical connectors (2) for the front (1) and rear solenoids.

17. Connect the sensor wires (1) located on the bottom of the pumps.

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Motor - Remove L221 L228

WE WE

WARNING Crushing hazard! Unit could fall if not properly supported. Follow jacking instructions provided for the unit. Use suitable jack stands. Be sure to position them properly. Failure to comply could result in death or serious injury. W0919A

DANGER Crushing hazard! Failure to engage the loader arm support pin could cause the loader arm to fall unexpectedly. Verify that the loader arm support pin is engaged. Failure to comply will result in death or serious injury. D0020A

Prior operation: Tilt the ROPS. 1. Place suitable container under chain tank drain plug and remove drain plug (1) and drain chain oil.

RAPH12SSL0087AA

931002069

2. The loader must be raised and supported with the tires off the ground. Used adequate blocks or jack stands to safely support the loader.

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Hydrostatic drive - Pump and motor components

3. Remove the wheel hardware (1) and pull wheels from hub.

931002070

931002080

931002082B

4. Remove the six bolts (2) securing the drive chain inspection cover and remove cover.

5. Remove front and rear axle housing hardware (4).

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Hydrostatic drive - Pump and motor components

6. Remove front and rear axle housings

931002083B

931002084

931002085B

7. Push the sprocket forward and remove chains from drive sprocket, as shown.

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8. Label and disconnect hydraulic hoses (1) from hydrostatic drive motor and cap the open hoses and ports.

931002086

9. Disconnect shift tube (on 2 speed equipped models). 10. Remove and discard hydraulic motor mounting hardware (2). NOTE: DO NOT reuse motor mounting hardware after tightening to spec. Hardware is permanently stretched during tightening and must be discarded if loosened.

11.

931002085B

931002087

Use acceptable lifting equipment and remove the drive motor/brake assembly.

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Hydrostatic drive - Pump and motor components

Motor - Disassemble - Single speed drive motor L221 L228

WE WE

1. Make reference marks on the motor case for correct alignment during assembly. Loosen and remove the socket head cap screws alternately, one turn at a time from the cover plate.

83115546

83115547

83115548

83115549

2. Remove the cover plate.

3. Remove the gasket.

4. Remove the disc spring.

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5. Use compressed air in the port to force the piston up for removal.

83115550

83115551

83115552

83115553

6. Remove the piston

7. Remove the O-ring.

8. Loosen and remove the socket head cap screws and washers from the brake housing.

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9. Use a soft hammer to loosen the brake housing.

83115554

10. Remove the brake housing from the motor case.

83115555

83115556

83115557

11. Remove the brake discs and shims as one unit from the shaft.

12. Remove the O-ring.

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13. Loosen the plug for the flushing spool valve.

83115558

83115559

83115560

83115561

14. Remove the flushing spool valve plug.

15. Remove the flushing valve spool, 2 springs, and washer from the valve port. Make a record of the parts assembly for use during the assembly procedure.

16. Loosen the plug for the flushing valve poppet.

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Hydrostatic drive - Pump and motor components

17. Remove the plug from the port.

83115562

83115563

83115564

83115565

18. Remove the spring and the flushing poppet.

19. Loosen the socket head cap screws.

20. Remove the socket head cap screws.

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Hydrostatic drive - Pump and motor components

21. Remove the rear motor case.

83115566

83115567

83115568

83115569

22. Remove the seal from the rear case.

23. Drop the rear case assembly from approximately 80 mm (3.1 in) onto a wooden or plastic surface. This will release the distributor from the rear case.

24. Remove the distributor from the rear case.

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Hydrostatic drive - Pump and motor components

25. Make a record of the number of springs and the stop pin location in the distributor for use during the assembly procedure.

83115570

83115571

83115572

83115573

26. Remove the cam from the front case.

27. Remove the seal from the front case.

28. Remove the cylinder block from the front case.

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29. Place the front case assembly in the press. Remove the split ring from the shaft.

83115574

83115575

83115576

83115577

30. Press the shaft out of the front case.

31. Press the seal out of the front case.

32. Press the outer bearing cup from the front case.

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33. Press the inner bearing cup from the front case.

83115578

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Motor - Assemble - Single speed drive motor L221 L228

WE WE

1. If removed, install a new inner bearing cup in the front case.

83115577

83115578

83115575

2. If removed, install a new outer bearing cup in the front case.

3. Lubricate a new shaft seal with clean hydraulic oil. Install the new shaft seal onto the shaft. 4. Place the shaft in a press. Warm the outer bearing. Press the outer bearing onto the shaft. 5. Cover the splines on the shaft with tape to protect the seal. Install the shaft into the front case. Remove the tape from the splines. 6. Warm the inner bearing. 7. Press the inner bearing onto the shaft and into the inner bearing cup. Press the bearing into the cup to a preload of 5000 kg (11023.1 lb). Rotate the front case during this procedure. Allow the assembly to cool. 8. Place special tool 380001894 onto the shaft. Using a press and apply a preload 2000 kg (4409.2 lb) to the inner bearing.

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9. Install the split ring onto the shaft.

83115574

10. With the preload still applied, measure the gap between the split ring and the bearing.

11. Remove the split ring. Install a shim with a thickness of 0.05 - 0.20 mm (0.002 - 0.008 in) greater than the measured gap between the split ring and the bearing surface.

12. Install the split ring on the shaft.

13. Release the preload from the bearing and remove the front case assembly from the press.

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14. Check the shaft to make sure it rotates in the front case assembly. 15. Install the cylinder block onto the shaft.

83115566

83115572

16. Lubricate the seal with clean hydraulic oil. Install the seal on the front case.

17. Install the cam on the cylinder block. Be sure to align the cam with the alignment mark on the front case.

83115571

83115570

18. Install the springs and the stop pin in the distributor.

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19. Lubricate the seals on the distributor with clean hydraulic oil. Install the distributor into the rear case. Be careful not to dislodge the springs while installing the distributor into the rear case. Make sure to the stop pin is aligned with the hole in the rear case. Tap the distributor with a soft hammer until it is seated in the rear case.

83115569

83115567

83115566

83115565

20. Lubricate the seal with clean hydraulic oil. Install the seal on the rear case.

21. Use the marks made during disassembly and install the rear case onto the cam.

22. Apply LOCTITE® 243™ to the threads and install the socket head cap screws into the rear case.

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23. Tighten the socket head cap screws alternately from side to side to a torque of 117 - 122 N·m (86.3 - 90.0 lb ft).

83115564

83115563

83115561

83115560

24. Lubricate the spring and flushing poppet with clean hydraulic oil. Install the spring and flushing poppet into the port.

25. Lubricate the O-ring on the plug with clean hydraulic oil. Install and tighten the plug.

26. Lubricate the springs and flushing spool with clean hydraulic oil. Install the 2 springs, washer, and flushing spool into the valve port.

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27. Lubricate the O-ring on the plug with clean hydraulic oil. Install and tighten the plug.

83115558

83115557

83115556

83115555

28. Lubricate the O-ring with clean hydraulic oil. Install the O-ring on the brake housing.

29. Lubricate with the brake discs and shims with clean hydraulic oil. Install the brake discs and shims as one unit on the shaft. Make sure all of the tabs on the brakes discs are aligned.

30. Install the brake housing on the rear motor case.

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31. Apply LOCTITE® 243™ to the threads and install the socket head cap screws into the brake housing. Tighten the socket head cap screws alternately from side to side to a torque of 70 - 77 N·m (51.6 - 56.8 lb ft).

83115553

83115552

83115551

83115549

32. Lubricate the seal with clean hydraulic oil. Install the seal in the brake housing.

33. Lubricate the seals on the piston with clean hydraulic oil and install the piston into the brake housing.

34. Install the disc spring on top of the piston.

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35. Install the gasket on the brake housing.

83115548

83115547

83115546

36. Install the cover plate onto the brake housing.

37. Install the socket head cap screws into the cover plate. Tighten the socket head cap screws alternately from side to side to a torque of 14 - 16 N·m (10.3 - 11.8 lb ft).

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Motor - Disassemble - Two speed drive motor L221 L228

WE WE

1. Make reference marks on the motor case for correct alignment during assembly. Loosen and remove the socket head cap screws alternately, one turn at a time from the cover plate.

83115546

83115547

83115548

83115549

2. Remove the cover plate.

3. Remove the gasket.

4. Remove the disc spring.

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5. Use compressed air in the port to force the piston up for removal.

83115550

83115551

83115552

83115553

6. Remove the piston.

7. Remove the O-ring.

8. Loosen and remove the socket head cap screws and washers from the brake housing.

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9. Use a soft hammer to loosen the brake housing.

83115554

10. Remove the brake housing from the motor case.

83115579

83115556

83115580

11. Remove the brake discs and shims as one unit from the shaft.

12. Remove the O-ring.

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13. Remove the two speed spool valve and spring from the valve port.

83115581

83115582

83115564

83115565

14. Remove the O-ring.

15. Loosen the socket head cap screws.

16. Remove the socket head cap screws.

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17. Remove the rear motor case.

83115708

83115567

83115568

83115709

18. Remove the seal from the rear case.

19. Drop the rear case assembly from approximately 80 mm (3.1 in) onto a wooden or plastic surface. This will release the distributor from the rear case.

20. Remove the distributor from the rear case. Make a record of the number of springs and the stop pin location in the distributor for use during the assembly procedure.

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21. Remove the cam from the front case.

83115571

83115572

83115573

83115574

22. Remove the seal from the front case.

23. Remove the cylinder block from the front case.

24. Place the front case assembly in the press. Remove the split ring from the shaft.

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25. Press the shaft out of the front case.

83115575

83115576

83115577

83115578

26. Press the seal out of the front case.

27. Press the inner bearing cup from the front case.

28. Press the outer bearing cup from the front case.

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Motor - Assemble - Two speed drive motor L221 L228

WE WE

1. If removed, install a new outer bearing cup in the front case.

83115575

83115577

83115575

2. If removed, install a new inner bearing cup in the front case.

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9. Install the split ring onto the shaft.

20115834

20115833

20115834

10. With the preload still applied, measure the gap between the split ring and the bearing.

11. Remove the split ring. Install a shim with a thickness of 0.05 - 0.20 mm (0.002 - 0.008 in) greater than the measured gap between the split ring and the bearing surface.

12. Install the split ring on the shaft.

13. Release the preload from the bearing and remove the front case assembly from the press. 14. Check the shaft to make sure it rotates in the front case assembly. 47683911 27/02/2015

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15. Install the cylinder block onto the shaft.

83115573

83115571

16. Lubricate the seal with clean hydraulic oil. Install the seal on the front case. Install the cam on the cylinder block. Be sure to align the cam with the alignment mark on the front case.

17. Install the springs and the stop pin in the distributor.

83115709

83115569

18. Lubricate the seals on the distributor with clean hydraulic oil. Install the distributor into the rear case. Be careful not to dislodge the springs while installing the distributor into the rear case. Make sure to the stop pin is aligned with the hole in the rear case. Tap the distributor with a soft hammer until it is seated in the rear case.

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19. Lubricate the seal with clean hydraulic oil. Install the seal on the rear case.

83115567

83115583

83115565

83115564

20. Use the marks made during disassembly and install the rear case onto the cam.

21. Apply LOCTITE® 243™ to the threads and install the socket head cap screws into the rear case.

22. Tighten the socket head cap screws alternately from side to side to a torque of 117 - 122 N·m (86.3 - 90.0 lb ft).

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23. Lubricate the two speed valve spring and spool with clean hydraulic oil. Install the two speed valve spring and spool into the valve port.

83115560

83115557

83115556

83115579

24. Lubricate the O-ring with clean hydraulic oil. Install the O-ring on the brake housing.

25. Lubricate with the brake discs and shims with clean hydraulic oil. Install the brake discs and shims as one unit on the shaft. Make sure all of the tabs on the brakes discs are aligned.

26. Install the brake housing on the rear motor case.

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27. Apply LOCTITE® 243™ to the threads and install the socket head cap screws into the brake housing. Tighten the socket head cap screws alternately from side to side to a torque of 70 - 77 N·m (51.6 - 56.8 lb ft).

83115553

83115552

83115551

83115549

28. Lubricate the seal with clean hydraulic oil. Install the seal in the brake housing.

29. Lubricate the seals on the piston with clean hydraulic oil and install the piston into the brake housing.

30. Install the disc spring on top of the piston.

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31. Install the gasket on the brake housing.

83115548

83115547

83115546

32. Install the cover plate onto the brake housing.

33. Install the socket head cap screws into the cover plate. Tighten the socket head cap screws alternately from side to side to a torque of 14 - 16 N·m (10.3 - 11.8 lb ft).

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Motor - Install L221 L228

WE WE

1. Apply a bead of LOCTITE® SI 598™ BLACK adhesive, (1), in corner between pilot and flange of motor, around diameter of pilot, similar to o-ring, (approximately 12.5 ml (0.4 US fl oz) per motor).

931001687A

931002004

2. Apply a 3 mm (0.1 in) bead of LOCTITE® SI 598™ BLACK around the outside of the bolt holes of the motor flange and two dabs per nut between the nut and motors.

3. Use acceptable lifting equipment and move the drive motor/brake assembly (1) into the chassis mounting location (2).

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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. Hardware is permanently stretched during tightening and must be discarded if loosened.

931002085B

931002086

5. Connect the hydraulic hoses (1) to hydrostatic drive motor to the correct ports 6. Connect shift tube (on 2 speed equipped models).

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7. Connect chains to drive sprocket

931002085B

931002083B

931002082B

8. Install front (1) and rear axle housings.

9. Install the chains to the drive sprockets. 10. Install front and rear axle housing hardware (1).

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11. Install chain oil drain plug (1). oil level is approximately mid-way up the inspection cover. Cover must be installed before filling with oil.

RAPH12SSL0087AA

931002080A

12. Install chain inspection cover (1) and mounting hardware (2) 13. Fill chain tank to correct level and install check plug.

14. Install wheels (1) and wheel hardware (2)

931002070

931002069

15. Remove supports and lower skid steer

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Motor - Drain fluid WE WE

C227 C232

1. Position the final drive hub so that one of the drain plugs (2) is in the six o’clock position. 2. Remove the other plug (1). 3. Remove the drain plug (2).

931002652

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Motor - Remove WE WE

C227 C232

Prior operation: Remove the rubber track. Please see Rubber track - Remove (48.100). 1. Loosen and remove the upper and lower mounting bolts (1) which fasten the rear cover (2) to the frame (3).

BS05C139_1

BS05C164_1

BS05C164_2

2. Loosen and remove all of the hydraulic lines that are connected to the drive motor. Place plugs in all of the lines. 3. Loosen and remove all of the connectors from the ports on the drive motor to allow room to slide the drive motor out of the frame. 4. Install clean plastic plugs into the ports (1) to avoid contamination.

5. Make a reference mark on the drive motor (2) and the frame (3) to be used for alignment of the drive motor during the installation procedure. 6. Loosen and remove the mounting bolts (1) which fasten the drive motor (2) to the frame (3). 7. Slide the drive motor (2) out of the frame (3).

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Motor - Disassemble WE

200 Series Compact Track Loaders

1. Remove the 2 plugs from the cover plate.

83115710

83115711

83115712VGFUKV

2. Drain motor oil in an acceptable container. 3. Remove the snap ring.

4. Mark the position of the cover plate as a reference for reassembly. 5. Remove the cover plate.

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6. Remove the center gear.

83115713

83115714

83115715

83115716_4

7. Remove the gear plate.

8. Remove and discard the O-ring.

9. Mark the position (1) of all the gears as a reference for reassembly. 10. Remove the snap rings.

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11. Remove the gears.

83115717

83115718

12. Remove the bushing.

NOTE: Disassembly of the flushing spool valve 13. Remove the plugs.

83115725_2

83115721

14. Remove and discard the O-rings..

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15. Remove the springs from both ends of the plunger.

83115722

83115723_3

83115724_2

83115725_3

16. Remove the spring seats from both ends of the plunger.

17. Remove the plunger assembly.

NOTE: Disassembly of the two speed control 18. Remove the plugs.

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19. Remove and discard the O-rings.

83115721

83115726_3

83115727_3

83115728_3

20. Remove the two speed spool (1).

NOTE: The two speed spool can only be removed from one opening. 21. Remove the spring (1).

NOTE: Disassembly of the flushing valve 22. Remove plug.

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23. Remove and discard the O-ring.

83115721

83115729_3

83115730

83115731_2

24. Remove the spring.

NOTE: Disassembly of the base plate 25. Remove the three plugs from around the bottom of the base plate.

26. Remove the base plate mount bolts.

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27. Carefully lift the base plate off the pins. Remove the base plate.

83115732GSF

83115733

83115734

83115733_3

28. Turn the base plate upside down.

29. Remove the valve plate.

30. Remove the pins (1) from their seat..

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31. Remove bearing from the base plate.

83115736

83115737

83115738

83115739

NOTE: Disassembly of the motor shaft and cylinder block 32. Remove the bearing inner ring from the motor shaft.

33. Remove the springs from the brake piston.

34. Remove and discard the O-ring.

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35. Mark the position of the brake piston as a reference for reassembly.

83115740

83115741

83115742

83115743

36. Remove the brake piston.

37. Separate the brake spacer from the brake piston.

38. Remove and discard the O-rings from the brake piston.

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39. Remove and discard the O-ring from the brake spacer.

83115744

83115745

83115746

83115747

NOTE: Remove the brake discs package 40. Remove the brake disc with internal teeth.

41. Then remove an external toothed steel disc.

42. Repeat the above steps until complete brake disc package is removed. NOTE: Brake disc package consists of 3 brake discs and 2 steel discs

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43. Remove the cylinder block.

83115748

83115749

83115767

83115751

44. Remove the pistons and retainer plate from the cylinder block.

45. Remove pistons from the retainer plate.

46. Remove the spherical retainer plate holder.

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47. Remove the 3 pins from the cylinder block (1) .

83115752

83115753

83115754

83115755

48. Remove the swash plate.

49. Remove the 2 pistons from their seat (1) .

50. Remove the springs from the pistons.

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51. Remove the 2 steel balls from their seats.

83115756

83115757

83115758

83115759

52. Remove the motor shaft.

53. Remove the inner bearing ring from the motor shaft.

54. Remove the bearing.

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55. Remove the seal ring.

83115760_2

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Motor - Assemble WE WE

C227 C232

1. Install the seal ring.

83115760ASSD

83115761HJL

83115762

83115763

2. Install the seal ring into the flanged hub.

3. Apply a thin coat of grease over the seal ring (1).

4. Install bearing.

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5. Seat the bearing into the flanged hub.

83115764GHK

83115765

83115757

83115756

6. Install the inner bearing ring onto the motor shaft.

7. Place the motor shaft into the bearing.

8. Place the 2 steel balls into their seats.

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9. Install the springs inside the pistons.

83115755

10. Install the 2 pistons in their housings (1).

83115754

83115753

83115752

11. Install the swash plate.

12. Install the three pins into the cylinder block (1).

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13. Install the spherical retainer. NOTE: Ensure the two splines are aligned

83115751

83115766

83115767

83115749

14. Piston orifice must be free of dust or dirt.

15. Install the pistons into the retainer plate.

16. Install the pistons and retainer plate into the cylinder lock.

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17. Install the cylinder block into the flanged hub on the motor shaft spline.

83115748

83115745

83115746

83115747

18. Install the brake disc package according to the following order: first insert one brake disc with internal teeth.

19. Then insert an external toothed steel disc.

20. Repeat the steps until 3 brake discs and 2 steel discs have been installed.

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21. Install the O-rings on the brake piston.

83115743

83115744

83115742

83115741

22. Install the O-ring on the brake spacer.

23. Install the brake spacer on the brake piston, paying attention not to damage the O-rings already in place.

24. Install the brake piston into the flanged hub while aligning the reference marks previously applied.

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25. Install O-ring.

83115739

83115738

83115737

83115735

26. Install the springs on the brake piston.

27. Install the bearing inner ring onto the motor shaft.

28. Install the bearing into the base plate (1). 29. Install the pins into the base plate (2).

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30. Install the valve plate on the base plate with the bronze surface upwards.

83115734

83115732GSF

83115731

83115730

31. Install the 3 O-rings for the oil passages on the flanged hub. 32. Place the base plate on the flanged hub. NOTE: Ensure the base plate is centered on the two pins and the oil passages are matched together

33. Install the base plate mount bolts and tightened to a torque of 145 N·m (106.95 lb ft).

34. Install the 3 plugs located around the bottom of the base plate. Torque plus to 2 - 3 N·m (17.7 - 26.6 lb in).

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35. Install the spring (1) into the two-speed spool (2) .

83115727

83115726

83115721

83115725

36. Install the two speed spool (1) into the base plate. NOTE: The spool will only fit through 1 of the 2 orifices.

37. Install the O-rings on the plugs.

38. Install and tighten the plugs to a torque of 49 - 59 N·m (36.1 - 43.5 lb ft).

NOTE: Assembly of the flushing valve

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39. Install the O-ring on the plug.

83115721

83115729_1

83115728

83115724

40. Install the spring into the base plate.

41. Install and tighten the plug to a torque of 88 - 96 N·m (64.9 - 70.8 lb ft).

NOTE: Assembly of the flushing spool valve 42. Slide plunger (1) inside the base plate.

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43. Install the spring seats (1) on each end of the plunger (2) .

83115723_2

83115722

83115721

83115725_1

44. Install the springs on each end of the plunger.

45. Install the O-rings on the 2 plugs.

46. Install and tighten the 2 plugs to a torque of 149 165 N·m (109.9 - 121.7 lb ft)

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47. Install the bushing into the gearbox (1).

83115768

83115717

83115769_1

83115716

48. Install the gears into the gearbox while aligning the reference marks (1) previously applied to the gears.

49. Seat the gears.

50. Install the snap rings on the gears.

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51. Install the O-ring around the gearbox.

83115715

83115714

83115713

83115712

52. Install the gear plate.

53. Install the center gear.

54. Use reference marks (1) to align and install the cover plate on the gearbox.

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55. Install the snap ring.

83115711

83115710

56. Service gearbox with 550 - 650 ml (18.6 - 22.0 US fl oz) .of NEW HOLLAND AMBRA HYPOIDE 140. 57. Install and tighten the end cover plugs to a torque of 20 - 30 N·m (14.8 - 22.1 lb ft).

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Motor - Install WE WE

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ]

1. Slide the drive motor (1) into the frame (2) mounting location. If the same motor is being installed, use the marks made during removal, and align the drive motor in the frame. If a new motor is being installed, transfer the reference mark from the old motor to the same location on the new motor, and align the drive motor in the frame.

BS05C164_3

BS05C164_4

BS05C156_1

2. Apply LOCTITE® 243™ to the threads of the mounting bolts (1). 3. Install the mounting bolts (1) into the frame.

4. Tighten the mounting bolts (1) to an initial torque of 67 163 Nm (50 - 120 lb ft), using the tightening sequence shown in the image. 5. After the initial torque is complete, tighten the mounting bolts to a final torque of 125 - 170 Nm (93 - 125 lb ft), using the tightening sequence shown in the image.

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6. Install the connectors into the motor ports (1), and tighten the connectors. 7. Connect the lines to the drive motor. Tighten all of the hydraulic lines.

BS05C164_1

BS05C139_1

8. Install the rear cover (2) onto the frame (3). 9. Apply LOCTITE® 243™ to the threads of the mounting bolts (1). 10. Install the upper and lower mounting bolts (1) into the rear cover (2). Tighten the mounting bolts (1).

Next operation: Install the rubber track. Please see Rubber track - Install (48.100)

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Motor - Filling WE WE

C227 C232

1. Position the final drive hub so that one of the fill plugs (1) is in the twelve o’clock position. 2. Remove the other plug (2). 3. Fill the final drive hub with TUTELA HYPOIDE EP GEAR LUBE SAE 80W-90 until oil starts to flow from the plug (2) that is at three o’clock or nine o’clock position.

931002651

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Servo control - Adjust WE WE WE WE

C227 C232 L221 L228

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

In order to correct a faulty hydrostatic drive, a systematic diagnostic procedure must be followed. Before attempting any of the procedures below, determine if the hydrostatic pump is faulty by raising the machine off of the ground and supporting the machine with a suitable lifting device, disconnecting the control linkage on the pump, releasing the brakes, running the machine, and observing the wheel/track motion. If you disconnect the linkage and the problem disappears, inspect the linkage and correct the problem. Please see Mechanical control - Adjust (29.200) for linkage adjustment procedures. If the machine travels with the linkage disconnected, please see the following steps:

Center the servo piston 1. Raise the machine off of the ground, and support the machine with a suitable lifting device. 2. Disconnect and cap the servo inlet line (1). NOTE: Disconnecting the servo inlet line will allow you to adjust both hydrostatic pumps without receiving hydraulic interference.

RAPH12SSL0449AA

RAPH12SSL0439AA

3. Start the machine, and run at a high idle. 4. Release the brakes. 5. Locate the faulty pump. 6. Remove the jam nut (1). NOTE: You do not need to remove the hydrostatic pumps for the following procedures; The hydrostatic pumps have been removed for picture clarity.

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7. Turn the servo adjustment screw in one direction until the wheels/track begin to rotate. Record the position of the adjustment screw. NOTE: If the adjustment screw requires more than one, full turn to begin tire/track movement, please see the steps in the “Center the servo piston spring” section of this document. 8. Turn the servo adjustment screw in the opposite direction until the wheels/track begin to rotate. Record the position of the adjustment screw. NOTE: If the adjustment screw requires more than one, full turn to begin tire/track movement, please see the steps in the “Center the servo piston spring” section of this document. RAPH12SSL0441AA

RAPH12SSL0438AA

9. Repeat steps 7 and 8 to verify your records. 10. Center the servo adjustment screw based on your records. 11. Install the jam nut. 12. Connect the servo inlet line. 13. Follow the steps in the “Center the servo control valve” section of this document.

Center the servo control valve 1. Disconnect the linkage on the faulty hydrostatic pump. 2. Loosen the adjustment bracket bolts (1) on the servo control of hydrostatic pump that is faulty.

3. Adjust the bracket for the servo control until the wheels/ track begin to move. Mark this position. 4. Adjust the bracket for the servo control in the opposite direction. When the wheels/track begin to move in the opposite direction, mark this position. 5. Repeat steps 3 and 4 to verify your markings. Make additional marks if necessary. 6. Center the adjustment bracket between your markings, and tighten the adjustment bracket bolts. 7. Reinstall the linkage. You may need to adjust the linkage. Please see Mechanical control - Adjust (29.200) for linkage adjustment procedures.

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8. Move the faulty hydrostatic pump’s control levers in both directions. The servo control is properly adjusted when an even amount of lever travel is required to begin the rotation of the wheels/tracks in either direction. Readjust the servo control and/or the linkage if necessary. 9. Test drive the machine. If the machine steers in either direction more than 1.8 m (6 ft) from the centerline after traveling 30.5 m (100 ft) forward or 15.2 m (50 ft) backward, or if one or both of the pumps continue to travel after the control levers have returned to neutral, recheck the linkage. Please see Mechanical control Adjust (29.200) for linkage adjustment procedures.

Center the servo piston spring If the adjustment screw requires more than one, full turn to begin tire movement, or a pump has the tendency to continue traveling in the direction that is was last going, please see the following steps:

23111053

Exploded view of the piston spring assembly

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Hydrostatic drive - Pump and motor components

1. Remove the jam nut (2). 2. Remove the bolts (1).

RAPH12SSL0439AA

RAPH12SSL0442AA

RAPH12SSL0440AA

3. Unscrew the servo piston cover (1).

4. Check the nuts for looseness. Inspect the spring assembly for damage and excessive movement. Adjust the lock nut and nut if necessary. NOTE: The nut (2) should be finger-tight against the spring cup (1). If the nut (2) is too tight, you will find a gap between the spring cup (1) and the retention ring (3). If the nut (2) is loose, you will find a gap between the nut (2) and the spring cup (1).

5. Install the servo piston cover. 6. Install the bolts. 7. Install the jam nut. 8. Repeat the steps in the “Center the servo piston” section of this document.

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Hydrostatic drive - Pump and motor components

Servo control - Adjust WE WE WE WE

C227 C232 L221 L228

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Travel adjustments for the Electric Hydraulic (EH) pumps are less involved because the EH pumps do not have mechanical control linkage. Before attempting to adjust the pumps, please see Hydrostatic transmission - Troubleshooting (29.202). If there are no problems with the drive motors, hoses, brakes, and axles, and the charge pressure and relief pressures are within specification, please use the Electronic Service Tool (EST) to calibrate the joysticks and the ground drive. If the machine continues to travel irregularly after calibration, please see the following steps:

Center the piston 1. Raise the machine off of the ground, and support the machine with a suitable lifting device. 2. Disconnect and cap the inlet line (1). NOTE: Disconnecting the inlet line will allow you to adjust both hydrostatic pumps without receiving hydraulic interference.

931001814

RAPH12SSL0443AA

3. Start the machine, and run at a high idle. 4. Release the brakes. 5. Observe the wheel/track movement. If the wheels/ tracks are not moving, please see the steps in the “Adjust the piston stops” section of this document. 6. If the wheels/tracks are moving, please continue with step 7. 7. Loosen the jam nut (1) on the faulty pump. NOTE: You do not need to remove the hydrostatic pumps for the following procedures; The hydrostatic pumps have been removed for picture clarity.

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Hydrostatic drive - Pump and motor components

8. Turn the adjustment screw (1) in one direction until the wheels/track begin to rotate. Record the position of the adjustment screw. 9. Turn the adjustment screw (1) in the opposite direction until the wheels/track begin to rotate. Record the position of the adjustment screw. 10. Repeat steps 8 and 9 to verify your records. 11. Center the adjustment screw based on your records. 12. Tighten the jam nut.

RAPH12SSL0443AA

931001814

RAPH12SSL0450AA

13. Connect the inlet line (1).

14. Calibrate the joysticks and ground drive, using the EST. 15. Test drive the machine. If the machine steers in either direction more than 1.8 m (6 ft) from the centerline after traveling 30.5 m (100 ft) forward or 15.2 m (50 ft) backward, please see the steps in the “Adjust the piston stops” section of this document.

Adjust the piston stops If the machine steers in either direction more than 1.8 m (6 ft) from the centerline after traveling 30.5 m (100 ft) forward or 15.2 m (50 ft) backward, the piston stops (1) for one of the hydrostatic pumps may be out of adjustment, which is causing one pump to travel faster or slower than the other pump.

1. Test drive the machine. Observe which direction the machine travels. 2. Shut off the machine.

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Hydrostatic drive - Pump and motor components

3. To adjust the speed of the drive motor, you will need to do the following: • Determine which drive motor is traveling faster. • Locate the hydrostatic pump associated with the faster drive motor. • Locate the two piston stop screws (2) on the faulty pump. NOTE: The piston stop screws may be covered. Remove the covers by gently tapping on the covers. • Locate the forward and reverse solenoids on the faulty pump. • If the machine incorrectly travels forward, loosen the jam nut (1) and adjust the piston stop screw (2) located near the reverse solenoid. If the machine incorrectly travels backward, loosen the jam nut (1) and adjust the piston stop screw (2) located near the forward solenoid. NOTE: To limit speed, turn the piston stop screw in. To gain speed, turn the piston stop screw out. 4. Tighten the jam nut (1). 5. Test drive the machine. Repeat steps 1 through 4 until machine travels correctly at the desired speed.

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RAPH12SSL0443AA

Index Hydrostatic drive - 29 Pump and motor components - 218 Motor - Assemble - Single speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor - Assemble - Two speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

118

Motor - Disassemble - Single speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor - Disassemble - Two speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104

Motor - Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102

Motor - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor - Filling (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

134

Motor - General specification - Single speed motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor - General specification - Two-speed motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

132

Motor - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

103

Pump - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Measure - Piston travel (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Charge pressure relief valve - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Charge pressure relief valve - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Pressure limiter valve - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Pressure limiter valve - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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Servo control - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

135

Servo control - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

139

(*) See content for specific models 47683911 27/02/2015

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Hydrostatic drive - 29 Hydrostatic transmission - 202

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Hydrostatic drive - 29 Hydrostatic transmission - 202

FUNCTIONAL DATA Hydrostatic transmission Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Hydrostatic transmission Decontaminating (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

DIAGNOSTIC Hydrostatic transmission Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

(*) See content for specific models 47683911 27/02/2015

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Hydrostatic drive - Hydrostatic transmission

Hydrostatic transmission - Dynamic description C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE WE

In a closed loop, hydrostatic transmission, the engine provides power to a pump that sends hydraulic oil to the drive motors. Each hydrostatic pump drives a corresponding drive motor. The drive motor turns a pair of chains by use of a dual sprocket, and the two chains turn the front and rear axles. In a hydrostatic, closed loop system, the hydrostatic pump and the drive motor are directly connected; the hydrostatic pump sends oil to the drive motor and the drive motor returns the oil back to the hydrostatic pump.

RAPH14SSL0013AA

Basic, hydrostatic, closed loop system Hydrostatic system components (1) Hydrostatic pump (2) Charge relief valve

(3) Drive motor (4) Pressure limiter valve

(5) Check valve (6) Charge pump

Because of the high pressures required to move the machine, some of the oil in the hydrostatic, closed loop system leaks into the case drain and flushing valve of the components. This lost oil must be resupplied to keep the closed loop system working as designed. A charge pump (6) is used to supply this lost oil. Located on the hydrostatic pump assembly (1), the charge pump (6) supplies cooled, filtered oil from the reservoir to the closed loop system. When the machine is traveling, the drive side of the closed loop has pressures too high to allow flow from the charge pump (6), but the return side of the closed loop has pressures similar to the charge pump’s pressure. The return side of the closed loop is where filtered oil will enter into the closed loop from the charge pump (6). Charge pump oil also enters the closed loop when the machine is in neutral, because pressure inside the closed loop while in neutral is less-than-or-equal-to the charge pump’s pressure. To prevent closed loop oil from escaping back into the charge side of the system, a check valve (5) is placed between the supply of charge pump oil and each side of the closed loop. While the machine is traveling, the load on the drive motor (3) can increase which causes the pressure in the closed loop to become excessive. A pressure limiter valve (4) is installed on each side of the closed loop to limit the maximum pressure. These pressure limiter valves (4) are nonadjustable and operate in only one direction.

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Hydrostatic drive - Hydrostatic transmission

Hydrostatic transmission - Decontaminating WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Any contamination in the hydrostatic system will stay in the closed loop. If the hydrostatic pump or a motor in the hydrostatic system is removed for repair or replacement, you must clean the hydrostatic system. If any contamination is left in the closed loop, the contamination will damage the remaining components of the hydrostatic system. 1. Remove the hydrostatic pump(s) and motor(s) from the circuit that has failed. If there is a quantity of contamination present, removal of the opposite pump and motor is also required. 2. Clean and inspect the interior and exterior of the hydrostatic pump(s) and motor(s). 3. Clean the hoses and tubes in the hydrostatic system by flushing the hoses and tubes with hot, soapy water. Hang the hoses and tubes and allow them to air dry. Hoses and tubes must be dry before installing. 4. Drain the hydraulic oil from the tank, and inspect for contamination. Replace the hydraulic oil if necessary.

83115762

5. Change the hydraulic oil filter. 6. Install the portable filter caddy, part number CAS10162A, and follow the manufacture’s directions. NOTE: The oil cooler has internal passages that can trap and hold contamination, which can be dislodged at a later time causing a repeated failure. Replacement of the oil cooler is necessary if the contamination of the hydraulic oil is significant.

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Hydrostatic drive - Hydrostatic transmission

Hydrostatic transmission - Troubleshooting L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE

Problem Possible Cause The machine steers more Throttle speed. than 1.8 m (6 ft) from the centerline after traveling 30.5 m (100 ft) forward or 15.2 m (50 ft) backward Tire(s). Joysticks are not calibrated correctly.

A hose is bent, kinked, or clogged. The parking brake is not releasing.

Correction The machine is designed to operate at high idle.

1. Check the pressures of the tires. 2. Inspect the tires for damage. 1. For electro hydraulic (EH) machines, calibrate the joysticks by using the electronic service tool (EST). 2. For mechanical controlled machines, inspect the linkage between the joysticks and the hydrostatic pumps. Please see Mechanical control - Adjust (29.200) . Inspect the hoses between the hydrostatic pumps, the motors, and the brake valve. 1. Inspect the hoses. 2. Check the charge pressure. Please see Pump Charge pressure relief valve Pressure test (29.218). 3. Check the operation of the solenoid at the brake valve.

4. Inspect the brakes inside the motor(s) for damage. The drive chain is worn. Inspect the drive chain. Please see Chain drive - Check (25.450). The axle bearings are worn. Inspect the axle bearings for looseness and damage. The hydrostatic pump(s) need adjustment. 1. Inspect the pressure limiter valves. Please see Pump Pressure limiter valve - Pressure test (29.218). 2. Adjust the servo(s) inside the pump(s). Please see Servo control - Adjust (29.218) . The hydrostatic drive components are 1. Inspect the motor(s). damaged. 2. Inspect the hydrostatic pump(s).

Hydrostatic transmission - Troubleshooting C227 C232

WE WE

Problem Possible Cause The machine steers more Throttle speed. than 1.8 m (6 ft) from the centerline after traveling 30.5 m (100 ft) forward or 15.2 m (50 ft) backward

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Correction The machine is designed to properly operate at high throttle.

Hydrostatic drive - Hydrostatic transmission

Problem

Possible Cause Track(s).

Correction 1. Inspect the tension of the track(s). Please see Rubber track - Tension adjust (48.100). 2. Inspect the track(s) for damage.

Joysticks are not calibrated correctly.

A hose is bent, kinked, or clogged. The parking brake is not releasing.

3. Inspect the track frame(s) and track frame components for damage. 1. For electro hydraulic (EH) machines, calibrate the joysticks by using the electronic service tool (EST). 2. For mechanical controlled machines, inspect the linkage between the joysticks and the hydrostatic pumps. Please see Mechanical control - Adjust - Machines with only hand controls (29.200). Inspect the hoses between the hydrostatic pumps, the motors, and the brake valve. 1. Inspect the hoses. 2. Check the charge pressure. Please see Pump Charge pressure relief valve Pressure test (29.218). 3. Check the operation of the solenoid at the brake valve.

4. Inspect the brakes inside the motor(s) for damage. The hydrostatic pump(s) need adjustment. 1. Inspect the pressure limiter valves. Please see Pump Pressure limiter valve - Pressure test (29.218). 2. Adjust the servo(s) inside the pump(s). Please see Servo control - Adjust (29.218). The hydrostatic drive components are 1. Inspect the motor. damaged. 2. Inspect the hydrostatic pump(s).

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Index Hydrostatic drive - 29 Hydrostatic transmission - 202 Hydrostatic transmission - Decontaminating (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydrostatic transmission - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydrostatic transmission - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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Hydrostatic drive - 29 Two-speed assembly - 134

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Hydrostatic drive - 29 Two-speed assembly - 134

TECHNICAL DATA Control valve General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Control valve Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

(*) See content for specific models 47683911 27/02/2015

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Hydrostatic drive - Two-speed assembly

Control valve - General specification L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

RAPH13SSL0967EA

Brake, two speed valve Hydraulic requirements: Sequence valve setting Filter rating Port identification

Charge pressure = 24 - 25.5 bar (350 - 370 psi) Brake release pressure = 15 bar (218 psi) 12 bar (174 psi) 40 – 50 microns P - Supply inlet T - Tank return 2SPD - Two speed shift B1 - Brake motor 1 B2 - Brake motor 2 PS2 - Brake pressure switch

Control valve - General specification L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

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Hydrostatic drive - Two-speed assembly

RAPH14SSL0006FA

Loader pilot interlock, brake, two speed valve Hydraulic requirements Sequence valve setting Filter rating Port identification

Control valve - General specification C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

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Hydrostatic drive - Two-speed assembly

RAPH14SSL0011FA

Brake, two speed valve Hydraulic requirements: Port identification

Charge pressure = 24 - 25.5 bar (350 - 370 psi) Brake release pressure = 15 bar (218 psi) P - Supply inlet T - Tank return 2SPD - Two speed shift B1 - Brake motor 1 B2 - Brake motor 2

Control valve - General specification C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

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Hydrostatic drive - Two-speed assembly

RAPH12SSL0381EA

Loader pilot interlock, brake, two speed valve Hydraulic requirements Port identification

Charge pressure = 24 - 25.5 bar (350 - 370 psi) Brake release pressure = 15 bar (218 psi) P - Supply inlet T - Tank return 2SPD - Two speed shift B1 - Brake motor 1 B2 - Brake motor 2 LV - Electrohydraulic pilot pressure PS2 - Brake pressure switch

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Hydrostatic drive - Two-speed assembly

Control valve - Component localization WE WE

C227 TIER 4B (FINAL) [NDM471837 - ] L221 TIER 4B (FINAL) [NEM479941 - ]

RAPH13SSL0863FA

Valve location Valve identification (1) Ride control valve

(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve

(5) High flow valve (6) Override valve for the loader arm

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(7) Self-leveling valve

Hydrostatic drive - Two-speed assembly

Control valve - Component localization WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

RAIL13SSL1004FA

Valve location Valve identification (1) Ride control valve

(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve

(5) Accumulator (6) High flow valve

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(7) Self level valve

Index Hydrostatic drive - 29 Two-speed assembly - 134 Control valve - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control valve - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

47683911 27/02/2015 EN

SERVICE MANUAL Brakes and controls C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Brakes and controls - 33

[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1

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Brakes and controls - 33 Parking brake or parking lock - 110

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Brakes and controls - 33 Parking brake or parking lock - 110

TECHNICAL DATA Parking brake control valve or manifold General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Front loader arm hydraulic system - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

FUNCTIONAL DATA Parking brake control valve or manifold Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

(*) See content for specific models 47683911 27/02/2015

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Brakes and controls - Parking brake or parking lock

Parking brake control valve or manifold - General specification L221 L228

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

RAPH13SSL0966EA

Brake valve Hydraulic requirements: Port identification

Charge pressure = 24 - 25.5 bar (350 - 370 psi) Brake release pressure = 15 bar (218 psi) P - Supply inlet T - Tank return B1 - Brake motor 1 B2 - Brake motor 2

Parking brake control valve or manifold - General specification L221 L228

WE Electro hydraulic controls WE Electro hydraulic controls

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Brakes and controls - Parking brake or parking lock

RAPH13SSL0965EA

Electrohydraulic (EH), brake valve Hydraulic requirements Port identification

Charge pressure = 24 - 25.5 bar (350 - 370 psi) Brake release pressure = 15 bar (218 psi) P - Supply inlet T - Tank return B1 - Brake motor 1 B2 - Brake motor 2 LV - EH pilot pressure PS2 - Brake pressure switch

Parking brake control valve or manifold - General specification L221 L228

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

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Brakes and controls - Parking brake or parking lock

RAPH13SSL0967EA

Brake, two speed valve Hydraulic requirements: Sequence valve setting Filter rating Port identification

Parking brake control valve or manifold - General specification L221 L228

WE Electro hydraulic controls WE Electro hydraulic controls

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Brakes and controls - Parking brake or parking lock

RAPH14SSL0006FA

Loader pilot interlock, brake, two speed valve Hydraulic requirements Sequence valve setting Filter rating Port identification

Parking brake control valve or manifold - General specification C227 C232

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

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Brakes and controls - Parking brake or parking lock

RAPH14SSL0011FA

Brake, two speed valve Hydraulic requirements: Port identification

Charge pressure = 24 - 25.5 bar (350 - 370 psi) Brake release pressure = 15 bar (218 psi) P - Supply inlet T - Tank return 2SPD - Two speed shift B1 - Brake motor 1 B2 - Brake motor 2

Front loader arm hydraulic system - General specification C227 C232

WE Electro hydraulic controls WE Electro hydraulic controls

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Brakes and controls - Parking brake or parking lock

RAPH12SSL0381EA

Loader pilot interlock, brake, two speed valve Hydraulic requirements Port identification

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Brakes and controls - Parking brake or parking lock

Parking brake control valve or manifold - Component localization WE WE

C227 L221 TIER 4B (FINAL) [NEM479941 - ]

RAPH13SSL0863FA

Valve location Valve identification (1) Ride control valve

(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve

(5) High flow valve (6) Override valve for the loader arm

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(7) Self-leveling valve

Brakes and controls - Parking brake or parking lock

Parking brake control valve or manifold - Component localization WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

RAIL13SSL1004FA

Valve location Valve identification (1) Ride control valve

(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve

(5) Accumulator (6) High flow valve

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(7) Self level valve

Index Brakes and controls - 33 Parking brake or parking lock - 110 Front loader arm hydraulic system - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking brake control valve or manifold - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking brake control valve or manifold - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

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SERVICE MANUAL Hydraulic systems C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Hydraulic systems - 35

[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.525] Auxiliary hydraulic valves and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5 [35.600] High flow hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6 [35.724] Front loader hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7 [35.701] Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8 [35.734] Tool quick coupler hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9

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C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Hydraulic systems - 35 Hydraulic systems - 000

FUNCTIONAL DATA Hydraulic systems Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic schematic frame 01 - Valves - Mechanical drive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic schematic frame 02 - Valves - Electro-Hydraulic (EH) drive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hydraulic schematic frame 03 - Pump and motor - Mechanical drive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Hydraulic schematic frame 04 - Pump and motor - Electro-Hydraulic (EH) drive (*) . . . . . . . . . . . . . . . . . 17 Hydraulic schematic frame 01 - Valves - Mechanical drive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Hydraulic schematic frame 02 - Valves - Electro-Hydraulic (EH) drive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Hydraulic schematic frame 03 - Pumps - Enhanced High-Flow (EHF) option pump assembly (*) . . . . . 29 Hydraulic schematic frame 04 - Pump and motor - Mechanical drive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Hydraulic schematic frame 05 - Pump and motor - Electro-Hydraulic (EH) 2 speed (*) . . . . . . . . . . . . . . 37 Hydraulic schematic frame 05 - Pump and motor - 2 speed option (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

SERVICE Hydraulic systems Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Depressurising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Decontaminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Component localization WE WE

C227 L221 TIER 4B (FINAL) [NEM479941 - ]

RAPH13SSL0863FA

Valve location Valve identification (1) Ride control valve

(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve

(5) High flow valve (6) Override valve for the loader arm

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(7) Self-leveling valve

Hydraulic systems - Hydraulic systems

Hydraulic systems - Component localization WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

RAIL13SSL1004FA

Valve location Valve identification (1) Ride control valve

(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve

(5) Accumulator (6) High flow valve

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(7) Self level valve

Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic schematic frame 01 - Valves Mechanical drive C227 L221

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

Component Check valve Hydraulic coupler valve (if applicable) Ride control valve (if applicable) Self level valve (if applicable) Auxiliary coupler Main control valve (loader valve) Secondary auxiliary valve (if applicable) High flow valve (if applicable) Hydraulic oil filter

Call-out reference (1) (2) (3) (4) (5) (6) (7) (8) (9)

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Hydraulic systems - Hydraulic systems

RAIL16SSL0239JA

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic schematic frame 02 - Valves Electro-Hydraulic (EH) drive C227 TIER 4B (FINAL) [NDM471837 - ] L221 TIER 4B (FINAL) [NEM479941 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Call-out reference (1) (2) (3) (4) (5) (6) (7) (8) (9)

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Hydraulic systems - Hydraulic systems

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Hydraulic systems - Hydraulic systems

RAIL16SSL0241JA

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Hydraulic systems - Hydraulic schematic frame 03 - Pump and motor - Mechanical drive C227 L221

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

Component Right-hand drive motor Left-hand drive motor Brake valve Two-speed/brake valve Hydrostatic pump assembly

Call-out reference (1) (2) (3) (4) (5)

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Hydraulic systems - Hydraulic systems

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Hydraulic systems - Hydraulic systems

RAIL16SSL0254JA

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Hydraulic systems - Hydraulic systems

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic schematic frame 04 - Pump and motor - Electro-Hydraulic (EH) drive C227 L221

WE Electro hydraulic controls WE Electro hydraulic controls

Component Right-hand drive motor Left-hand drive motor Brake valve Brake/two-speed valve Hydrostatic pump assembly

Call-out reference (1) (2) (3) (4) (5)

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Hydraulic systems - Hydraulic systems

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Hydraulic systems - Hydraulic systems

RAIL16SSL0240JA

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic schematic frame 01 - Valves Mechanical drive C232 L228

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

Component Check valve Hydraulic coupler valve (if applicable) Ride control valve (if applicable) Self-leveling valve (if applicable) Auxiliary coupler Main control valve (Loader valve) Secondary auxiliary valve (if applicable) High flow valve (if applicable) Hydraulic oil filter

Call-out reference (1) (2) (3) (4) (5) (6) (7) (8) (9)

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RAIL16SSL0246JA

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Hydraulic systems - Hydraulic systems

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic schematic frame 02 - Valves Electro-Hydraulic (EH) drive C232 TIER 4B (FINAL) [NFM402195 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Call-out reference (1) (2) (3) (4) (5) (6) (7) (8) (9)

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Hydraulic systems - Hydraulic systems

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Hydraulic systems - Hydraulic systems

RAIL16SSL0243JA

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic schematic frame 03 - Pumps Enhanced High-Flow (EHF) option pump assembly C232 TIER 4B (FINAL) [NFM402195 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

WE WE

Component Loop flushing valve Charge pump (Enhanced High-Flow - EHF) Hydrostatic pump Auxiliary pump (standard flow)

Call-out reference (1) (2) (3) (4)

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Hydraulic systems - Hydraulic systems

RAIL16SSL0242JA

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Hydraulic systems - Hydraulic systems

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic schematic frame 04 - Pump and motor - Mechanical drive C232 TIER 4B (FINAL) [NFM402195 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

Component Right-hand drive motor Left-hand drive motor Electro hydraulic/brake valve Electro hydraulic/two-speed/brake valve Hydrostatic pump assembly

Call-out reference (1) (2) (3) (4) (5)

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RAIL16SSL0245JA

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Hydraulic systems - Hydraulic schematic frame 05 - Pump and motor - Electro-Hydraulic (EH) 2 speed C232 TIER 4B (FINAL) [NFM402195 - ]

WE Electro hydraulic controls

Component Right-hand drive motor Left-hand drive motor Electro hydraulic/two-speed/brake valve Hydrostatic pump assembly

Call-out reference (1) (2) (3) (4)

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RAIL16SSL0244JA

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Hydraulic systems - Hydraulic schematic frame 05 - Pump and motor - 2 speed option L228 TIER 4B (FINAL) [NFM401134 - ]

Component Right-hand drive motor Left-hand drive motor Brake valve Electro hydraulic/two-speed/brake valve Hydrostatic pump assembly

Call-out reference (1) (2) (3) (4) (5)

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RAIL16SSL0247JA

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Hydraulic systems - Cleaning 1. Prepare the portable filter CAS10162A by doing the following steps: (A) Remove all the hydraulic oil from the inlet and outlet hoses for the portable filter. (B) Remove the filter element from the portable filter. (C) Remove all hydraulic oil from the portable filter. (D) Clean the inside of the housing for the filter element. (E) Install a new filter element in the portable filter. 2. Determine whether the contamination is microscopic or visible. 3. If the contamination is microscopic: (A) Check the maintenance schedule for the machine to learn if the hydraulic oil must be changed. If necessary, change the hydraulic oil. Change the hydraulic filter. (B) Do steps 6 through 37. 4. If the contamination is visible, do the following steps: (A) Change the hydraulic oil and hydraulic filter. (B) Do steps 5 through 37. 5. Check the amount of contamination in the hydraulic system by doing the following steps: (A) Disassemble one cylinder in two different circuits. Check for damage to seals, scoring of the cylinder wall, etc. Repair the cylinders as necessary. (B) If, in your judgment, the damage to the cylinders was caused by severe contamination and is not the result of normal wear, it is necessary to remove, clean and repair all valves, pumps, lines, cylinders, hydraulic reservoir, etc. in the hydraulic system. 6. Remove the cap from the reservoir and install the adapter CAS1871 on the reservoir. 7. Connect the vacuum pump CAS10192 to the adapter CAS1871. Oil reservoir - Apply vacuum (35.300)

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Hydraulic systems - Hydraulic systems

8. Start the vacuum pump. 9. The hydraulic reservoir is located at the rear of the machine. Loosen and remove the drain plug from the reservoir. 10. Using the fitting kit CAS10508, install the valve in the hole for the drain plug. Make sure that the valve is closed. 11. Stop the vacuum pump. 12. Connect the inlet hose for the portable filter to the valve that is installed in the hole for the drain plug. 13. Disconnect the vacuum pump and remove CAS1871 adapter from reservoir. 14. Install the outlet hose for the portable filter in the hydraulic reservoir filler neck. 15. Open the valve that is installed in the hole for the drain plug. (A) Check fluid level in reservoir. Add if necessary. 16. Move the switch for the portable filter to the ON position. 17. Start and run the engine at half throttle. 18. Run the portable filter for 10 minutes with the engine running at half throttle. 19. Continue to run the portable filter. Increase the engine speed to full throttle. Do the following to heat the oil to operating temperature: (A) Increase the engine speed to full throttle. (B) Hold the bucket control lever in the ROLLBACK position for five seconds. (C) Return the bucket control lever in the NEUTRAL position for five seconds. (D) Repeat steps 19B and 19C until the oil is at operating temperature; 49 - 66 °C (120 - 150 °F). 20. With the engine running at full throttle and the portable filter running, completely extend and retract the lift cylinders and the bucket cylinders. Continue to operate the cylinders, one after the other for 30 minutes. NOTE: If the filter light in the machine illuminates, stop the engine, change the filter, then continue with procedure. 21. Decrease the engine speed to low idle. 22. Continue to run the portable filter for 10 minutes. During this time, move the hose up and down to help mix the oil in the reservoir. 23. Stop the portable filter. 24. Stop the engine. 25. Remove the hose from the hydraulic reservoir. 26. Oil reservoir - Apply vacuum (35.300) 27. Close the valve that is installed in the hole for the drain plug. 28. Disconnect the inlet hose for the portable filter from the valve. 29. Start the vacuum pump. 47683911 27/02/2015

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30. Remove the valve from the hole for the drain plug. 31. Install and tighten the drain plug. 32. Stop the vacuum pump. 33. Disconnect the vacuum pump from the opening in the reservoir. 34. Install new hydraulic filter elements on the machine. 35. Start the engine. Check for oil leakage around the new hydraulic filter. 36. Stop the engine. 37. Check the level of the oil in the reservoir and add oil as required. Oil reservoir - Filling (35.300)

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Hydraulic systems - Depressurising Before removing components from the hydraulic system, depressurize the hydraulic circuits.

Hydraulic cylinders Loader arm cylinders 1.

Support the loader arm with suitable lifting equipment.

Shut OFF the engine.

Hydraulic coupler 1.

Remove the bucket or attachment from the mounting plate.

Leave the hydraulic coupler in the unlocked position.

20092924

93109392

Pumps and motors Hydrostatic drive pumps, fixed displacement pumps, and motors 1. Shut OFF the engine.

Ride Control™ 1. Ride control system 1.

Raise and secure the loader arm. Please see Cab tilting system - Tilt (90.150) for details about securing the loader arm.

Shut OFF the engine.

Turn the machine ON but do not start the engine.

Press the ride control button (1) while pulling up on the override valve.

Auxiliary and High Flow (HF) 2. For attachments connected to standard auxiliary or standard high flow: • All units are equipped with the “connect under pressure” manifold that bleeds pressure from the circuit during the connect or the disconnect.

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Enhanced High Flow (EHF) 3. For attachments connected to Enhanced High Flow (EHF) aux: • EHF attachments should all be motor driven which will automatically bleed the pressure off when the engine is turned OFF.

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Decontaminating WARNING Crushing hazard! If you service the machine with the loader lift arms raised, always use the support strut. Remove the retaining pin and place the support strut onto the cylinder rod. Install the retaining pin into the support strut. Lower the lift arms onto the support strut. Failure to comply could result in death or serious injury. W0230A

1. Start and run the engine at 1500 RPM (r/min). 2. To depressurize the lift base end of the loader arm, pull the loader boom down valve. 3. To depressurize the tilt rod end, roll the coupler back, then when the handle is moved to dump pressure on the tilt base end, the pressure will be reduced on the rod end. NOTE: This process must be done while the engine is running. Once the engine is off, charge pressure is reduced which closes the port lock valve on the loader valve not allowing the pressure in the cylinders to be relieved. 4. Stop the engine. 5. Depress the auxiliary hydraulic interlock override button, and leave the seat within 30 s. Move each control lever in both directions to release pressure in the hydraulic circuits. 6. Loosen and remove the filler cap from the reservoir. 7. Drain the hydraulic oil from the reservoir. (A) Have available acceptable equipment to drain the hydraulic oil. (B) Remove the drain plug from the bottom of the reservoir. 8. Remove the hydraulic filter element from the machine. 9. Install new hydraulic filter element on the machine. 10. Install the drain plug in the bottom of the reservoir. 11. Fill the hydraulic reservoir. Oil reservoir - Filling (35.300) 12. Disconnect the line from the ROD end and BARREL end of each cylinder. 13. Be sure all control levers are in the NEUTRAL position. 14. Start and run the engine at low idle. NOTICE: Check the oil level in the hydraulic reservoir frequently while doing step 13. Have another person hold a container under the hydraulic lines while you do step 13. 15. Slowly move the control lever for each bucket and lift cylinders in both directions until oil begins to flow from the open line. Hold the control lever in place until clean oil flows from the open line. 16. Stop the engine. 17. Connect the system line to the BARREL end of each cylinder. 47683911 27/02/2015

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18. Connect a suitable drain line to the ROD end of each cylinder and place the other end in an acceptable container for contaminated oil. 19. Start the engine and run the engine at low idle. 20. Slowly and completely extend all cylinders. As the piston rod comes in/out of the cylinder, oil will be pushed out of the ROD end of the cylinders. NOTICE: Any attachment or part of an attachment that is raised must be supported with acceptable equipment to prevent the attachment from falling. 21. Support any attachments that will be in the RAISED position. 22. Stop the engine. 23. Disconnect the drain lines and connect the system lines to the cylinders. 24. Check the oil level in the hydraulic reservoir. Add oil as required. 25. Install the filler cap on the reservoir. 26. Remove the hydraulic filter element from the machine. 27. Install a new hydraulic filter element on the machine. 28. Start and run the engine at 1500 RPM, operate each hydraulic circuit to completely extend and retract the cylinders. 29. Stop the engine and check for leaks. Check the oil level in the hydraulic reservoir. Add oil as required. Oil reservoir - Filling (35.300)

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Index Hydraulic systems - 35 Hydraulic systems - 000 Hydraulic systems - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Decontaminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Depressurising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Hydraulic schematic frame 01 - Valves - Mechanical drive (*) . . . . . . . . . . . . . .

Hydraulic systems - Hydraulic schematic frame 02 - Valves - Electro-Hydraulic (EH) drive (*) . . . . .

Hydraulic systems - Hydraulic schematic frame 03 - Pump and motor - Mechanical drive (*) . . . . .

Hydraulic systems - Hydraulic schematic frame 03 - Pumps - Enhanced High-Flow (EHF) option pump assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Hydraulic schematic frame 04 - Pump and motor - Electro-Hydraulic (EH) drive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Hydraulic schematic frame 04 - Pump and motor - Mechanical drive (*) . . . . .

Hydraulic systems - Hydraulic schematic frame 05 - Pump and motor - 2 speed option (*) . . . . . . .

Hydraulic systems - Hydraulic schematic frame 05 - Pump and motor - Electro-Hydraulic (EH) 2 speed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Hydraulic systems - 35 Reservoir, cooler, and filters - 300

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Hydraulic systems - 35 Reservoir, cooler, and filters - 300

SERVICE Oil reservoir Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Apply vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Filling (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Oil cooler/Heat exchanger Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Hydraulic systems - Reservoir, cooler, and filters

Oil reservoir - Drain fluid WE WE WE WE

C227 C232 L221 L228

WARNING Chemical hazard! When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions. Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals. Failure to comply could result in death or serious injury. W0371A

Prior operation: Remove the battery. Please see Battery - Remove (55.302) NOTE: The drain plug for the hydraulic tank is located inside of the battery compartment. 1. Remove the filler cap on the hydraulic tank. 2. Place a container under the battery compartment. 3. Slowly remove the drain plug.

RAIL15SSL0099BA

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Oil reservoir - Apply vacuum 1. Remove the cap from the hydraulic reservoir. 2. Install an adapter cap CAS1871 on the filler neck. 3. Connect the vacuum pump CAS10193 to the adapter. 4. Start the vacuum pump.

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Oil reservoir - Filling WE WE WE WE

C227 C232 L221 L228

1. Lower the loader lift arms to the ground and shut off the engine. 2. Clean the reservoir filler cap and the area around the filler cap with cleaning solvent. 3. Turn the filler cap 1/2 turn to relieve air pressure from the reservoir. Do not remove the filler cap from the reservoir until the pressure is relieved. 4. Remove the filler cap from the reservoir. 5. Add the correct oil to the reservoir until the proper oil level in the reservoir is established. Fill the reservoir until the oil level is at the midpoint of the sight gauge. Install the reservoir cap.

93107491

93106865

6. Start and run the engine and operate the hydraulics. Lower the loader lift arms to the ground. Stop the engine and check the oil level in the reservoir. Add oil as required.

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Oil cooler/Heat exchanger - Remove WE WE WE WE

C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

Prior operation: Drain the hydraulic tank. Please see Oil reservoir - Drain fluid (35.300). Prior operation: Remove the radiator. Please see Radiator - Remove (10.400). 1. Label and disconnect oil cooler hydraulic lines (1) and cap the opened ports.

931001881

931001882

931001884

2. Remove oil cooler mounting hardware (1).

3. Remove oil cooler (1).

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Oil cooler/Heat exchanger - Install 1. Place oil cooler (1) in proper mounting location.

931001884

931001882

931001881

2. Install oil cooler mounting hardware (1).

3. Connect oil cooler hydraulic lines (1) to correct ports.

Next operation: Add hydraulic oil. Please see Oil reservoir - Filling (35.300). Next operation: Install the radiator. Please see Radiator - Install (10.400).

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Index Hydraulic systems - 35 Reservoir, cooler, and filters - 300 Oil cooler/Heat exchanger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil cooler/Heat exchanger - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil reservoir - Apply vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil reservoir - Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil reservoir - Filling (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Hydraulic systems - 35 Fixed displacement pump - 104

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Hydraulic systems - 35 Fixed displacement pump - 104

TECHNICAL DATA Fixed displacement pump Pump - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Fixed displacement pump Flow test - Auxiliary couplers (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Flow test - T fitting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Preliminary test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

(*) See content for specific models 47683911 27/02/2015

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Pump - General specification WE WE

C227 TIER 4B (FINAL) [NDM471837 - ] L221 TIER 4B (FINAL) [NEM479941 - ]

RAPH14SSL0002GA

Fixed displacement pump Type

Gear pump

Pump displacement

36.6 cm³ (2.23 in³)

Engine RPM

2475 RPM

Pump flow at RPM

92.4 L/min (24.4 US gpm)

High flow pump displacement (if applicable) 13.7 cm³ (0.84 in³) Combined pump flow at RPM (if applicable) 127.2 L/min (33.6 US gpm)

Fixed displacement pump - General specification L228

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RAPH14SSL0002GA

Fixed displacement pump Type

Gear pump

Pump displacement

36.6 cm³ (2.23 in³)

Engine RPM

2475 RPM

Pump flow at RPM

92.3 l/min (24.4 US gpm)

High flow pump displacement (if applicable) 13.7 cm³ (0.84 in³) Combined pump flow at RPM (if applicable) 143.8 l/min (38.0 US gpm)

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Fixed displacement pump - Flow test - Auxiliary couplers WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

CAUTION Burn hazard! Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding. Failure to comply could result in minor or moderate injury. C0107B

Pump efficiency test using the auxiliary couplers NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: Two persons are required to perform the flow meter tests to safely avoid possible injury. One person must be seated in the operators seat when the engine is running. The second person is to control the flow meter and take the readings. 1. Attach the flow meter, part number 380500047, to the auxiliary couplers on the loader arm. NOTE: Verify that the flow inlet and outlet direction is correct on the flow meter.

RAPH12SSL0241AA

931007504

2. Start the machine and run at full throttle. 3. Adjust the machine’s RPM to 200 RPM less than the full throttle RPM. 4. Record the set RPM on the data collection sheet located on the following page.

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Pump flow with no restriction 5. Verify that the flow meter has no restriction on the hydraulic pump. Record the pump flow on the data collection sheet located on the following page. Please see Fixed displacement pump - General specification (35.104) for specification about the gear pumps. NOTE: Image 3 is an example of a flow reading. Image 3 may not match your reading.

RAPH12SSL0242AA

RAPH12SSL0243AA

Pump flow with restriction 6. Adjust the flow meter pressure until 152 bar (2200 psi) is achieved. Verify that the machine is running at the set RPM recorded on the data collection sheet located on the following page. Adjust RPM if necessary. Record the pump flow on the data collection sheet located on the following page. Please see Fixed displacement pump - General specification (35.104) for specification about the gear pumps. NOTE: Image 2 is an example of a flow reading. Image 2 may not match your reading.

Pump efficiency 7. Pump efficiency is determined by dividing the pump flow with restriction value by the pump flow without restriction value, then multiplying that new value by 100. Record the pump efficiency on the data collection sheet located on the following page. NOTE: Pump efficiency should be no less than 70 %.

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Engine RPM - Set RPM

__________RPM

Notes: Test 1: Pump flow - Pump flow at without restriction

__________l/min __________gpm

Notes: Test 2: Pump flow with restriction - Pump flow with 152 bar (2200 psi) restriction

__________l/min __________gpm

Notes: Test 3: Pump efficiency - Calculated pump efficiency __________% NOTE: Calculated pump efficiency is determined by dividing Test 2’s value by Test 1’s value, then multiplying that new value by 100. Notes:

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Fixed displacement pump - Flow test - T fitting WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

Pump efficiency test using the T fitting method NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: To avoid possible injury, two people are required to perform the following test . One person must be seated in the operator’s seat while the engine is running and the hydraulic controls are enabled. The second person is to control the flow meter and record the readings on the flow meter. 1. Locate the main control valve. 2. Install the T fitting (1) into the pump outlet, and attach the inlet hose (2) for the flow meter, part number 380500047, to the T fitting. NOTE: Verify that the flow direction is correct on the flow meter.

RAPH12SSL0246AA

RAPH12SSL0247AA

3. Place the outlet hose (1) for the flow meter with hose adapter in the hydraulic tank. NOTE: Verify that the flow direction is correct on the flow meter.

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4. Start the machine and run the engine at high idle. Adjust the machine’s RPM to 200 RPM less than the full RPM. Record the set RPM on the data collection sheet located on the following page.

931007504

RAPH12SSL0242AA

RAPH12SSL0243AA

Pump flow with no restriction 5. Verify that the flow meter has no restriction on the hydraulic pump. Record the pump flow on the data collection sheet located on the following page. Please see Fixed displacement pump - General specification (35.104) for specification about the pumps. NOTE: Image 4 is an example of a flow reading. Image 4 may not match your reading.

Pump flow with restriction 6. Adjust the flow meter pressure until 152 bar (2200 psi) is achieved. Verify that the machine is running at the set RPM recorded on the data collection sheet located on the following page. Adjust RPM if necessary. Record the pump flow on the data collection sheet located on the following page. Please see Fixed displacement pump - General specification (35.104) for specification about the pumps. NOTE: Image 3 is an example of a flow reading. Image 3 may not match your reading.

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Engine RPM - Set RPM

__________RPM

Notes: Test 1: Pump flow - Pump flow without restriction

__________l/min __________gpm

Notes: Test 2: Pump flow with restriction - Pump flow with 152 bar (2200 psi) restriction

__________l/min __________gpm

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Fixed displacement pump - Remove WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

WARNING Pressurized system! System is still under pressure. Release pressure according to instructions in this manual. Failure to comply could result in death or serious injury. W1044A

1. Label and disconnect the pump supply hose (1). Cap the open ports.

931001955

931002073

2. Label and disconnect the pump hydraulic tube (1). Cap the open ports.

3. Remove the retaining bolts (1).

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Fixed displacement pump - Install WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

NOTICE: The hydrostatic pumps have different options for gear pumps. The pictures below may vary from the pump you are working on. The procedure is the same. 1. Install gear pump (1) and retaining bolts (2). Tighten bolts to torque.

931002073

931001955

2. Connect gear pump hydraulic tube (1). NOTE: Picture shown is of a single gear pump. If the pump you are working on is a double gear pump, connect second hydraulic tube.

3. Connect gear pump supply hose (1).

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Fixed displacement pump - Preliminary test WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

When hydraulic components are replace, air can get into the hydraulic system. Air bubbles can be catastrophic to a hydraulic system. The following procedure bleeds air from the hydraulic system. Please perform this test if the pump has been removed or if any hydraulic lines for the pump have been removed. 1. Fill the reservoir with the appropriate oil to the proper level. 2. Loosen the supply hose at the pump. 3. Tighten the connection when oil flows from the connection.

931002073

RAPH14SSL0351BA

RAIL14SSL0418AA

4. Lower the cab. Please see Cab tilting system - Lower (90.150) for details.

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5. Start the engine and run at a low idle for two to three minutes.

931007504

RAPH14SSL0351BA

RAIL14SSL0418AA

6. Lower the loader arm slowly.

7. Turn off the machine. 8. Check the reservoir level, and add oil as necessary.

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9. Connect a flow meter, part number 380500047, to the auxiliary couplers. Open all of the valves on the flow meter to allow a free flow of oil through the flow meter.

RAPH12SSL0241AA

931007504

RAPH12SSL0242AA

10. Restart the engine and run at a low idle.

11. Engage the standard auxiliary system to purge the auxiliary lines of air. Allow oil to flow through the auxiliary system for two to three minutes. If the pump has been replaced, verify that the pump has the correct flow by observing the flow meter. NOTE: Image 9 is an example of a flow reading. Image 9 may not match your reading. NOTE: Please see Fixed displacement pump - General specification (35.104) for specifications about your pump.

12. Turn off the machine, and check the installation for leaks. 13. Check the reservoir level, and add oil as necessary. 47683911 27/02/2015

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Index Hydraulic systems - 35 Fixed displacement pump - 104 Fixed displacement pump - Flow test - Auxiliary couplers (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fixed displacement pump - Flow test - T fitting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fixed displacement pump - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fixed displacement pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fixed displacement pump - Preliminary test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fixed displacement pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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Hydraulic systems - 35 Main control valve - 359

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Hydraulic systems - 35 Main control valve - 359

TECHNICAL DATA Main control valve General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Main control valve Test - Circuit leakage (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Remove - Proportional auxiliary valve retract solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install - Proportional auxiliary valve retract solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Remove - Proportional auxiliary valve extend solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install - Proportional auxiliary valve extend solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Remove - Spool solenoids (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install - Spool solenoids (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Remove - Spool position sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Install - Spool position sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Remove - Loader port lock solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install - Loader port lock solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Relief valve Main relief valve - Pressure test - T fitting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Pressure test - Auxiliary couplers (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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Hydraulic systems - Main control valve

Main control valve - General specification C227 C232 L221 L228

WE WE WE WE

RAIL15SSL0024FA

Main control valve Main relief setting Circuit relief setting

Valve identification

207 - 217 bar (3000 - 3145 psi) A1 = 220 - 235 bar (3190 - 3408 psi) A2 = 255 - 270 bar (3698 - 3916 psi) B2 = 225 - 240 bar (3263 - 3481 psi) (1) Main relief (2) Port lock cartridge (3) A1, pressure relief (4) A2, pressure relief (5) Load check (6) B1, hydraulic, anti-cavitation (7) B2, pressure relief (8) Plug

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Torque setting (Installation)

42.0 N·m (31.0 lb 24.0 N·m (18.0 lb 24.0 N·m (18.0 lb 24.0 N·m (18.0 lb 42.0 N·m (31.0 lb 24.0 N·m (18.0 lb 24.0 N·m (18.0 lb 42.0 N·m (31.0 lb

ft) ft) ft) ft) ft) ft) ft) ft)

Hydraulic systems - Main control valve

Port identification

Solenoid identification

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 (9) Port lock coil

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Hydraulic systems - Main control valve

Main control valve - Test - Circuit leakage WE WE WE WE

C227 C232 L221 L228

NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: Two persons are required to perform the flow meter tests to safely avoid possible injury. One person must be seated in the operators seat when the engine is running. The second person is to control the flow meter and take the readings. 1. Locate the main control valve. 2. Install the “T” fitting (1) into the hydraulic gear pump outlet, and attach the flow meter, part number 380500047, (2) hose to the “T” fitting. NOTE: Verify that the flow inlet direction is correct on the flow meter.

RAPH12SSL0246AA

RAPH12SSL0247AA

3. Place the other flow meter hose (1) with hose adapter in the hydraulic tank. NOTE: Verify that the flow outlet direction is correct on the flow meter.

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Hydraulic systems - Main control valve

4. Start the machine and run at full throttle.

931007504

RAPH12SSL0329AA

5. Adjust the flow meter pressure until 124 bar (1800 psi) is achieved. While watching the flow meter liter per minute (l/min) gauge or gallon per minute (gpm) gauge, stroke each loader arm and bucket function to the end of cylinder travel on the machine, and activate the primary auxiliary couplers in both directions. Record the pump flow on the data collection sheet located on the following page. Compare the flow of every stroked function. Differences in pump flow indicate internal leaks and/or easier paths to tank. NOTE: Pump flow should be within 4 l/min (1 US gpm) of pump specification. Please see Fixed displacement pump - General specification (35.104) for specifications on the gear pumps. NOTE: Image 4 is an example of a flow reading. Image 4 may not match your reading.

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Hydraulic systems - Main control valve

Test 6: Circuit leakage with restriction NOTE: For “T” fitting test only - Bucket rollback

__________l/min __________gpm

- Bucket dump

__________l/min __________gpm

- Loader raise

__________l/min __________gpm

- Loader lower

__________l/min __________gpm

- Auxiliary up

__________l/min __________gpm

- Auxiliary down

__________l/min __________gpm

Notes:

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Hydraulic systems - Main control valve

Main control valve - Remove - Proportional auxiliary valve retract solenoid WE Mechanical hydraulic controls WE Mechanical hydraulic controls WE Mechanical hydraulic controls

200 Series Compact Track Loaders L221 L228

Prior operation: Tilt the ROPS 1. Locate proportional auxiliary valve retract solenoid (1) on the loader valve block (2).

931002092B

931002095

2. Disconnect connector (1) from the proportional auxiliary valve retract solenoid (2).

3. Remove the two bolts securing the proportional auxiliary valve retract solenoid on the loader valve block.

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Hydraulic systems - Main control valve

Main control valve - Install - Proportional auxiliary valve retract solenoid WE Mechanical hydraulic controls WE Mechanical hydraulic controls WE Mechanical hydraulic controls

200 Series Compact Track Loaders 200 Series Skid Steer Loaders L228

1. Insert the proportional auxiliary valve retract solenoid (1) into the loader valve block (2).

931002092B

931002095

2. Connect connector (1) to the proportional auxiliary valve retract solenoid (2).

3. Insert the two retaining screws (1) into proportional auxiliary valve retract solenoid. Tighten to 5 N·m (3.7 lb ft).

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Hydraulic systems - Main control valve

Main control valve - Remove - Proportional auxiliary valve extend solenoid WE Mechanical hydraulic controls WE Mechanical hydraulic controls WE Mechanical hydraulic controls

200 Series Compact Track Loaders 200 Series Skid Steer Loaders L228

Prior operation: Tilt the ROPS 1. Locate proportional auxiliary valve extend solenoid (1) on the loader valve block (2).

931002092B

931002095

2. Disconnect connector (1) from the proportional auxiliary valve extend solenoid (2).

3. Remove the two bolts securing the proportional auxiliary valve extend solenoid on the loader valve block.

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Hydraulic systems - Main control valve

Main control valve - Install - Proportional auxiliary valve extend solenoid WE Mechanical hydraulic controls WE Mechanical hydraulic controls WE Mechanical hydraulic controls

200 Series Compact Track Loaders 200 Series Skid Steer Loaders L228

1. Insert the proportional auxiliary valve extend solenoid (1) into the loader valve block (2).

931002092B

931002095

2. Connect connector (1) to the proportional auxiliary valve extend solenoid (2).

3. Insert the two retaining screws (1) into proportional auxiliary valve extend solenoid. Tighten to 5 N·m (3.7 lb ft).

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Hydraulic systems - Main control valve

Main control valve - Remove - Spool solenoids WE WE WE WE

C227 C232 L221 L228

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Prior operation: Tilt the ROPS 1. Locate the following solenoids: 1.

Loader valve retract

Loader valve extend

Bucket valve extend

Bucket valve retract

Auxiliary valve extend

Auxiliary valve retract

2. Disconnect the electrical connector from the solenoid. 3. Remove the two bolts securing the solenoid on the loader valve block. 4. Remove the solenoid.

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RAPH12SSL0445AA

Hydraulic systems - Main control valve

Main control valve - Install - Spool solenoids WE WE WE WE

C227 C232 L221 L228

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

1. Locate the following solenoids: 1.

Loader valve retract

Loader valve extend

Bucket valve extend

Bucket valve retract

Auxiliary valve extend

Auxiliary valve retract

2. Install the solenoid. 3. Insert the two retaining screws into the solenoid. Torque the bolts to 5 N·m (44 lb in). 4. Reconnect the electrical connector.

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RAPH12SSL0445AA

Hydraulic systems - Main control valve

Main control valve - Remove - Spool position sensors WE WE WE WE

C227 C232 L221 L228

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

1. Locate the following sensors: 1.

Boom position sensor

Bucket position sensor

Auxiliary sensor

2. Disconnect the electrical connector. 3. Remove the nut holding the sensor. 4. Remove the sensor.

RAPH12SSL0446AA

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Hydraulic systems - Main control valve

Main control valve - Install - Spool position sensors WE WE WE WE

C227 C232 L221 L228

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

1. Locate the following sensors: 1.

Boom position sensor

Bucket position sensor

Auxiliary sensor

2. Insert the sensor into the main control valve. 3. Thread the nut onto sensor. 4. Connect the electrical connector.

RAPH12SSL0446AA

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Hydraulic systems - Main control valve

Main control valve - Remove - Loader port lock solenoid WE Electro hydraulic controls WE Electro hydraulic controls WE Electro hydraulic controls

200 Series Compact Track Loaders 200 Series Skid Steer Loaders L228

1. Locate the loader control valve (1) on the right hand side of the machine. NOTE: Image 1 is an example of the main control valve for Electro-Hydraulic (EH) controlled machines. The loader control valve on mechanically controlled machines is in the same location.

RAPH12SSL0446AA

931002090

2. Disconnect the electrical connector (1) from the solenoid.

3. Remove the nut from the solenoid (1).

4. Remove the solenoid.

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Hydraulic systems - Main control valve

Main control valve - Install - Loader port lock solenoid WE Electro hydraulic controls WE Electro hydraulic controls WE Electro hydraulic controls

200 Series Compact Track Loaders 200 Series Skid Steer Loaders L228

1. Place solenoid onto the loader control valve. Thread nut (1) onto valve body.

931002090

2. Connect the electrical connector (1) to the solenoid.

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Hydraulic systems - Main control valve

Main control valve - Remove WE WE WE WE

C227 C232 L221 L228

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

WARNING Burn hazard! Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid temperature should not exceed 40 °C (104 °F). Failure to comply could result in death or serious injury. W0241A

WARNING Pressurized system! Never attempt to drain fluids or remove filters when the engine is running. Turn off the engine and relieve all pressure from pressurized systems before servicing the machine. Failure to comply could result in death or serious injury. W0905A

WARNING Avoid injury! Always do the following before lubricating, maintaining, or servicing the machine. 1. Disengage all drives. 2. Engage parking brake. 3. Lower all attachments to the ground, or raise and engage all safety locks. 4. Shut off engine. 5. Remove key from key switch. 6. Switch off battery key, if installed. 7. Wait for all machine movement to stop. Failure to comply could result in death or serious injury. W0047A

1. Apply vacuum to the hydraulic reservoir. 2. Label and disconnect the four rear solenoid connections (1).

931001708

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Hydraulic systems - Main control valve

3. Label and disconnect the six front solenoid connections (1).

931001709

931001713

931001715

931001710

4. Label and disconnect the six hydraulic tubes (1) from the control valve and cap the opened ports.

5. Label and disconnect the drain hoses (1) from the control valve.

6. Label and disconnect the two hoses (1) and one tube (2) from the top of the control valve.

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Hydraulic systems - Main control valve

7. Disconnect the hydraulic tubes (1) located at the bottom of the valve block.

931001714

931001711

931001718

931001719

8. Disconnect the hydraulic hoses (1) from the solenoid block.

9. Remove the three valve mounting bolts (1) (one shown).

10. Remove the loader valve.

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Hydraulic systems - Main control valve

Main control valve - Install WE WE WE WE

C227 C232 L221 L228

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

1. Position the control valve into the machine mounting location.

931001719

931001718

931001711

2. Install the three valve mounting bolts (1) (one shown).

3. Connect hydraulic hoses (1) to solenoid block.

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Hydraulic systems - Main control valve

4. Connect hydraulic tubes (1) located at the bottom of valve block.

931001714

931001710

931001715

931001713

5. Connect two hoses (1) and one tube (2) to the top of control valve.

6. Connect the two drain hoses (1) to control valve.

7. Connect the six hydraulic tubes (1) to there correct ports on the control valve.

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Hydraulic systems - Main control valve

8. Connect the six front solenoid connections (1).

931001709

931001708

9. Connect rear solenoid connections (1).

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Hydraulic systems - Main control valve

Main relief valve - Pressure test - T fitting WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Pressure test using the T fitting method NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: Two persons are required to perform the flow meter tests to safely avoid possible injury. One person must be seated in the operators seat when the engine is running. The second person is to control the flow meter and take the readings. 1. Locate the main control valve. 2. Install the T fitting (1) into the hydraulic gear pump outlet, and attach the flow meter, part number 380500047, (2) hose to the T fitting. NOTE: Verify that the flow inlet direction is correct on the flow meter.

RAPH12SSL0246AA

RAPH12SSL0247AA

3. Place the other flow meter hose (1) with hose adapter in the hydraulic tank. NOTE: Verify that the flow outlet direction is correct on the flow meter.

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Hydraulic systems - Main control valve

4. Start the machine and run at high idle.

931007504

BS06H186AA

RAPH12SSL0244AA

Main relief pressure 5. Stroke a bucket function to the end of the cylinder travel on the machine, and maintain the bucket in that position; this will put a load on the machine.

1. Slowly turn the pressure screw on the flow meter while watching the flow meter pressure gauge and liter per minute (l/min) gauge or gallon per minute (gpm) gauge. Pump flow will remain relatively constant until the main relief pressure is achieved. At the point of pressure relief, pump flow will significantly drop below pump specification on the flow meter. Record the main relief pressure. Please see Main control valve - General specification (35.359) for specification about the main control valve. NOTE: Image 5 is an example of a flow reading. Image 5 may not match your reading.

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Hydraulic systems - Main control valve

2. Release the stroked bucket function. 3. Reset the flow meter.

BS06H186AA

RAPH12SSL0329AA

Cracking pressure 4. Stroke a bucket function to the end of the cylinder travel on the machine, and maintain the bucket in that position; this will put a load on the machine.

5. Slowly turn the pressure screw on the flow meter while watching the flow meter pressure gauge and liter per minute (l/min) gauge or gallon per minute (gpm) gauge. Pump flow will remain relatively constant until the cracking pressure is achieved. At the point of cracking pressure, pump flow will drop approximately 11 l/min (3 US gpm). Record the cracking pressure. NOTE: Cracking pressure should be within 15 % of the main relief pressure.

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Hydraulic systems - Main control valve

6. Release the stroked bucket function. 7. Reset the flow meter.

BS06H186AA

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Hydraulic systems - Main control valve

Relief valve - Pressure test - Auxiliary couplers WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

Pressure test using the auxiliary couplers NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: Two persons are required to perform the flow meter tests to safely avoid possible injury. One person must be seated in the operators seat when the engine is running. The second person is to control the flow meter and take the readings. 1. Attach the flow meter, part number 380500047, to the auxiliary couplers on the loader arm. NOTE: Verify that the flow inlet and outlet direction is correct on the flow meter.

RAPH12SSL0241AA

931007504

2. Start the machine and run at high idle.

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Hydraulic systems - Main control valve

Main relief pressure 1. Start the machine, activate the hydraulics, and activate the auxiliary function in one direction on the machine. Slowly turn the pressure screw on the flow meter while watching the flow meter pressure gauge and liter per minute (l/min) gauge or gallon per minute (gpm) gauge. Pump flow will remain relatively constant until the main relief pressure is achieved. At the point of pressure relief, pump flow will significantly drop below pump specification on the flow meter. Record the main relief pressure. Please see Main control valve - General specification (35.359) for specification about the main control valve. NOTE: Image 3 is an example of a flow reading. Image 3 may not match your reading.

RAPH12SSL0244AA

RAPH12SSL0329AA

2. Release the auxiliary switch. Reset the flow meter.

Cracking pressure 3. Activate the auxiliary function in one direction on the machine. Slowly turn the pressure screw on the flow meter while watching the flow meter pressure gauge and liter per minute (l/min) gauge or gallon per minute (gpm) gauge. Pump flow will remain relatively constant until the cracking pressure is achieved. At the point of cracking pressure, pump flow will drop approximately 11 l/min (3 US gpm). Record the cracking pressure. NOTE: Cracking pressure should be within 15 % of the main relief pressure.

4. Release the auxiliary switch. Reset the flow meter.

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Index Hydraulic systems - 35 Main control valve - 359 Main control valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main control valve - Install - Loader port lock solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main control valve - Install - Proportional auxiliary valve extend solenoid (*) . . . . . . . . . . . . . . . . . . . .

Main control valve - Install - Proportional auxiliary valve retract solenoid (*) . . . . . . . . . . . . . . . . . . . .

Main control valve - Install - Spool position sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main control valve - Install - Spool solenoids (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main control valve - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main control valve - Remove - Loader port lock solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main control valve - Remove - Proportional auxiliary valve extend solenoid (*) . . . . . . . . . . . . . . . . .

Main control valve - Remove - Proportional auxiliary valve retract solenoid (*) . . . . . . . . . . . . . . . . . .

Main control valve - Remove - Spool position sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main control valve - Remove - Spool solenoids (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main control valve - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main control valve - Test - Circuit leakage (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main relief valve - Pressure test - T fitting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relief valve - Pressure test - Auxiliary couplers (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Hydraulic systems - 35 Auxiliary hydraulic valves and lines - 525

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Hydraulic systems - 35 Auxiliary hydraulic valves and lines - 525

TECHNICAL DATA Optional control valve General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Optional control valve Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Auxiliary hydraulic valves and lines Auxiliary hydraulic function control - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Lines Depressurising (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Hydraulic systems - Auxiliary hydraulic valves and lines

Optional control valve - General specification C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

WE WE WE WE

RAPH14SSL0020FA

Secondary auxiliary valve Operating pressure Maximum flow Relief valve setting Port identification

207 - 217 bar (3000 - 3145 psi) at supply inlet: 87 l/min (23.0 US gpm) at ports A and B: 30 - 38 l/min (8 - 10 US gpm) at 138 bar (2000 psi). 221 bar (3200 psi) at 18.9 l/min (5.0 US gpm) P – Pressure inlet L – To main control valve T – Tank return A – Male auxiliary B – Female auxiliary

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Hydraulic systems - Auxiliary hydraulic valves and lines

Optional control valve - Component localization WE WE

C227 L221 TIER 4B (FINAL) [NEM479941 - ]

RAPH13SSL0863FA

Valve location Valve identification (1) Ride control valve

(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Secondary auxiliary valve

(5) High flow valve (6) Override valve for the loader arm

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(7) Self-leveling valve

Hydraulic systems - Auxiliary hydraulic valves and lines

Optional control valve - Component localization WE WE

C232 L228 TIER 4B (FINAL) [NFM401134 - ]

RAIL13SSL1004FA

Valve location Valve identification (1) Ride control valve

(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Secondary auxiliary valve

(5) Accumulator (6) High flow valve

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(7) Self-leveling valve

Hydraulic systems - Auxiliary hydraulic valves and lines

Auxiliary hydraulic function control - Test WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

Testing for circuit leakage NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: To avoid possible injury, two people are required to perform the following test . One person must be seated in the operator’s seat while the engine is running and the hydraulic controls are enabled. The second person is to control the flow meter and record the readings on the flow meter. 1. Locate the fixed displacement pump(s). 2. Install the T fitting into the fixed displacement pump outlet (1), and attach the inlet hose for flow meter, part number 380500047, to the T fitting. NOTE: Verify that the flow direction is correct on the flow meter.

931001956

RAPH12SSL0247AA

3. Place the outlet hose for the flow meter (1) with hose adapter in the hydraulic tank. NOTE: Verify that the flow direction is correct on the flow meter.

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Hydraulic systems - Auxiliary hydraulic valves and lines

4. Start the machine and run the engine at high idle.

931007504

RAPH12SSL0329AA

5. Adjust the flow meter pressure until 124 bar (1800 psi) is achieved. While watching the flow meter liter per minute (l/min) gauge or gallon per minute (gpm) gauge, activate the auxiliary couplers in both directions. Record the pump flow on the data collection sheet located on the following page. Compare the flow of every auxiliary function. Differences in pump flow indicate internal leaks and/or easier paths to tank. NOTE: Pump flow should be within 4 l/min (1 US gpm) of pump specification. Please see Fixed displacement pump - General specification (35.104) for specifications on the pumps. NOTE: Image 4 is an example of a flow reading. Image 4 may not match your reading.

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Hydraulic systems - Auxiliary hydraulic valves and lines

Test 6: Circuit leakage with restriction NOTE: For T fitting test only - Standard auxiliary up

__________l/min __________gpm

- Standard auxiliary down

__________l/min __________gpm

- Secondary auxiliary up (if applicable)

__________l/min __________gpm

- Secondary auxiliary down (if applicable)

__________l/min __________gpm

Notes:

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Hydraulic systems - Auxiliary hydraulic valves and lines

Lines - Depressurising WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

1. Using the palm of your hand, push the quick disconnect coupling towards the Connect-Under-Pressure (CUP) valve. When done properly, the coupling will move about 10.0 mm (25/64 in), relieving the stored pressure.

631068399

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Index Hydraulic systems - 35 Auxiliary hydraulic valves and lines - 525 Auxiliary hydraulic function control - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lines - Depressurising (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional control valve - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional control valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Hydraulic systems - 35 High flow hydraulics - 600

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Hydraulic systems - 35 High flow hydraulics - 600

TECHNICAL DATA High flow hydraulic pump General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Pilot valve General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA High flow hydraulics Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Pilot valve Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Pilot valve Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Hydraulic systems - High flow hydraulics

High flow hydraulic pump - General specification C227 TIER 4B (FINAL) [NDM471837 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

RAPH14SSL0003GA

High flow pump Type Pump displacement Engine RPM Pump flow at RPM

Gear pump 13.7 cm³ (0.84 in³) 1800 RPM 23 l/min (6.1 US gpm)

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Hydraulic systems - High flow hydraulics

Pilot valve - General specification C227 C232 L221 L228

WE WE WE WE

RAPH14SSL0021EA

High flow valve Hydraulic requirements

Relief valve setting Port identification

Flow : 45 l/min (12 US gpm) System pressure: 210 bar (3050 psi) Maximum pressure drop across the valve: 45 l/min (12 US gpm) at 10 bar (145 psi) 224 bar (3250 psi) P – Supply inlet T – Tank return AUX – Auxiliary outlet

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Hydraulic systems - High flow hydraulics

High flow hydraulics - Overview WE WE WE WE

C227 C232 L221 L228

If equipped with a high flow system, the operator can command additional flow to the auxiliary circuit by engaging auxiliary high flow function. This will provide increased flow to the auxiliary circuit. Please see High flow hydraulic pump - General specification (35.600) for specifications about the high flow pumps. High flow feature is engaged by pressing the rocker switch (1) mounted on left hand A post. The switch selects HF (high flow) or HP (high pressure) and is illuminated when high flow or enhanced high flow (EHF) is on. This allows the operator to enable/disable the function depending on the attachment requirements. NOTE: HP will activate only if the machine is equipped with EHF.

RCPH11SSL003AAD

The External Auxiliary Control can be controlled ONLY if ALL of the following conditions are met 1. Operator is seated properly 2. Operator Restraint engaged 3. The ignition is in the ON position 4. HF switch is activated

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Hydraulic systems - High flow hydraulics

Pilot valve - Component localization WE WE

C227 L221 TIER 4B (FINAL) [NEM479941 - ]

RAPH13SSL0863FA

Valve location Valve identification (1) Ride control valve

(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve

(5) High flow valve (6) Override valve for the loader arm

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(7) Self-leveling valve

Hydraulic systems - High flow hydraulics

Pilot valve - Component localization WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

RAIL13SSL1004FA

Valve location Valve identification (1) Ride control valve

(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve

(5) Accumulator (6) High flow valve

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(7) Self level valve

Hydraulic systems - High flow hydraulics

Pilot valve - Pressure test WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. 1. Connect a 345 bar (5000 psi) pressure gauge, part number 380500129, to the high flow, outlet auxiliary coupler. NOTE: Verify flow direction for accurate reading and machine safety.

93106839B

931007504

BS06H186AA

2. Start the machine, and raise the engine speed to full throttle.

3. Engage the auxiliary hydraulics. 4. Stroke a bucket function to the end of the cylinder travel on the machine, and hold the bucket in that position using the joystick; This will put a load on the machine.

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Hydraulic systems - High flow hydraulics

5. Select High Flow (HF) on the rocker switch (1).

RCPH11SSL003AAD

RAPH12SSL0448AA

BS06H186AA

931001689

6. Record the pressure on the pressure gauge. Please see Pilot valve - General specification (35.600) for specifications on the high flow pilot valve.

7. Release the stroked bucket function. 8. Disengage the auxiliary hydraulics.

9. If the recorded pressure is not within specification, remove the cap (1) on the relief valve and adjust.

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Hydraulic systems - High flow hydraulics

10. Repeat steps 2 through 9 until the relief valve is within specification.

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Hydraulic systems - High flow hydraulics

Pilot valve - Remove WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

1. Locate valve (1) on floor of the skid loader under hydraulic pump.

931001948

931001689

2. Disconnect the left hydraulic tube (2). NOTE: Arrow indicates forward direction.

3. Disconnect hydraulic tubes (3) and (4) from the right of the valve. NOTE: Arrow indicates forward direction.

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Hydraulic systems - High flow hydraulics

4. Disconnect the valves electrical connection (5).

931001689

931001690

5. Remove the two mounting bolts (2).

6. Remove valve.

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Hydraulic systems - High flow hydraulics

Pilot valve - Install WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

1. Locate the proper location on the floor for installation of valve.

931001948

931001689

2. Install the two mounting bolts (1) through the valve and secure it to the floor. NOTE: Arrow indicates forward direction.

3. Connect the two hydraulic tubes (2) and (3) to the right side of the valve. NOTE: Arrow indicates forward direction.

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Hydraulic systems - High flow hydraulics

4. Connect the top hydraulic tube (4). NOTE: Arrow indicates forward direction.

931001689

5. Connect electrical connection (5). NOTE: Arrow indicates forward direction.

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Index Hydraulic systems - 35 High flow hydraulics - 600 High flow hydraulic pump - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High flow hydraulics - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pilot valve - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pilot valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pilot valve - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pilot valve - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pilot valve - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Hydraulic systems - 35 Front loader hydraulic system control - 724

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Hydraulic systems - 35 Front loader hydraulic system control - 724

FUNCTIONAL DATA Loader bucket self-leveling controls Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Exploded view - Valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sectional view - Valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Component localization - Valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Component localization - Valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Loader bucket self-leveling controls Adjust - Valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Remove - Valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install - Valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

DIAGNOSTIC Loader bucket self-leveling controls Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Hydraulic systems - Front loader hydraulic system control

Loader bucket self-leveling controls - Overview WE WE WE WE

C227 C232 L221 L228

As the loader arm cylinder extends, flow from the rod port is directed to port A (1). Flow entering port A (1) is able to pass through the adjustable orifice and fixed orifice in the flow divider spool. The proportion of the flow split is determined by size of the adjustable orifice. Please see the charts below for specifications about your machine’s flow split. The remainder of the flow passes through the fixed orifice, out port B (4) back to the control valve and returns to tank. The flow that passes through the adjustable orifice flows out port D (2) and is teed to the base end of the bucket cylinders. The resistance on the movement of the bucket cylinders creates a pressure high enough to open the unloading spool in the self-leveling valve. As the bucket cylinders extends, the flow from the rod port of the bucket cylinders enters port C (3) past the open unloading spool around the flow divider spool and out port B (4) back to the control valve and returns to tank. RAIL12SSL0327BA

Port identification chart Self leveling valve port identification

A = Lift cylinder rod end B = CV work port B1 C = Tilt cylinder rod end D = Tilt cylinder base end

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Hydraulic systems - Front loader hydraulic system control

Loader bucket self-leveling controls - Exploded view - Valve C227 C232 L221 L228

WE WE WE WE

RAPH12SSL0328FA

Self-leveling valve Self-leveling valve identification (1) Plug (4) Valve body (7) Pin (10) Jam nut (13) Plunger

(2) O-ring (5) Load check plunger (8) Adjustment cap (11) Cap (14) Unloading spool

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(3) Flow divider spool (6) Load check spring (9) Set screw (12) Spring

Hydraulic systems - Front loader hydraulic system control

Loader bucket self-leveling controls - Sectional view - Valve C227 C232 L221 L228

WE WE WE WE

The self-leveling control valve consists of a spring loaded, flow divider spool (10) with a fixed orifice (4) in the center. The fixed orifice (4) controls how far the flow divider spool (10) opens when oil is directed to it. An adjustable orifice (3) is used to control the amount of oil sent out of the valve body, and therefore regulates the amount of leveling for the bucket. The self-leveling valve has a check valve assembly (5) that allows oil to flow to the base of the bucket cylinder and prevents oil from backfeeding through the self-leveling valve when the bucket spool is actuated. The unloading spool (9) allows a controlled amount of oil to escape from the rod end of the bucket cylinder as self-leveling is occurring. Because bucket leveling is controlled by a flow divider spool (10), the amount of leveling that occurs depends on the oil flow from the loader lift cylinder, and therefore changes with engine speed. The system is designed to operate with the engine at high idle. At speeds less than high idle, the bucket may not maintain level as the loader is raised. Raising the loader very slowly can affect the bucket leveling, because sufficient oil flow is not available to provide adequate pressure through the fixed orifice (4).

RAIL13SSL0993GA

Self-leveling valve 47683911 27/02/2015

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Hydraulic systems - Front loader hydraulic system control

Self-leveling valve identification (1) Self-leveling solenoid (2) Port A (3) Adjustable orifice (4) Fixed orifice

(5) Check valve (6) Port D (7) Port C (8) Unloading valve spring

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(9) Unloading spool (10) Flow divider spool (11) Port B

Hydraulic systems - Front loader hydraulic system control

Loader bucket self-leveling controls - Component localization Valve WE WE

C227 L221 TIER 4B (FINAL) [NEM479941 - ]

RAPH13SSL0863FA

Valve location Valve identification (1) Ride control valve

(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve

(5) High flow valve (6) Override valve for the loader arm

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(7) Self-leveling valve

Hydraulic systems - Front loader hydraulic system control

Loader bucket self-leveling controls - Component localization Valve WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

RAIL13SSL1004FA

Valve location Valve identification (1) Ride control valve

(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve

(5) Accumulator (6) High flow valve

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(7) Self-leveling valve

Hydraulic systems - Front loader hydraulic system control

Loader bucket self-leveling controls - Adjust - Valve WE WE WE WE

C227 C232 L221 L228

DANGER Crushing hazard! If you service the machine with the loader lift arms raised, always use the support strut. Remove the retaining pin and place the support strut onto the cylinder rod. Install the retaining pin into the support strut. Lower the lift arms onto the support strut. Failure to comply will result in death or serious injury. D0084A

1. Locate the set screw (1) on the top, right of the selfleveling valve. NOTE: The set screw (1) may be covered. Remove the cover by gently tapping on the cover. 2. Loosen the jam nut on the set screw (1). 3. Turn the set screw (1) • counter-clockwise to increase flow to the bucket cylinders • clockwise to decrease flow to the bucket cylinders 4. Tighten the jam nut. 931001981

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Hydraulic systems - Front loader hydraulic system control

Loader bucket self-leveling controls - Remove - Valve WE WE WE WE

C227 C232 L221 L228

Prior operation: Tilt the ROPS. 1. Locate the control valve (1).

931001804

931001701

931001702

2. Disconnect the electrical connection (1).

3. Disconnect the hydraulic tube (1) and cap the opened ports.

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Hydraulic systems - Front loader hydraulic system control

4. Disconnect the lower tubes (1) and cap the ports.

931001981

931001707

5. Disconnect the front tube (1) and cap the port.

6. Remove the mounting hardware (1).

7. Remove the control valve.

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Hydraulic systems - Front loader hydraulic system control

Loader bucket self-leveling controls - Install - Valve WE WE WE WE

C227 C232 L221 L228

1. Install control valve (1) onto body in correct location.

931001804

931001981

2. Install mounting hardware (1).

3. Connect front tube (1).

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Hydraulic systems - Front loader hydraulic system control

4. Connect lower tubes (1).

931001981

931001702

931001701

5. Connect hydraulic tube (1).

6. Connect electrical connection (1).

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Hydraulic systems - Front loader hydraulic system control

Loader bucket self-leveling controls - Troubleshooting C227 C232 L221 L228

WE WE WE WE

Problem Possible Cause Correction The loader arm delays at Self-leveling is designed to work at high Run the engine at high idle. the start of self leveling. idle. There is air in system. Lift and lower the loader arm and roll the bucket to rid the system of air. The bucket dumps its The unloading spool in the self leveling Remove and inspect the unloading spool for damage. contents without the valve is leaking. operator’s request. The packing in the cylinder is damaged. Inspect the cylinder’s internal components. Self leveling is Self-leveling is designed to operate at high Run the engine at high idle. insufficient. idle. The adjustable orifice in the self leveling Adjust the orifice in the self leveling valve. valve is out of adjustment. Please see Loader bucket self-leveling controls - Adjust (35.724). The unloading spool spring in the self lev- Inspect the unloading spool components in the self leveling valve. eling valve is damaged. The flow divider spool in the self leveling Inspect the flow divider spool in the self levvalve is stuck. eling valve. With the bucket in the The dampening orifice in the unloading Remove the unloading spool and clean the dumping position, the spool in the self leveling valve is plugged. dampening orifice. loader arm is slow to raise. The bucket does not Self-leveling is designed to work at high Run the engine at high idle. move when using the idle. self-leveling system. The adjustable orifice in the self leveling Adjust the orifice. Please see Loader valve is unadjusted. bucket self-leveling controls - Adjust (35.724). The dampening orifice in the unloading Remove the unloading spool and clean the spool in the self leveling valve is plugged. dampening orifice. Electrical problem. 1. Check for power and ground at the switch and solenoid. The bucket does not maintain level while raising the loader arm with the engine at high idle. The loader arm has an unstable self-level.

The bucket excessively drifts towards the dumping direction.

The bucket excessively drifts towards the scooping direction.

The flow divider spool is stuck.

2. Inspect the solenoid for damage. Inspect the flow divider spool.

Self-leveling is designed to work at high Run the engine at high idle. idle. There is air in system. Lift and lower the loader arm and roll the bucket to rid system of air. The packing in the cylinder is damaged. Inspect the cylinder’s internal components.

There is excessive leakage in the main con- Inspect the main control valve for damage. trol valve. The unloading spool in the self leveling Inspect the unloading spool. valve is stuck. The packing in the cylinder is damaged. Inspect the cylinder’s internal components.

There is excessive leakage in the main con- Inspect the main control valve for damage. trol valve.

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Hydraulic systems - Front loader hydraulic system control

Problem

External leakage.

Possible Cause Correction The lift check in the self leveling valve is Inspect the lift check for leakage. damaged. There may be a damaged o-ring on the self Inspect the o-rings for damage. . leveling valve.

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Index Hydraulic systems - 35 Front loader hydraulic system control - 724 Loader bucket self-leveling controls - Adjust - Valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loader bucket self-leveling controls - Component localization - Valve (*) . . . . . . . . . . . . . . . . . . . . . .

Loader bucket self-leveling controls - Exploded view - Valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loader bucket self-leveling controls - Install - Valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loader bucket self-leveling controls - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loader bucket self-leveling controls - Remove - Valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loader bucket self-leveling controls - Sectional view - Valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loader bucket self-leveling controls - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Hydraulic systems - 35 Front loader arm hydraulic system - 701

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Hydraulic systems - 35 Front loader arm hydraulic system - 701

TECHNICAL DATA Front loader arm hydraulic system General specification - Override valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Ride control solenoid valve block General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Accumulator General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

FUNCTIONAL DATA Front loader arm hydraulic system Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Ride control solenoid valve block Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Accumulator Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SERVICE Lift arm cylinder Depressurising (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Ride control solenoid valve block Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Accumulator Visual inspection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 (*) See content for specific models 47683911 27/02/2015

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Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Depressurising (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Discharging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Charging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

DIAGNOSTIC Front loader arm hydraulic system Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

(*) See content for specific models 47683911 27/02/2015

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Front loader arm hydraulic system - General specification Override valve C227 C232 L221 L228

WE WE WE WE

RAPH12SSL0340GA

Override valve for the loader arm Hydraulic requirements:

Flow = 22.7 l/min (6 US gpm). System pressure = 210 bar (3050 psi).

Port identification

1 - Tank return 2 - Lift cylinder base port

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Front loader arm hydraulic system - General specification C227 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

WE WE Electro hydraulic controls WE Electro hydraulic controls

RAPH14SSL0006FA

Loader pilot interlock, brake, two speed valve Hydraulic requirements Sequence valve setting Filter rating Port identification

Front loader arm hydraulic system - General specification C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

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RAPH12SSL0381EA

Loader pilot interlock, brake, two speed valve Hydraulic requirements Port identification

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Ride control solenoid valve block - General specification C227 C232 L221 L228

WE WE WE WE

RAPH12SSL0338GA

Ride control valve Hydraulic Requirements

Port Identification

Flow = 22.7 l/min (6 US gpm) System Pressure = 210 bar (3045 psi) Maximum pressure drop across valve = 10 bar (145 psi) at 23 l/min (6 US gpm) 1 – Tank Return 2 – Lift Cylinder Rod Port 3 – Accumulator 4 – Lift Cylinder Base Port

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Accumulator - General specification C227 C232 L221 L228

WE WE WE WE

RAPH15SSL0009BA

Manufacturer Fluid Capacity Charge with dry nitrogen Port

Parker 750 ml (25.4 US fl oz) 21 bar (300 psi) Internal straight thread 3/4-16 UNF - 2B

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Front loader arm hydraulic system - Component localization WE Electro hydraulic controls WE

C227 L221 TIER 4B (FINAL) [NEM479941 - ]

RAPH13SSL0863FA

Valve location Valve identification (1) Ride control valve

(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve

(5) High flow valve (6) Override valve for the loader arm

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(7) Self-leveling valve

Hydraulic systems - Front loader arm hydraulic system

Ride control solenoid valve block - Component localization WE WE

C227 TIER 4B (FINAL) [NDM471837 - ] L221 TIER 4B (FINAL) [NEM479941 - ]

RAPH13SSL0863FA

Valve location Valve identification (1) Ride control valve

(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve

(5) High flow valve (6) Override valve for the loader arm

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(7) Self-leveling valve

Hydraulic systems - Front loader arm hydraulic system

Ride control solenoid valve block - Component localization WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

RAIL13SSL1004FA

Valve location Valve identification (1) Ride control valve

(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve

(5) Accumulator (6) High flow valve

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(7) Self level valve

Hydraulic systems - Front loader arm hydraulic system

Accumulator - Component localization WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

RAIL13SSL1004FA

Valve location Valve identification (1) Ride control valve

(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve

(5) Accumulator (6) High flow valve

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(7) Self level valve

Hydraulic systems - Front loader arm hydraulic system

Lift arm cylinder - Depressurising WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

1. Support the loader arm with suitable lifting equipment. 2. Shut off the engine. 3. Use the override valve (1) to relieve pressure in the cylinders.

RAPH12UTL0644AA

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Lift arm cylinder - Remove WE

C227

Prior operation: Relieve the pressure in the lift arm cylinder. Please see Lift arm cylinder - Depressurising (35.701). 1. Label and disconnect cylinder hoses (1) and cap open ports

931001628

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2. Remove lift cylinder rod end snap rings (1) from boom arm.

931001621

931001616

931001625

931001629

3. Remove rod end pins and washers (1).

4. Lower cylinders (1) down.

5. Remove lock nut (1) and pin retaining bolt (2) on both sides of the lift arm.

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6. Remove rod end pins and washers from both sides of the lift arm.

931001630

931001632

7. Remove cylinders

Next operation: Lift arm cylinder - Install (35.736)

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Lift arm cylinder - Remove WE WE WE

C232 L221 L228

Prior operation: Relieve the pressure in the lift arm cylinder. Please see Lift arm cylinder - Depressurising (35.701).

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1. Label and disconnect cylinder hoses (1) and cap open ports

93112872

93112873

931001616

93112875

2. Remove lift cylinder rod end pin (2) and retaining bolt (1) and nut (3) from boom arm.

3. Remove rod end pins and washers (1).

4. Lower cylinders (1) down.

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5. Remove lock nut (1) and pin retaining bolt (2) on frame.

93112874

931001630

931001632

6. Remove rod end pins and washers from both sides of the frame.

7. Remove cylinders

Next operation: Lift arm cylinder - Install (35.701)

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Hydraulic systems - Front loader arm hydraulic system

Lift arm cylinder - Disassemble WE WE WE WE

C227 C232 L221 L228

Prior operation: Lift arm cylinder - Remove (35.701) 1. Clean the outside of the cylinder. If the hoses were removed from the cylinder, remove the hoses. 2. Fasten the tube (1) in a vise, or other holding equipment can be used. Be careful not to damage the tube. 3. Loosen the gland (5) in the tube with a gland wrench. 4. To prevent damage to the tube, pull the piston rod (3) straight out of the tube. 5. Fasten the piston rod end in a vise. To prevent damage to the piston rod, place a padded support below the piston rod near the piston. 6. Loosen and remove the nut that connects the piston on the piston rod. 7. Remove the piston (6) from the piston rod. 8. Remove and discard the seal (11), wear ring (13) and backup ring (12) from the piston. 9. Remove and discard the O-ring (9), backup ring (10), seals (8), and wiper (7) from the gland (5).

20111254

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(1) Tube (2) Bushing (3) Piston Rod

(4) Bushing (5) Packing gland (6) Piston

(7) Wiper (8) Seal (kit) (9) O-ring

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(10) Backup ring (11) Seal (12) Backup Ring

(13) Wear ring (14) Nut (15) Rod end

Hydraulic systems - Front loader arm hydraulic system

Lift arm cylinder - Assemble WE WE WE WE

C227 C232 L221 L228

Prior operation: Lift arm cylinder - Disassemble (35.701)

20111254

1. 2. 3. 4. 5. 6.

Tube Bushing Piston Rod Bushing Packing gland Piston

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. 47683911 27/02/2015

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5. Lubricate a new O-ring (9) with clean hydraulic oil. Insert the O-ring into the groove and onto the backup ring on the outside of the gland. 6. Fasten the piston rod end (15) in a vise. 7. Remove any marks or sharp edges on the chamfered end of the piston rod. 8. Lubricate the bore of the gland with clean hydraulic oil. 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).

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24. If hoses were removed with the cylinder, install new O-rings, if equipped, on the hose fittings. Lubricate the new O-rings with clean hydraulic oil and install the hoses.

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Lift arm cylinder - Install WE

C227

Prior operation: Lift arm cylinder - Remove (35.701) 1. Lubricate the rod end pins, (1), with LOCTITE® SILVER GRADE ANTI-SEIZE lubricant. 2. Install the cylinder onto the skid steer.

931001630

931001629

931001616

3. Install pin retaining bolt (1), and locknut, (2). 4. Torque the upper pivot pin hardware to 38 Nm ( 28 lb ft.

5. Install the rod end pins and washers (1) through the lift arms and cylinder end.

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6. Install rod end snap rings (1).

931001618

931001628

7. Install the hydraulic cylinder hoses (1), and position to prevent contact with other components, fenders, etc. Tighten hose fittings to standard torque. 8. Lower the lift arm. 9. Start the skid steer and cycle the boom several times to remove trapped air from the system and check the cylinder for leaks.

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Lift arm cylinder - Install WE WE WE

C232 L221 L228

Prior operation: Lift arm cylinder - Remove (35.701) 1. Lubricate the rod end pins, (1), with LOCTITE® SILVER GRADE ANTI-SEIZE lubricant. 2. Install the cylinder onto the skid steer.

931001630

931001629

931001616

3. Install pin retaining bolt (1), and locknut, (2). 4. Torque the upper pivot pin hardware to 38 Nm ( 28 lb ft.

5. Install the rod end pins and washers (1) through the lift arms and cylinder end.

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6. Install rod end snap rings (1).

931001618

931001628

7. Install the hydraulic cylinder hoses (1), and position to prevent contact with other components, fenders, etc. Tighten hose fittings to standard torque. 8. Lower the lift arm 9. Start the skid steer and cycle the boom several times to remove trapped air from the system and check the cylinder for leaks.

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Ride control solenoid valve block - Remove WE WE WE WE

C227 C232 L221 L228

Prior operation: Relieve the pressure in the ride control system. Please see Accumulator - Depressurising (35.701). 1. Locate the ride control valve (1) on the skid steer chassis.

931001804

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2. Disconnect the valve electrical connection (1).

931001696

931001693

931001698

3. Remove hose clamp and disconnect drain hose (1) and cap open ports.

4. Disconnect the lower hydraulic tube (1) and cap open ports.

5. Disconnect the two upper hydraulic tubes (1) and cap open ports.

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6. Remove mounting hardware (1).

931001698

931001700

7. Remove valve.

Next operation: Ride control solenoid valve block - Install (35.701)

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Ride control solenoid valve block - Install WE WE WE WE

C227 C232 L221 L228

Prior operation: Ride control solenoid valve block - Remove (35.701) 1. Locate valve (1) position on body.

931001804

931001698

2. Install mounting hardware (1).

3. Connect upper tubes (1).

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4. Connect the lower hydraulic tube (1).

931001693

931001696

5. Connect drain hose (1) and secure with hose clamp.

6. Connect valve electrical connection (1).

7. Disengage cab lock and tilt cab down.

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Accumulator - Visual inspection WE WE WE WE

C227 C232 L221 L228

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

9. Guard 10. Gas valve assembly 11. Cap 12. Valve core

Prior operation: Accumulator - Disassemble (35.701) 1. Clean all parts in cleaning solvent.

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13. Body 14. Gland without gas valve

Hydraulic systems - Front loader arm hydraulic system

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. 3. In a rotary motion, use an emery cloth with medium grit to remove small scratches on the piston (3), glands (2) and (14), and tube (1). 4. Inspect the glands (2) and (14), for rust or corrosion. Clean and remove the rust or corrosion from the gland. 5. Inspect the piston (3). Check to see if it is worn or damaged. If the piston is worn or damaged, replace with a new accumulator. 6. Inspect the gland ends of the tube (1) for sharp edges. Remove the sharp edges. Sharp edges can damage the seals (4), quad ring (5), and O-rings (6). Next operation: Accumulator - Assemble (35.701)

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Accumulator - Pressure test WE WE WE WE

C227 C232 L221 L228

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.

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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. 15. Turn the stem into valve (F) and read the pressure on gauge (E). 16. The pressure must be 275 - 325 psi ( 1897 2241 kPa, 19 - 23 bar). If the pressure is too low, charge the accumulator with dry nitrogen.

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Hydraulic systems - Front loader arm hydraulic system

Accumulator - Depressurising WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

1. Support the loader arm with suitable lifting equipment. 2. Shut off the engine but do not shut off the machine, i.e. power on, engine off. 3. Press and hold the glide ride button (1) to activate glide ride .

RAIL14SSL0309AA

RAPH12UTL0644AA

4. Use the override valve (1) to relieve pressure in the cylinders.

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Hydraulic systems - Front loader arm hydraulic system

Accumulator - Discharging WE WE WE WE

C227 C232 L221 L228

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)

(E) (F)

1. Use the accumulator charging kit 380001737 to discharge the accumulator. The tool must be disconnected from the nitrogen tank. 2. Close valves (B), (C) and (D). 3. Adjust the regulator (A) to the minimum pressure setting by turning the knob counterclockwise. 4. Turn the T-handle on valve (F) fully out. 5. Remove the guard and cap from the accumulator charging stem. 6. Connect valve (F) to the stem on the accumulator. 7. Turn the T-handle inward on valve (F) to engage the pin in the valve stem. 8. Open valve (D). Check the charge pressure on gauge (E).

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(G) - To nitrogen tank (H) - To accumulator

Hydraulic systems - Front loader arm hydraulic system

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.

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Hydraulic systems - Front loader arm hydraulic system

Accumulator - Disassemble WE WE WE WE

C227 C232 L221 L228

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

9. Guard 10. Gas valve assembly 11. Cap 12. Valve core

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13. Body 14. Gland without gas valve

Hydraulic systems - Front loader arm hydraulic system

Next operation: Accumulator - Visual inspection (35.701)

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Hydraulic systems - Front loader arm hydraulic system

Accumulator - Assemble WE WE WE WE

C227 C232 L221 L228

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

9. Guard 10. Gas valve assembly 11. Cap 12. Valve core

Prior operation: Accumulator - Disassemble (35.701) 1. Slide one new seal (4), on one end of the piston. 2. Slide one new quad ring (5) into the middle groove of the piston. 3. Slide one new seal (4) on the other end of the piston. 4. Lubricate the bore of the tube (1) and the piston (3) with clean hydraulic oil. NOTE: The piston must be installed slowly to prevent damage to the threads on the quad ring.

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13. Body 14. Gland without gas valve

Hydraulic systems - Front loader arm hydraulic system

5. Start the piston (3) into the gas valve end of the tube (1). A soft hammer and wood block may be used to drive the piston farther into the tube. Carefully drive the piston at least 2 in ( 51 mm) into the tube. Keep pressure against the piston when driving the piston into the tube, to prevent damage to the quad ring (5). Follow the same procedure for the non-gas valve end of the tube. 6. If used, install a new back ring (7) on the gland (2). Make sure the backup ring is installed. Follow the same procedure for the non-gas valve end of the tube. 7. Install the O-ring (6) next to the backup ring (7). If a backup ring is not used, install an O-ring in the groove on the gland. Follow the same procedure for the nongas valve end of the tube.

BS04D006

8. Lubricate the O-ring (6) and the backup ring (7) with clean hydraulic oil. Start the gland (2) into the tube (1). Follow the same procedure for the non-gas valve (14) end of the tube. 9. Fasten the tube (1) in the vise. Tighten the gland (2). Follow the same procedure for the non-gas valve end of the tube 10. Install a new O-ring (6)on the body (13)of the gas valve assembly (10). 11. Install the valve core (12) in the body (13). 12. Lubricate the O-ring (6) with clean hydraulic oil. Install and tighten the gas valve assembly (10)in the gland (2). 13. Install the cap (11). 14. Charge the accumulator with dry nitrogen. Please refer to Accumulator - Charging (35.701) 15. Install the guard (9) and cap screws (8).

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Hydraulic systems - Front loader arm hydraulic system

Accumulator - Charging C227 C232 L221 L228

WE WE WE WE

SPECIAL TOOLS

BS06M002

380001676 Nitrogen Regulator Valve

BS06M003-01

380001390 Accumulator Charging Hose NOTE: Check the pressure in the accumulator according to the instructions in this section. Keep the nitrogen charging kit connected to the accumulator.

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Hydraulic systems - Front loader arm hydraulic system

BT09C458

Nitrogen Charging Kit 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

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.

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Hydraulic systems - Front loader arm hydraulic system

4. Slowly turn valve (D) clockwise while watching the pressure gauge (B). Stop turning valve (D) when the needle on gauge (B) reaches 10 bar (145 psi). NOTE: If the needle goes over the needed pressure, quickly open and close valve (E) and check the pressure again. The charging kit is now ready to be installed on the accumulator. 5. Remove the cap from the accumulator. 6. Loosen the sealing plug with an Allen wrench. 7. Back off the needle valve (A) on the accumulator end of the charging hose by turning it counterclockwise to the maximum position. This prevents nitrogen from escaping from the accumulator when the charging hose is attached to the accumulator gas charging valve. 8. Install the charging hose fitting onto the accumulator. 9. Tighten the needle valve by turning it clockwise. Slowly open the gauge valve (E) and observe the reading on the gauge. This reading is the nitrogen pressure level inside the accumulator. 10. Fill the accumulator to a charge pressure of 20.7 22.4 bar (300 - 325 psi). 11. Close valve (E) by turning to the right (clockwise). After a few minutes open valve (E) and check the accumulator for leakage. 12. Back off the needle valve (A) on accumulator end of the charging hose by turning it counterclockwise the maximum amount. This will prevent nitrogen from escaping from the accumulator as the hose is removed. 13. Close the valve on the nitrogen supply tank. 14. Adjust the regulator (D) to the minimum pressure setting by turning the knob counterclockwise. 15. Slowly remove the charging hose from the accumulator pressure valve. NOTE: A small amount of nitrogen will escape when disconnecting the hose. 16. Install the cap on the accumulator, torque to 1.13 N·m (10 lb in). NOTE: A small amount of nitrogen will escape when disconnecting the hose.

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Hydraulic systems - Front loader arm hydraulic system

Front loader arm hydraulic system - Troubleshooting C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Problem The loader arm will not raise when commanded.

WE WE WE WE

Possible Cause The OPERATE button on the instrument cluster has not been pushed. The seat belt is not being used. The seat switch doesn’t not sense an operator. The override valve is releasing pressure in the loader arm cylinders. The cab door (If equipped with cab door) is opened. The cab door switch (If equipped with cab door) is not functioning correctly. The joysticks are not calibrated correctly. The Joystick linkage may need readjustment. The solenoid for the loader pilot interlock (only on electro hydraulic controls) on the brake valve is not functioning as designed. The port lock solenoid on the main control valve is not functioning as designed. Hydraulic pressure is low.

Correction 1. If the OPERATE button is flashing, press the OPERATE button. Use the seat belt. Test the seat switch. Inspect the override valve. Ensure that the cab door is fully closed. 1. Align the cab door switch. 2. Test the cab door switch. Calibrate the joysticks, using the Electronic Service Tool (EST). Adjust the linkage. Inspect the solenoid.

Inspect the port lock solenoid.

Check the charge pressure at the main control valve. Please see Pump Charge pressure relief valve - Pressure test (29.218). Main control valve not operating as de- Inspect the main control valve. signed. Linkage is damaged. Inspect the linkage. Main relief valve faulty Test the main relief valve pressure. Please see Main relief valve - Pressure test - T fitting (35.350). Gear pump faulty Test the main gear pump flow efficiency. Please see Fixed displacement pump Flow test - T fitting (35.104).

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Index Hydraulic systems - 35 Front loader arm hydraulic system - 701 Accumulator - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accumulator - Charging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accumulator - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accumulator - Depressurising (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accumulator - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accumulator - Discharging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accumulator - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accumulator - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accumulator - Visual inspection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front loader arm hydraulic system - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front loader arm hydraulic system - General specification - Override valve (*) . . . . . . . . . . . . . . . . . .

Front loader arm hydraulic system - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front loader arm hydraulic system - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift arm cylinder - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift arm cylinder - Depressurising (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift arm cylinder - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift arm cylinder - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift arm cylinder - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ride control solenoid valve block - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ride control solenoid valve block - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ride control solenoid valve block - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ride control solenoid valve block - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Hydraulic systems - 35 Tool quick coupler hydraulic system - 734

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Hydraulic systems - 35 Tool quick coupler hydraulic system - 734

TECHNICAL DATA Tool quick coupler hydraulic system General specification - Valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Tool quick coupler hydraulic system Component localization - Valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Component localization - Valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Tool quick coupler hydraulic system Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Quick coupler cylinder Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Hydraulic systems - Tool quick coupler hydraulic system

Tool quick coupler hydraulic system - General specification - Valve C227 C232 L221 L228

WE WE WE WE

RAPH12SSL0386EA

Hydraulic coupler valve Relief pressure Port identification

172 bar (2500 psi) P - Pump supply inlet T - Tank return C1 - Cylinder base end C2 - Cylinder rod end

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Hydraulic systems - Tool quick coupler hydraulic system

Tool quick coupler hydraulic system - Component localization - Valve WE WE

C227 L221 TIER 4B (FINAL) [NEM479941 - ]

RAPH13SSL0863FA

Valve location Valve identification (1) Ride control valve

(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve

(5) High flow valve (6) Override valve for the loader arm

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(7) Self-leveling valve

Hydraulic systems - Tool quick coupler hydraulic system

Tool quick coupler hydraulic system - Component localization - Valve WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

RAIL13SSL1004FA

Valve location Valve identification (1) Ride control valve

(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve

(5) Accumulator (6) High flow valve

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(7) Self level valve

Hydraulic systems - Tool quick coupler hydraulic system

Tool quick coupler hydraulic system - Remove WE WE WE WE

C227 C232 L221 L228

WARNING Pressurized system! System is still under pressure. Release pressure according to instructions in this manual. Failure to comply could result in death or serious injury. W1044A

1. Remove the bucket or attachment from the mounting plate.

20092924

93106838

931001722

2. Set the quick coupler in the unlocked position.

3. Label and disconnect electrical connection (1).

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Hydraulic systems - Tool quick coupler hydraulic system

4. Label and disconnect the bucket hydraulic tubes (1) and cap the open ports.

931001720

5. Label and disconnect the supply tube (1) and cap the open ports.

6. Label and disconnect the drain hose (1).

7. Remove the mounting hardware (2).

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Hydraulic systems - Tool quick coupler hydraulic system

8. Remove the command valve.

931001721

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Hydraulic systems - Tool quick coupler hydraulic system

Tool quick coupler hydraulic system - Install WE WE WE WE

C227 C232 L221 L228

1. Locate where the command valve (1) should be positioned on the body.

931001720

2. Install the mounting hardware (1).

3. Connect the valve drain hose (1).

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Hydraulic systems - Tool quick coupler hydraulic system

4. Connect the valve supply tube (1).

931001720

931001722

5. Connect the bucket hydraulic tubes (2).

6. Connect the electrical connection (1).

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Hydraulic systems - Tool quick coupler hydraulic system

Quick coupler cylinder - Remove WE WE WE WE

C227 C232 L221 L228

1. Remove the bucket or attachment from the mounting plate.

20092924

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Hydraulic systems - Tool quick coupler hydraulic system

2. Set the quick coupler in the unlocked position.

93106838

931001791

931001788

931001786

3. Remove snap ring (1).

4. Remove retaining pin (1).

5. Disconnect hydraulic hoses (1) and (2), from manifold.

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Hydraulic systems - Tool quick coupler hydraulic system

6. Remove rod end hydraulic hose (1).

931001789

931001783

931001784

7. Disengage the roll pin and bucket locking pin (1).

8. Remove cylinder.

Next operation: Quick coupler cylinder - Install (35.734)

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Hydraulic systems - Tool quick coupler hydraulic system

Quick coupler cylinder - Install WE WE WE WE

C227 C232 L221 L228

Prior operation: Quick coupler cylinder - Remove (35.734) 1. Hold cylinder in mounting location on the skid steer and engage bucket locking pin (1) through the rod end.

931001782

931001788

931001791

2. Through the top of the cylinder install the retaining pin (1).

3. Secure the retaining pin with a snap ring (1).

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Hydraulic systems - Tool quick coupler hydraulic system

4. Connect the rod end hydraulic hose (1).

931001789

931001786

WARNING Unexpected movement! When cylinders are connected to the machine hydraulic system, cycle the hydraulic circuits several times to remove air from the cylinder and hose. Air in the system can cause erratic operation or can cause equipment to drop unexpectedly. Failure to comply could result in death or serious injury. W1083A

Connect hydraulic hoses (1) and (2), to the manifold.

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Index Hydraulic systems - 35 Tool quick coupler hydraulic system - 734 Quick coupler cylinder - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quick coupler cylinder - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tool quick coupler hydraulic system - Component localization - Valve (*) . . . . . . . . . . . . . . . . . . . . . .

Tool quick coupler hydraulic system - General specification - Valve (*) . . . . . . . . . . . . . . . . . . . . . . . .

Tool quick coupler hydraulic system - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tool quick coupler hydraulic system - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

47683911 27/02/2015 EN

SERVICE MANUAL Frames and ballasting C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Frames and ballasting - 39

[39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1

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Frames and ballasting - 39 Ballasts and supports - 140

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Frames and ballasting - 39 Ballasts and supports - 140

SERVICE Counterweight Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Frames and ballasting - Ballasts and supports

Counterweight - Remove WE WE WE WE

C227 C232 L221 L228

Prior operation: Remove the battery. See Battery - Remove (55.302).

Left hand side 1. Support the counterweight with a suitable lifting device. Remove corner mounting hardware (1). 2. Remove the counterweight.

RAPH12SSL0289AA

RAPH12SSL0041AA

Right hand side 3. Support the counterweight with a suitable lifting device. Remove corner mounting hardware (1). 4. Remove the counterweight.

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Frames and ballasting - Ballasts and supports

Center bumper 5. Support the center bumper with a suitable lifting device. Remove center bumper mounting hardware (1).

RAPH12SSL0040AA

931001656

6. Remove center bumper (3).

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Frames and ballasting - Ballasts and supports

Counterweight - Install WE WE WE WE

C227 C232 L221 L228

1. Place rear center bumper (1) in position.

931001656

RAPH12SSL0040AA

RAPH12SSL0289AA

2. Install center bumper mounting hardware (2).

3. Install left hand side counterweight and secure in place with mounting hardware (1).

NOTE: Perform the same operation on right hand side. 47683911 27/02/2015

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Index Frames and ballasting - 39 Ballasts and supports - 140 Counterweight - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Counterweight - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

47683911 27/02/2015 EN

SERVICE MANUAL Wheels C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

47683911 27/02/2015

Contents Wheels - 44

[44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1 [44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2

47683911 27/02/2015

Wheels - 44 Front wheels - 511

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Wheels - 44 Front wheels - 511

TECHNICAL DATA Front wheels Tire pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(*) See content for specific models 47683911 27/02/2015

44.1 [44.511] / 2

Wheels - Front wheels

Front wheels - Tire pressure WE WE

L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

WARNING Explosion hazard! Always maintain correct tire pressure as indicated in this manual. DO NOT inflate tires above the recommended pressure. Excessive pressure could result in tire failure. Failure to comply could result in death or serious injury. W0109A

TIRE Heavy Duty

Premium

Premium with liner Severe Duty Non-Pneumatic

SIZE 10 x 16.5 12 x 16.5 27/10.5 x 15 10 x 16.5 12 x 16.5 14 x 17.5 10 x 16.5 12 x 16.5 10 x 16.5 12 x 16.5 12 x 16.5

PRESSURE 290 - 345 kPa (42 - 50 psi) 290 - 345 kPa (42 - 50 psi) 359 - 414 kPa (52 - 60 psi) 290 - 345 kPa (42 - 50 psi) 290 - 345 kPa (42 - 50 psi) not required

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Wheels - Front wheels

Front wheels - Torque L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

WE WE

63109344

Torque pattern Torque table Taper nut torque Flange nut torque

169.5 N·m (125 lb ft) 203.5 N·m (150 lb ft)

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Index Wheels - 44 Front wheels - 511 Front wheels - Tire pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front wheels - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

44.1 [44.511] / 5

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Wheels - 44 Rear wheels - 520

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Wheels - 44 Rear wheels - 520

TECHNICAL DATA Rear wheels Tire pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(*) See content for specific models 47683911 27/02/2015

44.2 [44.520] / 2

Wheels - Rear wheels

Rear wheels - Tire pressure WE WE

L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

TIRE Heavy Duty

Premium

Premium with liner Severe Duty Non-Pneumatic

SIZE

PRESSURE

10 x 16.5 12 x 16.5 27/10.5 x 15 10 x 16.5 12 x 16.5 14 x 17.5 10 x 16.5 12 x 16.5 10 x 16.5 12 x 16.5 12 x 16.5

290 - 345 kPa (42 - 50 psi) 290 - 345 kPa (42 - 50 psi) 359 - 414 kPa (52 - 60 psi) 290 - 345 kPa (42 - 50 psi) 290 - 345 kPa (42 - 50 psi) not required

Rear wheels - Torque L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

WE WE

63109344

Torque pattern

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Wheels - Rear wheels

Torque table Taper nut torque Flange nut torque

169.5 N·m (125 lb ft) 203.5 N·m (150 lb ft)

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Index Wheels - 44 Rear wheels - 520 Rear wheels - Tire pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear wheels - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

44.2 [44.520] / 5

CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

47683911 27/02/2015 EN

SERVICE MANUAL Tracks and track suspension C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

47683911 27/02/2015

Contents Tracks and track suspension - 48

[48.130] Track frame and driving wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.1 [48.100] Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.2 [48.134] Track tension units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.3 [48.138] Track rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.4

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Tracks and track suspension - 48 Track frame and driving wheels - 130

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Tracks and track suspension - 48 Track frame and driving wheels - 130

SERVICE Sprocket Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(*) See content for specific models 47683911 27/02/2015

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Tracks and track suspension - Track frame and driving wheels

Sprocket - Remove WE WE

C227 C232

Prior operation: Remove the rubber track. Please see Rubber track - Remove (48.100). 1. Make reference marks on the cover (1) and the drive sprocket (2) to be used for alignment and the bolt torque procedure during installation.

231002477A

2. Loosen and remove the bolts (1) from the drive sprocket (2). 3. Using acceptable lifting equipment, lift the track above the drive sprocket to allow the guide teeth to disengage from the drive sprocket. 4. Slide the drive sprocket off of the hub and remove the drive sprocket.

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Tracks and track suspension - Track frame and driving wheels

Sprocket - Install WE WE

C227 C232

NOTE: The following photos are for reference only. 1. Slide the drive sprocket over the hub. If the same sprocket that was removed is being installed, use the alignment marks that were made during removal procedure to align the drive sprocket on the hub. 2. Lift the track above the drive sprocket to allow the drive sprocket to engage the guide teeth (1) on the track. Make sure the drive sprocket is between the guide teeth (1) on the track.

231002477A

3. Apply LOCTITE® 243™ to the threads of the bolts (1). 4. Install the bolts (1) into the drive sprocket (2).

5. Use the reference mark on the hub as the starting point, torque the bolts to 67 - 163 Nm (50 - 120 lb ft) in the sequence shown.

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6. Tighten the bolts to a final torque of 285 - 320 Nm (208 - 235 lb ft) in the sequence shown.

231002477A

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Index Tracks and track suspension - 48 Track frame and driving wheels - 130 Sprocket - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sprocket - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

48.1 [48.130] / 6

Tracks and track suspension - 48 Tracks - 100

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Tracks and track suspension - 48 Tracks - 100

SERVICE Rubber track Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Tension adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

(*) See content for specific models 47683911 27/02/2015

48.2 [48.100] / 2

Tracks and track suspension - Tracks

Rubber track - Remove WE WE

C227 C232

1. Park the machine on a level surface. 2. Lift the machine off of the ground approximately 12.7 cm (5 in), using adequate lifting equipment.

231002469

231002468A

231002478

231002469

3. Remove the screws (1) from the adjuster cover (2), and remove the cover.

4. Slowly loosen the grease valve (1) on the adjuster (2) until the grease begins to discharge from the adjuster (2). Allow the grease to completely discharge from the adjuster (2) to release the tension on the track as the idler wheel moves rearward. NOTE: Do not remove the grease valve body from the adjuster. Internal parts (ball, spring, and poppet) may be lost.

5. The idler wheel (1) can be moved farther rearward either by pushing the idler wheel rearward or by lifting on the center (2) of the track.

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6. Lift the track (2) off of the drive sprocket (1).

231002469

7. Remove the rubber track from the frame (2)

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Rubber track - Install WE WE

C227 C232

1. Install the rubber track around the rear idler wheel (1). Verify that the rear idler wheel is between the guide teeth (2) on the track.

231002473

231002474

2. Continue installing the rubber track towards the front idler wheel (1), engaging the track guide teeth (3) between the rollers (2) and then around the front idler wheel (1). Verify that the front idler wheel (1) is between the guide teeth (3) on the track.

Next operation: Adjust the rubber track. Please see Rubber track - Tension adjust (48.100).

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Tracks and track suspension - Tracks

Rubber track - Tension adjust WE WE

C227 C232

1. Park the machine on a level surface. 2. Lift the machine off of the ground approximately 12.7 cm (5 in), using adequate lifting equipment.

231002469

231002468A

231002478

3. Remove the screws (1) from the adjuster cover (2), and remove the cover (2).

4. Loosen the grease valve (1), but do not remove. NOTE: Do not remove the grease valve body from the adjuster. Internal parts (ball, spring, and poppet) may be lost. 5. Install a grease gun on the grease valve (1).

6. To tighten the track on the frame, apply grease to the adjuster (2).

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7. Apply grease to the adjuster until the distance from the bottom of the two center rollers (1) to the top surface (2) of the track is within 12 - 19 mm (3/64 - 3/4 in) 8. To loosen the track, loosen the grease valve on the adjuster until grease discharges from the adjuster. Allow the grease to discharge from the adjuster until the distance from the bottom of the two center rollers to the top surface of the track is within 12 - 19 mm (3/64 - 3/4 in).

231002475

231002478

9. When the distance is within the specifications, tighten the grease valve (1) to a torque of 90 ± 10 Nm (66 ± 10 lb ft). NOTE: Do not remove the grease valve body from the adjuster. Internal parts (ball, spring, and poppet) may be lost.

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Index Tracks and track suspension - 48 Tracks - 100 Rubber track - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rubber track - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rubber track - Tension adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

48.2 [48.100] / 8

Tracks and track suspension - 48 Track tension units - 134

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Tracks and track suspension - 48 Track tension units - 134

SERVICE Track tensioner Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Idler wheel Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

(*) See content for specific models 47683911 27/02/2015

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Tracks and track suspension - Track tension units

Track tensioner - Remove WE WE

C227 C232

Prior operation: Refer to Rubber track - Remove (48.100) and remove the track from the machine 1. Remove the track from the machine.

231002469

231002470

2. Slide the track tension assembly (2) out of the main frame (1).

3. Slide the yoke assembly (2) off of the track tension assembly (1).

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Tracks and track suspension - Track tension units

Track tensioner - Install WE WE

C227 C232

1. Slide the yoke assembly (2) onto the track tension assembly (1).

231002471

231002470

2. Slide the track tension assembly (2) into the main frame (1).

Next operation: Refer to Rubber track - Install (48.100) and install the track. After the track has been installed, follow the procedure Rubber track - Tension adjust (48.100) and adjust the tension of the track.

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Tracks and track suspension - Track tension units

Idler wheel - Remove WE WE

C227 C232

Prior operation: Refer to Rubber Track - Rubber track - Remove (48.100) and remove the track from the machine.

Front idler wheel 1. Remove the track from the machine. Slide the track tension assembly (2) out of the main frame (1).

231002470

231002471

231002472

2. Loosen and remove the mounting screw (1) in the yoke (2) which fastens the front idler wheel (3) to the yoke (2). 3. Remove the front idler wheel (3) from the yoke (2).

Rear idler wheel 1. Loosen and remove the bolt (1) and washer from the rear idler wheel (2). 2. Remove the rear idler wheel (2) from the main frame (3).

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Tracks and track suspension - Track tension units

Idler wheel - Install WE WE

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ]

Front idler wheel 1. Install the front idler wheel (3) into the yoke (2). 2. Apply LOCTITE® 243™ to the threads of the screw (1). 3. Install the screw (1) into the yoke and into the front idler wheel.

231002471

231002470

23112927

4. Slide the track tension assembly (2) into the frame (1).

Rear idler wheel 1. Verify that all paint is removed from all contact surfaces on the end cap and the shaft.

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Tracks and track suspension - Track tension units

2. Add one keeper to each end of the rear idler. NOTE: Two keepers are required.

23112930

23112931

23112932

23112933

3. Apply LOCTITE® 243™ to the threads of the bolts. 4. Install both bolts, but do not tighten.

5. Insert one shim (1) on each end of the rear idler (2). NOTE: A total of two shims are needed.

Location of the shims.

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Tracks and track suspension - Track tension units

6. Move the idler as far back in holes as possible.

23112934

231002472

7. Torque the bolt (1) to 381 - 516 N·m (281 - 381 lb ft).

8. Verify that the end cap ears are not pinched by the track frame after the bolts are tightened.

23112935

Next operation: Install the rubber track. Please see Rubber track - Install (48.100).

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Index Tracks and track suspension - 48 Track tension units - 134 Idler wheel - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Idler wheel - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Track tensioner - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Track tensioner - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

48.3 [48.134] / 9

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Tracks and track suspension - 48 Track rollers - 138

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Tracks and track suspension - 48 Track rollers - 138

SERVICE Track rollers Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(*) See content for specific models 47683911 27/02/2015

48.4 [48.138] / 2

Tracks and track suspension - Track rollers

Track rollers - Remove WE WE

C227 C232

Prior operation: Refer to Rubber track - Remove (48.100) and remove the track from the machine. NOTE: Photos are for reference only. Photo shows track installed on the machine. 1. After the track has been removed from the machine, loosen and remove the cap screws and washers (1) from the roller (2). Remove the roller (2) from the track assembly.

231002476

2. Repeat the procedure above and remove the remaining rollers (1) from the track assembly.

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Tracks and track suspension - Track rollers

Track rollers - Install WE WE

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ]

1. Verify that all paint is removed from any contact surface on the end cap and shaft.

23112927

23112928

23112929

23112939

2. Inspect the inside edge at all roller locations for any excess paint or rough edges. Remove as required.

3. Install the roller without the bolts, and push roller against inside track frame wall. 4. Use a shim as a guide to determine the required number of shims needed to fill gap between the roller and the track frame wall. NOTE: A maximum of one shim on each end of the roller may be required. NOTE: If only one shim is required, install the shim between the roller and the outside track frame wall.

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Tracks and track suspension - Track rollers

5. Install the shim as shown in image 5.

23112937

23112938

23112939

231002476

6. Apply LOCTITE® 243™ to the threads of the bolts. 7. Install the bolts in the roller, but do not tighten. 8. Repeat steps 1 - 6 for any additional rollers that are being replaced,

9. Spin the roller by hand. NOTE: The rollers should spin easily.

10. Torque the mounting bolt (1) to 195 - 265 N·m (144 196 lb ft).

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Tracks and track suspension - Track rollers

11. Spin the roller by hand. NOTE: The rollers should spin easily.

23112939

Next operation: Install the rubber track. Please see Rubber track - Install (48.100).

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Index Tracks and track suspension - 48 Track rollers - 138 Track rollers - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Track rollers - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

47683911 27/02/2015 EN

SERVICE MANUAL Cab climate control C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Cab climate control - 50

[50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1 [50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2

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Cab climate control - 50 Heating - 100

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Cab climate control - 50 Heating - 100

SERVICE Heater core Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

(*) See content for specific models 47683911 27/02/2015

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Cab climate control - Heating

Heater core - Remove WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

Prior operation: Tilt the cab. Please see Cab tilting system - Tilt (90.150) Prior operation: Discharge the A/C (if applicable). Please see Air conditioning - Discharging (50.200). 1. Detach the heater hoses (2) from the heater core. 2. Detach the A/C lines (1) from the evaporator (if applicable). 3. Remove the nuts (3), and detach the seat from the cab.

RAIL15SSL0042BA

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Cab climate control - Heating

4. Carefully lower the cab. Please see Cab tilting system - Lower (90.150) for assistance.

RAIL14SSL0418AA

RAPH14SSL0351BA

RAIL15SSL0041BA

5. Disconnect the seat switch (2) from the wiring harness. 6. Disconnect the seat belt switch (if applicable) (1) from the wiring harness.

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Cab climate control - Heating

7. Remove the seat (1) from the cab.

93109313

93106883

RAIL15SSL0073BA

RAIL15SSL0040BA

8. Remove the access cover (1) for the cab filter by turning the knobs (2) counter clockwise and lifting the cover (1) off of the HVAC assembly.

9. Remove the fasteners from the panel.

10. Remove the panel from the cab.

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Cab climate control - Heating

11. Disconnect the HVAC assembly from the wiring harness.

RAIL15SSL0028BA

12. Disconnect the joystick from the wiring harness.

RAIL15SSL0072BA

RAIL15SSL0039BA

13. Detach and remove the joystick assembly (1) from the cab. 14. Repeat steps 12 and 13 on the opposite side.

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Cab climate control - Heating

15. Remove the fasteners (2) from the air duct (3). 16. Remove the screws (1) from the HVAC assembly . 17. Remove the air duct (3) from the cab. 18. Repeat steps 15 – 17 on the opposite side.

RAIL15SSL0038BA

931001774

19. Remove the screws (1) from the HVAC assembly. 20. Remove the HVAC assembly (2) from the cab.

21. Place the HVAC assembly on a workbench. 22. Remove the screws (1) from the HVAC assembly. 23. Remove the clips (2) from the HVAC assembly.

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Cab climate control - Heating

24. Flip the HVAC assembly. 25. Remove the screws (1) from the HVAC assembly. 26. Remove the clips (2) from the HVAC assembly.

RAIL15SSL0036BA

RAIL15SSL0033BA

RAIL15SSL0034BA

27. Separate and remove the lower half of the HVAC assembly.

28. Separate the two halves of the HVAC assembly.

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Cab climate control - Heating

29. Remove the heater core from the HVAC assembly.

RAIL15SSL0035BA

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Heater core - Install WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

1. Insert the heater core into the HVAC assembly.

RAIL15SSL0035BA

RAIL15SSL0034BA

RAIL15SSL0033BA

2. Connect the two halves of the HVAC assembly.

3. Connect the lower half to the HVAC assembly.

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Cab climate control - Heating

4. Verify that the rubber seals are install properly.

RAIL15SSL0032BA

RAIL15SSL0036BA

931001774

5. Install the clips (2) onto the HVAC assembly. 6. Install the screws (1) into the HVAC assembly.

7. Flip the HVAC assembly. 8. Install the clips (2) onto the HVAC assembly. 9. Install the screws (1) into the HVAC assembly.

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Cab climate control - Heating

10. Install the HVAC assembly (2) into the cab. 11. Install the screws (1) that attach the HVAC assembly to the cab.

931001774

RAIL15SSL0038BA

RAIL15SSL0072BA

12. Install the air duct (3) into the cab. 13. Install the fasteners (2) that attach the air duct (3) to the cab. 14. Install the screws (1) that attach the air duct to the HVAC assembly. 15. Repeat steps 12 – 14 on the opposite side.

16. Connect the joystick to the wiring harness.

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Cab climate control - Heating

17. Attach the joystick assembly to the cab. 18. Repeat steps 16 and 17 on the opposite side.

RAIL15SSL0039BA

RAIL15SSL0028BA

RAIL15SSL0040BA

19. Connect the HVAC assembly to the wiring harness.

20. Install the panel into the cab.

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21. Install the fasteners that attach the panel to the cab.

RAIL15SSL0073BA

93106883

93109313

22. Install the access cover (1), and tighten onto the HVAC assembly by turning the knobs (2) clockwise.

23. Install the seat (1) from the cab.

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Cab climate control - Heating

24. Connect the seat switch (2) to the wiring harness. 25. Connect the seat belt switch (if applicable) (1) to the wiring harness.

RAIL15SSL0041BA

93107498

RAPH11SSL0016BA

26. Carefully tilt the cab. Please see Cab tilting system - Tilt (90.150) for assistance.

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27. Attach the seat to the cab by installing the nuts (3). 28. Attach the heater hoses (2) to the heater core. 29. Attach the A/C lines (1) to the evaporator (if applicable).

RAIL15SSL0042BA

Next operation: Add NEW HOLLAND AMBRA ACTIFULL™ OT EXTENDED LIFE COOLANT. Please see Capacities () for specifications. Next operation: Charge the A/C system (if applicable). Please see Air conditioning - Charging (50.200).

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Index Cab climate control - 50 Heating - 100 Heater core - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heater core - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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Cab climate control - 50 Air conditioning - 200

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Cab climate control - 50 Air conditioning - 200

TECHNICAL DATA Air conditioning General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Air conditioning Dynamic description - A/C thermal operation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Air conditioning Leakage test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Discharging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Charging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Compressor drive belt Tension adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Air-conditioning evaporator Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

DIAGNOSTIC Air conditioning Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

(*) See content for specific models 47683911 27/02/2015

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Cab climate control - Air conditioning

Air conditioning - General specification C227 C232 L221 L228

WE WE WE WE

A/C system capacities • 1.5 kg (3.3 lb) of R134A refrigerant. • 197 ml (6.67 US fl oz) of PAG SP20

Air Temperature (F) Entering A/C Unit (Fresh or Recirculated) 50 60 70 80 90 100 110

Inlet - Outlet Temperature Differential (Low Humidity) 10 15 20 25 30 30 35

Inlet - Outlet Temperature Differential (High Humidity) 10 10 15 20 25 25 30

Ambient Air Temperature (F) Entering Condenser 50 60 70 80 90 100 110

Suction Pressure (PSIG) at Evaporator Outlet 5-15 5-15 10-20 10-20 15-25 15-25 15-30

Discharge Pressure (PSIG) at Compressor Outlet 75-125 100-150 125-175 150-225 175-250 200-275 225-352

NOTE: The pressure temperature chart is based on the following conditions: (1) Engine operating at 1500 rpm. No engine load. (2) Fan speed control in maximum position (full clockwise) and all louvers open. (3) Cab temperature control set to maximum cooling (full counterclockwise). (4) A/C switch ON. Cab door open. (5) All panels and access doors installed and closed. (6) Cab filter clean and installed. Heater valve closed. (7) Measurements taken 15 minutes after start-up. (8) The warmest inlet air temperature (Fresh or Recirculated) should be used for the differential equations.

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Cab climate control - Air conditioning

Air conditioning - Dynamic description - A/C thermal operation C227 TIER 4B (FINAL) [NDM471837 - ] C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE WE

The refrigerant circuit of the air conditioning system contains five major components: • compressor, • condenser, • receiver-drier, • expansion valve, • and evaporator. These components are connected by tubes and hoses and operate as a closed system. The air conditioner system is charged with HFC-134a refrigerant. The compressor receives the refrigerant as a low pressure gas. The compressor then compresses the refrigerant and sends it in the form of a high pressure gas to the condenser. Air flow through the condenser removes the heat from the refrigerant. As the heat is removed the refrigerant is “condensed” to a high pressure liquid. The high pressure refrigerant liquid flows from the condenser to the receiver-drier. The receiver-drier is a container filled with moisture removing material, which removes any moisture that may have entered the air conditioner system in order to prevent corrosion of the internal components. NOTE: Not all refrigerant leaves the condenser as a liquid. Some leaves as a gas without affecting system performance. Liquid refrigerant pools at the bottom of the receiver-drier, while the lighter gas collects at the top. Since the pick-up tube draws refrigerant from the bottom of the receiver-drier, only liquid refrigerant flows to the thermal expansion valve. The refrigerant, still in high pressure liquid form, flows from the receiver-drier to the expansion valve. The expansion valve provides a restriction to refrigerant flow to cause a pressure drop which allows the liquid refrigerant to expand, decreasing its temperature and pressure. NOTE: The thermal expansion valve is internally equalized: the need for refrigerant to handle the heat load is balanced with the ability to fully vaporize the refrigerant within the one valve. This low temperature, low pressure liquid or mist flows through the evaporator. The hot cab air passes through the evaporator fins cooling the air and evaporating the liquid refrigerant. The low pressure gas returns to the compressor and the cycle starts all over again.

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RCPH07CCH490ABC

Low pressure gas

1. Compressor

4. Thermal expansion valve

Low pressure liquid

2. Condenser

5. Evaporator

High pressure gas

3. Receiver-drier

High pressure liquid

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Air conditioning - Leakage test WE WE WE WE

C227 C232 L221 L228

WARNING Avoid injury! Avoid breathing air-conditioning refrigerant, lubricant vapor or mist. If accidental system discharge occurs, ventilate the work area before resuming service. Failure to comply could result in death or serious injury. W1000B

NOTICE: A/C systems are to be maintained by a certified professional. Do not attempt the following without A/C certification.

Vacuum test 1. Shut off the engine. 2. Remove the caps from the service ports on the machine. 3. Verify the charging station valves are in the closed position. 4. Connect the hose from the low pressure gauge to the low pressure port on the machine. 5. Connect the hose from the high pressure gauge to the high pressure port on the machine. 6. Turn in both thumbscrews to depress the service valves. 7. Open the high and low valves on the charging station. 8. Make certain the refrigerant tank valves are open. 9. Turn on the charging station, and vacuum the system for approximately 15–30 minutes. 10. Wait approximately 15–30 minutes, then check the gauges on the charging station. If the A/C system has a leak, it will not hold vacuum. 11. Repair all leaks, and charge the system.

LAIL11TS0543B0A

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Electronic leak detection test 1. Verify the appropriate amount of refrigerant in the machine. 2. Start the engine and run the A/C system for approximately ten minutes. 3. Use the electronic leak detector to inspect all connections. ATTENTION: The engine is running. Be aware of moving components. Failure to comply could result in death or serious injury. 4. Shut off the engine. 5. Use the electronic leak detector to inspect all connections. NOTE: When checking the compressor seal for a leak, remove the dust cover and rotate the clutch shaft clockwise.

FNH00855

RCPH07CCH416ABC

NOTE: To properly check the expansion valve for leaks, remove the insulation tape. 6. Repair all leaks, and charge the system.

UV leak detection test 1. Please see the instructions from the manufacturer of the UV leak detection tool for proper use. 2. Repair all leaks, and charge the system.

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Air conditioning - Discharging WE WE WE WE

C227 C232 L221 L228

Prior operation: Operate the air conditioning system for approximately ten minutes before starting the following procedure. Turn the system off after ten minutes of operation. NOTICE: A/C systems are to be maintained by a certified professional. Do not attempt the following procedure without A/C certification. NOTE: Recovered refrigerant passes through an oil separator and filter-drier before entering the refrigerant tank. The moisture indicator will turn green when dry refrigerant passes over it. 1. Clean the external surfaces of the compressor and hoses. 2. Remove the caps from the service ports on the machine. 3. Verify the valves on the charging station, part number 34788, are in the closed position. 4. Connect the hose from the low pressure gauge to the low pressure port on the machine. 5. Connect the hose from the high pressure gauge to the high pressure port on the machine. 6. Turn in both thumbscrews to depress the service valves. 7. Open the high and low valves on the charging station, part number 34788. 8. Make certain the refrigerant tank valves are open. 9. Turn on the charging station, part number 34788, and recover the refrigerant.

RAPH15SSL0059CA

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Air conditioning - Charging WE WE WE WE

C227 C232 L221 L228

NOTICE: A/C systems are to be maintained by a certified professional. Do not attempt the following procedure without A/C certification.

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1. Clean the external surfaces of the compressor and hoses. 2. Remove the caps from the service ports on the machine. 3. Verify the valves on the charging station, part number 34788, are in the closed position. 4. Connect the hose from the low pressure gauge to the low pressure port on the machine. 5. Connect the hose from the high pressure gauge to the high pressure port on the machine. 6. Turn in both thumbscrews to depress the service valves. 7. Open the high and low valves on the charging station, part number 34788. 8. Make certain the refrigerant tank valves are open. 9. Turn on the charging station, part number 34788. 10. Vacuum the system for approximately 15–45 minutes. 11. Verify that the system holds a vacuum for approximately fifteen minutes. If the system does not hold a vacuum, please see Air conditioning - Leakage test (50.200). If the system holds a vacuum, please proceed to step 12 12. Charge the system with 1.5 kg (3.3 lb) of R134A refrigerant. 13. Close any opened valves, and carefully remove the manifold gauge hoses. 14. Install the caps on the service ports. 15. Start the engine and run at 1500 rpm. Operate the air conditioner system at maximum cooling setting and blower speed with the door and windows open. NOTE: The compressor will not operate if the system pressure is too low or too high. If the compressor fails to operate and the condenser blowers also fail to operate when you actuate the A/C switch, check the system pressure to determine if refrigerant is present. Check for continuity at the pressure switch located at the receiver-dryer and the temperature switch located at the evaporator.

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RAPH15SSL0059CA

Cab climate control - Air conditioning

Compressor drive belt - Tension adjust WE WE WE WE

C227 C232 L221 L228

Use the following procedure to adjust the air conditioning compressor belt. 1.

Loosen the adjusting bracket bolt (1).

Loosen the mounting bolt (2).

Loosen the adjusting bolt jam nut (3).

Tighten the adjusting bolt (4) until tight. The belt is tightened correctly when a force of 1 kg (2.2 lb) is applied perpendicular to the belt at the center of the span with a 3 mm (0.1 in) deflection.

Tighten the adjusting bolt jam nut (3).

Tighten the adjusting bracket bolt (1) and mounting bolt (2).

RAPH12SSL0064BA

NOTE: Check the compressor belt tension after the first 10 hours of operation on a new machine or if a new belt has been installed. Measure the deflection of the belt at center of span with perpendicular load of applied, and adjust as necessary.

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Air-conditioning evaporator - Remove WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

Prior operation: Tilt the cab. Please see Cab tilting system - Tilt (90.150) Prior operation: Discharge the A/C. Please see Air conditioning - Discharging (50.200). 1. Detach the heater hoses (2) from the heater core. 2. Detach the A/C lines (1) from the evaporator (if applicable). 3. Remove the nuts (3), and detach the seat from the cab.

RAIL15SSL0042BA

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4. Carefully lower the cab. Please see Cab tilting system - Lower (90.150) for assistance.

RAIL14SSL0418AA

RAPH14SSL0351BA

RAIL15SSL0041BA

5. Disconnect the seat switch (2) from the wiring harness. 6. Disconnect the seat belt switch (if applicable) (1) from the wiring harness.

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7. Remove the seat (1) from the cab.

93109313

93106883

RAIL15SSL0073BA

RAIL15SSL0040BA

8. Remove the access cover (1) for the cab filter by turning the knobs (2) counter clockwise and lifting the cover (1) off of the HVAC assembly.

9. Remove the fasteners from the panel.

10. Remove the panel from the cab.

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11. Disconnect the HVAC assembly from the wiring harness.

RAIL15SSL0028BA

12. Disconnect the joystick from the wiring harness.

RAIL15SSL0072BA

RAIL15SSL0039BA

13. Detach and remove the joystick assembly (1) from the cab. 14. Repeat steps 12 and 13 on the opposite side.

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15. Remove the fasteners (2) from the air duct (3). 16. Remove the screws (1) from the HVAC assembly . 17. Remove the air duct (3) from the cab. 18. Repeat steps 15 – 17 on the opposite side.

RAIL15SSL0038BA

931001774

19. Remove the screws (1) from the HVAC assembly. 20. Remove the HVAC assembly (2) from the cab.

21. Place the HVAC assembly on a workbench. 22. Remove the screws (1) from the HVAC assembly. 23. Remove the clips (2) from the HVAC assembly.

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24. Flip the HVAC assembly. 25. Remove the screws (1) from the HVAC assembly. 26. Remove the clips (2) from the HVAC assembly.

RAIL15SSL0036BA

RAIL15SSL0033BA

RAIL15SSL0034BA

27. Separate and remove the lower half of the HVAC assembly.

28. Separate the two halves of the HVAC assembly.

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29. Remove the evaporator from the HVAC assembly.

RAIL15SSL0037BA

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Air-conditioning evaporator - Install WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

1. Insert the evaporator into the HVAC assembly.

RAIL15SSL0037BA

RAIL15SSL0034BA

RAIL15SSL0033BA

2. Connect the two halves of the HVAC assembly.

3. Connect the lower half to the HVAC assembly.

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4. Verify that the rubber seals are install properly.

RAIL15SSL0032BA

RAIL15SSL0036BA

931001774

5. Install the clips (2) onto the HVAC assembly. 6. Install the screws (1) into the HVAC assembly.

7. Flip the HVAC assembly. 8. Install the clips (2) onto the HVAC assembly. 9. Install the screws (1) into the HVAC assembly.

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10. Install the HVAC assembly (2) into the cab. 11. Install the screws (1) that attach the HVAC assembly to the cab.

931001774

RAIL15SSL0038BA

RAIL15SSL0072BA

16. Connect the joystick to the wiring harness.

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17. Attach the joystick assembly to the cab. 18. Repeat steps 16 and 17 on the opposite side.

RAIL15SSL0039BA

RAIL15SSL0028BA

RAIL15SSL0040BA

19. Connect the HVAC assembly to the wiring harness.

20. Install the panel into the cab.

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21. Install the fasteners that attach the panel to the cab.

RAIL15SSL0073BA

93106883

93109313

22. Install the access cover (1), and tighten onto the HVAC assembly by turning the knobs (2) clockwise.

23. Install the seat (1) from the cab.

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Cab climate control - Air conditioning

24. Connect the seat switch (2) to the wiring harness. 25. Connect the seat belt switch (if applicable) (1) to the wiring harness.

RAIL15SSL0041BA

93107498

RAPH11SSL0016BA

26. Carefully tilt the cab. Please see Cab tilting system - Tilt (90.150) for assistance.

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Cab climate control - Air conditioning

27. Attach the seat to the cab by installing the nuts (3). 28. Attach the heater hoses (2) to the heater core. 29. Attach the A/C lines (1) to the evaporator (if applicable).

RAIL15SSL0042BA

Next operation: Add NEW HOLLAND AMBRA ACTIFULL™ OT EXTENDED LIFE COOLANT. Please see Capacities () for specifications. Next operation: Charge the A/C system. Please see Air conditioning - Charging (50.200).

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Cab climate control - Air conditioning

Air conditioning - Troubleshooting C227 TIER 4B (FINAL) [NDM471837 - ] C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE WE

Problem Possible Cause A/C will not blow cold air. The refrigerant is too low. The compressor clutch intermittently engages.

The evaporator fan has failed.

Correction Check for leaks. Please see Air conditioning - Leakage test (50.200). 1. Check the fuse. 2. Check the relay. 3. Check for voltage and ground at the fan.

4. Verify that the fan has movement and is not seized. Low flow rate through the condenser is 1. Check the refrigerant level. causing high pressure which is activating 2. Check the refrigerant quality. the high pressure switch. 3. Check the functionality of the compressor.

A/C will not operate.

Broken low pressure switch. Broken high pressure switch. A refrigerant leak is causing low pressure which is activating the low pressure switch. The electromagnet clutch on the compressor is worn. Damaged or disconnected connector.

Broken fuse. Broken relay. Broken switch. Refrigerant leak.

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4. Check for clogs in the system. Inspect the low pressure switch. Inspect the high pressure switch. Check for leaks. Please see Air conditioning - Leakage test (50.200). Replace the clutch or compressor assembly. Check the electrical connections of the switches, relays, control module, and compressor. Check the fuse. Check the relay. Check the switch. Test for leaks. Please see Air conditioning - Leakage test (50.200).

Index Cab climate control - 50 Air conditioning - 200 Air conditioning - Charging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Discharging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Dynamic description - A/C thermal operation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Leakage test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-conditioning evaporator - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-conditioning evaporator - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor drive belt - Tension adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

47683911 27/02/2015 EN

SERVICE MANUAL Electrical systems C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Electrical systems - 55

[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.011] Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.019] Hydrostatic drive control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.036] Hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.051] Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls. . . . . . . . . . . . . . . . . . . . . 55.7 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 [55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11 [55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.12 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.13 [55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.14 [55.518] Wiper and washer system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.15 [55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.16 [55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.17

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Electrical systems - 55 Electrical system - 000

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Electrical systems - 55 Electrical system - 000

SERVICE Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures - Requirements . . . . . . . . . . . . . . . . . . . . . . . 3 H1 - Calibration procedures - Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Electronic Service Tool (EST) - H1 - Calibration procedures - Ground Drive . . . . . . . . . . . . . . . . . . . . . . . . 6 H1 - Calibration procedures - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Program - Controller - Video (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Electronic Service Tool (EST) - H1 - Calibration procedures - Loader valve . . . . . . . . . . . . . . . . . . . . . . . 10

DIAGNOSTIC Electrical system Testing Diode Testing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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Electrical systems - Electrical system

Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures - Requirements Calibration involves setting correct hardware parameters for joysticks, ground drive pumps, loader valve, and throttle mechanism. Unless noted otherwise, the operator has 30 seconds to complete each calibration step. The calibration procedure will have to be restarted if a step times out. The parameters associated with each calibration procedure will be saved when that particular procedure completes successfully. If there are problems completing one of the five calibration procedures, only that procedure will need to be repeated, not all five. The audible alarm and calibration messages will not be displayed if any error codes are active. If any calibration fails, see Electrical system - H1 - Calibration procedures - Troubleshooting (55.000) for troubleshooting steps.

RAPH16SSL0231QA

1. For service training videos on calibration procedures visit the eTim service tool or the dealer portal. 2. If new software is available, download it before calibrating using the following steps. • Connect the EST hardware to the machine diagnostic connector and laptop. • Flash the new Application Software onto the machine controller (UCM) with the Electronic Service Tool (EST) programming menu. • Flash the new instrument cluster (IC) software to the IC with the EST configuration menu. • Set the machine configurations (serial number, model, door, etc.) in the EST configuration menu. 3. Calibration Preparation Steps • Connect the EST hardware to the machine diagnostic connector and laptop. • Open the EST configuration menu. • Clear any fault codes from the IC display by cycling the Aux Override button until the display is clear.

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Electrical systems - Electrical system

Electrical system - H1 - Calibration procedures - Joystick The purpose of the Joystick Calibration is to calibrate the main axis of the left-hand and right-hand joystick and the proportional thumbwheel. Perform this calibration if a joystick is replaced, if there is an operator complaint about the feel of the loader or ground drive functions, and a code 1211 - Calibration Functions - Joystick Calibration not Complete JOYNU fault active.

RAPH16SSL0231QA

1. For service training videos on calibration procedures visit the dealer portal. 2. Ensure the prerequisite requirements are complete per Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures - Requirements (55.000). 3. Ensure the following conditions are met: • Joysticks in Neutral • Proportional Auxiliary Roller Switch in Neutral • Key ON • Engine ON • Hydraulics OFF - Operate button flashing • Operator Present - operator in seat with lap bar (CASE)/ seat belt (New Holland) engaged • No Active Joystick Related Fault Codes 4. In the EST configuration menu, open the 'Calibration Joystick' item. 5. Press the 'SET UP CONTROLLER FOR CALIBRATION' button. • Ensure 'START CALIBRATION' is now active. 6. Press the 'START CALIBRATION' button. • Ensure that the text "C-J1" is displayed on the instrument cluster screen. 7. Press and release the loader float button to start capturing step 1 values. • Verify that an audible beep is heard from the instrument cluster and the text "C-J2" is displayed on the cluster screen upon completion of step 1.

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Electrical systems - Electrical system

8. Move the proportional auxiliary roller switch to the upper or left-hand detent (toward the smaller icon). Move both joysticks to the front right-hand corner. Press and release the loader float button to start capturing step 2 values. • Verify that an audible beep is heard from the instrument cluster and the text "C-J3" is displayed on the cluster screen upon completion of step 2. 9. Move the proportional auxiliary roller switch to the lower or right detent (towards the larger icon). Move and hold both joysticks to the back left-hand corner. Press and release the loader float button to start capturing step 3 values. • Verify that an audible beep is heard from the instrument cluster upon completion of step 3. • Verify that the instrument cluster screen returns to normal message display.

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Electrical systems - Electrical system

Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures - Ground Drive The purpose of the Ground Drive Calibration is to calibrate the left-hand and right-hand drive pumps. There are 2 parts to the ground drive calibration (Static and Dynamic). This is a semi-automatic procedure, therefore most of the operator interaction is via the instrument cluster display screen only. Perform this calibration whenever one of the pumps is replaced or service, if the operator complains about the feel of the ground drive, if the Universal Control Module (UCM) is replaced, Fault code 1212 - Calibration Functions Ground Drive Calibration not Complete is active, or if a software update requires it.

RAPH16SSL0231QA

1. For service training videos on calibration procedures visit the dealer portal. NOTE: It is not unusual to see a small amount of machine movement during calibrations the UCM finds the command current that brings the pump on stroke. Significant machine movement during calibration (more than 0.3 m (1.0 ft)) is not expected and is a symptom of a problem in the system. 2. Ensure the prerequisite requirements are complete per Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures - Requirements (55.000). 3. 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 at FULL throttle 4. In the EST configuration menu, open the 'Calibration Ground Drive' item. 5. Press the 'SET UP CONTROLLER FOR CALIBRATION' button. • Ensure 'START CALIBRATION' is now active.

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Electrical systems - Electrical system

6. Press the 'START CALIBRATION' button. • Ensure that the text "C-G1" is displayed on the cluster screen. 7. Move the right-hand joystick to the front right-hand corner (away from the operator) and press and release the loader float button. Keep the right-hand joystick in the top right-hand 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. 8. Keep the right-hand joystick at the top right-hand corner (away from the operator). • 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. 9. Keep the right-hand joystick at the top right-hand corner (away from the operator). • 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. 10. Keep the right-hand joystick at the top right-hand corner (away from the operator). • 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. 11. Keep the right-hand joystick at the top right-hand corner (away from the operator). • Verify that an audible beep is heard from the instrument cluster upon completion of step 5. 12. Release the right-hand joystick. • Verify that the EST Calibration Operation Status window says "Calibration Completed Successfully." Verify that the instrument cluster screen returns to normal message display. 13. Exit out of the Calibration - Ground Drive screen

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Electrical systems - Electrical system

Electrical system - H1 - Calibration procedures - Troubleshooting These are the codes that may be encountered during calibration. If seen, check condition description and compare to calibration procedure prerequisite conditions.

RAPH16SSL0231QA

Display Text CD01

Condition Name Calibration Enable Fail

CD02

Calibration Sustain Fail

CD03

Device Fault

CD04

Calibration Timeout

CD05

Operator Interrupt

CD06

Calibration Value High

CD07

Calibration Value Low

CD08

Signal Unstable

Condition Description Calibration Enable Condition(s) not met at time of initiation Calibration Sustain Condition(s) not met during cal routine Device Fault Calibration Sustain Condition(s) not met during cal routine Calibration Step was not completed within allotted time Calibration interrupted by Operator via cluster Cal button Calibration value higher than upper-end of acceptance range Calibration value lower than lower-end of acceptance range Signal being calibrated outside of settling noise tolerance

1. Troubleshooting Suggestions 1.

For CD01 - CD05, restart calibration procedure with the 'START CALIBRATION' button. If this does not work, Press 'Exit' on EST calibration procedure and re-enter the calibration state and the individual calibration procedure.

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.

Occasionally closing and reopening the EST is required to restart a calibration.

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Software Reaction Exit calibration and use old values Exit calibration and use old values Exit calibration and use old values

Exit calibration and use old values Exit calibration and use old values Beep and flash code - give operator a chance to retry cal step Beep and flash code - give operator a chance to retry cal step Beep and flash code - give operator a chance to retry cal step

Electrical systems - Electrical system

Electrical system - Program - Controller - Video WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

RAPH16SSL0231QA

1. For service training videos on calibration and programming procedures visit the dealer portal.

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Electrical systems - Electrical system

Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures - Loader valve The purpose of the Loader Calibration Procedure is to calibrate the command current to a nominal pressure for each spool and calibrate the neutral position of the loader attachment spool sensors. This is a semi-automatic procedure, therefore most of the operator interaction is via the cluster display screen only. NOTE: It is not unusual to see a small amount of loader or bucket movement during calibration as the UCM finds the command current that shifts the valve spools. Significant implement movement during calibration (more than 1 foot) should not be expected and is a symptom of a problem in the system. 1. Ensure the prerequisite requirements are complete per Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures - Requirements (55.000). 2. Ensure the following conditions are met • Joysticks in Neutral • Proportional Auxiliary Roller Switch in Neutral • Key ON • Engine ON • Hydraulics ON • Park Brake Engaged (park brake light on) with the park brake switch, not the OPERATE Button on the IC • Hydraulic Oil Temperature between 15 - 80 °C (59.0 - 176.0 °F) • Operator Present • Engine RPM less than 1200 RPM • No Joystick Related Fault Codes • No Loader Related Fault Codes 3. In the EST configuration menu, open the 'Calibration Loader Valve' item. 4. Press the 'SET UP CONTROLLER FOR CALIBRATION' button. • Ensure 'START CALIBRATION' is now active. 5. Press the 'START CALIBRATION' button. • Ensure that the text "C-L1" is displayed on the cluster screen. 6. Move the right joystick to the top right corner (away from the operator) and press and release the loader float button. Keep the right joystick in the top right corner for the entirety of the loader calibration. • Verify that an audible beep is heard from the instrument cluster and the text "C-L2" is displayed on the cluster screen upon completion of the previous step. 7. Keep the right joystick at the top right corner (away from the operator). • Verify that an audible beep is heard from the instrument cluster and the text "C-L3" is displayed on the cluster screen upon completion of the previous step.

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Electrical systems - Electrical system

8. Keep the right joystick at the top right corner (away from the operator). • Verify that an audible beep is heard from the instrument cluster and the text "C-L4" is displayed on the cluster screen upon completion of the previous step. 9. Keep the right joystick at the top right corner (away from the operator). • Verify that an audible beep is heard from the instrument cluster and the text "C-L5" is displayed on the cluster screen upon completion of the previous step. 10. Keep the right joystick at the top right corner (away from the operator). • Verify that an audible beep is heard from the instrument cluster and the text "C-L6" is displayed on the cluster screen upon completion of the previous step. 11. Keep the right joystick at the top right corner (away from the operator). • Verify that an audible beep is heard from the instrument cluster and the text "C-L7" is displayed on the cluster screen upon completion of the previous step. 12. Keep the right joystick at the top right corner (away from the operator). • Verify that an audible beep is heard from the instrument cluster upon completion of the previous step. 13. Release the right joystick. • Verify that the EST Calibration Operation Status window says "Calibration Completed Successfully." Verify that the instrument cluster screen returns to normal message display. 14. Exit out of the Calibration - Loader Valve screen.

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Electrical systems - Electrical system

Electrical system - Testing Diode Testing C227 C232 L221 L228

WE WE WE WE

Test N°1 Test Point 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. Other Result Result If reading is the same in both directions, the diode is shorted. (Possible If reading is near 3 V or infinite in both directions, the diode is open. Cause) Action Replace diode.

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Index Electrical systems - 55 Electrical system - 000 Electrical system - H1 - Calibration procedures - Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical system - H1 - Calibration procedures - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical system - Program - Controller - Video (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical system - Testing Diode Testing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures - Ground Drive . . . .

Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures - Requirements . . . .

Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures - Loader valve . . . . .

(*) See content for specific models 47683911 27/02/2015

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Electrical systems - 55 Fuel injection system - 010

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Electrical systems - 55 Fuel injection system - 010

SERVICE Fuel injection system Common rail pressure sensor - Configure - Reset ECU data (Rail pressure sensor) (*) . . . . . . . . . . . . . . 3 Common rail Relief valve - Configure - Reset ECU data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - Fuel injection system

Common rail pressure sensor - Configure - Reset ECU data (Rail pressure sensor) WE WE WE WE

C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

NOTE: Active dosing faults require additional key cycles in order for the Engine Control Unit (ECU) to determine the fault has been repaired. Afterrun must be completed between each key cycle. 1. Connect the Electronic Service Tool (EST) and turn the key switch ON without starting the engine. 2. Click the “Configuration” icon (1).

NHPH14ENG0006AA

NHPH14ENG0017AA

3. Select “Replacement of the Rail Pressure Sensor - Reset ECU Data. 4. Click the “CONFIGURE SELECTED ITEM” button. 5. Click the “RESET” button (1).

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Electrical systems - Fuel injection system

Common rail Relief valve - Configure - Reset ECU data The Engine Control Unit (ECU) monitors for sudden decreases in rail pressure. The ECU counts and stores these events to monitor Pressure Relief Valve (PRV) degradation. The counter needs to be manually reset when the PRV is replaced. NOTE: This procedure is only to be used after the PRV has been replaced. 1. Connect the Electronic Service Tool (EST) and turn the key switch ON without starting the engine. 2. Click the “Configuration” icon (1).

NHPH14ENG0006AA

NHPH14ENG0020AA

NHPH14ENG0021AA

3. Select “Replacement of the Rail Pressure Relief Valve (PRV) – Reset ECU Data” (1). 4. Click the “CONFIGURE SELECTED ITEM” button (2).

5. Click the “RESET” button (1).

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Index Electrical systems - 55 Fuel injection system - 010 Common rail Relief valve - Configure - Reset ECU data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Common rail pressure sensor - Configure - Reset ECU data (Rail pressure sensor) (*) . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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Electrical systems - 55 Fuel tank system - 011

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Electrical systems - 55 Fuel tank system - 011

TECHNICAL DATA Fuel level sensor General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Fuel level sensor Overview Potentiometers (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Fuel level sensor Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Electrical systems - Fuel tank system

Fuel level sensor - General specification C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

WE WE WE WE

SS13K026

Fuel sending unit Conversion table Instrument panel display 8 bars 7 bars 6 bars 5 bars 4 bars 3 bars 2 bars 1 bar

Resistance of the fuel level sensor 0 - 32 Ω 33 - 67 Ω 68 - 87 Ω 88 - 131 Ω 132 - 171 Ω 172 - 200 Ω 201 - 230 Ω 231 - — Ω

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Electrical systems - Fuel tank system

Fuel level sensor - Overview Potentiometers WE WE WE WE

C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

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

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

Rotary to linear actuators contain a potentiometer used to provide position information.

1Z0O2004112130

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Electrical systems - Fuel tank system

(fixed contact) resistive component of the potentiometer and reference ground to the other while the signal is taken from the pin attached to the wiper (movable contact). First measure the resistance across the full range of the potentiometer, the pins attached to the stationary (fixed contact) resistive component of the potentiometer and then from either end to the pin attached to the wiper (movable contact). In the latter test the resistance value should change, continuously and smoothly, as the wiper is manually moved. As the resistance varies with temperature, the test specifications are usually given at 20 °C (68 °F). NOTE: Like switches a growing number of potentiometers, as well as other variable resistive devices, are incorporating electronics. These devices are referred to as Sensors rather than Potentiometers or Varistors and often cannot be continuity tested with a multi-meter.

Potentiometer Adjustment When installing potentiometers, it is important to ensure that they do not bottom out in either direction, to prevent damage. Most potentiometers have slotted mounting holes to allow some adjustment. Before tightening the mounting hardware, operate the attaching linkage fully in both directions to confirm proper potentiometer positioning.

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Electrical systems - Fuel tank system

Fuel level sensor - Remove WE WE WE WE

C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

1. Locate and open rear engine hood (1).

93107449

931002032

931002098

2. Remove hardware (1) from air filter housing (2).

3. Disconnect connector X-014 (1) from the fuel level sender B-001 (2).

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Electrical systems - Fuel tank system

4. Label and disconnect the fuel lines (1).

931002098

5. Remove hardware (1) and fuel level sender retainer (2).

6. Remove fuel level sender B-001 (1) from fuel tank.

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Electrical systems - Fuel tank system

Fuel level sensor - Install WE WE WE WE

C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

1. Insert fuel level sender B-001 (1) into the fuel tank.

93111533

93111534

931002098

2. Place the fuel level sender retainer (1), and hardware (2) onto fuel tank. Tighten hardware.

3. Reconnect the fuel lines (1).

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Electrical systems - Fuel tank system

4. Reconnect connector X-014 (1) to the fuel level sender B-001 (2).

931002098

931002032

93107449

5. Install air filter housing (1) and bolts (2). Tighten the bolts.

6. Close rear engine hood (1).

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Index Electrical systems - 55 Fuel tank system - 011 Fuel level sensor - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel level sensor - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel level sensor - Overview Potentiometers (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel level sensor - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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Electrical systems - 55 Engine cooling system - 012

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Electrical systems - 55 Engine cooling system - 012

TECHNICAL DATA Engine coolant temperature sensor General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Engine coolant temperature sensor Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - Engine cooling system

Engine coolant temperature sensor - General specification C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

WE WE WE WE

Conversion chart Sensor resistance >128318 Ω 128318 Ω 88806.4 Ω 63399.2 Ω 44472.7 Ω 32123.4 Ω 23479.7 Ω 17393.7 Ω 13020.7 Ω 9851.1 Ω 7528.2 Ω 5807.9 Ω 4521.3 Ω 3550 Ω 2810 Ω 2241.5 Ω

Coolant temperature <-40 °C (<-40 °F) -40 °C (-40 °F) -35 °C (-31 °F) -30 °C (-22 °F) -25 °C (-13 °F) -20 °C (-4 °F) -15 °C (5 °F) -10 °C (14 °F) -5 °C (23 °F) -0 °C (32 °F) 5 °C (41 °F) 10 °C (50 °F) 15 °C (59 °F) 20 °C (68 °F) 25 °C (77 °F) 30 °C (86 °F)

Sensor resistance 1801.2 Ω 1457.5 Ω 1187.3 Ω 973.3 Ω 802.8 Ω 665.9 Ω 465.8 Ω 392.6 Ω 332.5 Ω 79.2 Ω 70 Ω 62 Ω 55.1 Ω 49.1 Ω > 49.1 Ω

Conversion chart Coolant temperature <21 °C (<70 °F) 21 °C (70 °F) 37 °C (99 °F) 60 °C (140 °F) 82 °C (180 °F) 98 °C (208 °F) 101 °C (214 °F) 104 °C (219 °F) 108 °C (226 °F) >108 °C (>226 °F)

Instrument panel display 1 bar 1 bar 2 bars 3 bars 4 bars 5 bars 6 bars 7 bars 8 bars 8 bars

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Coolant temperature 35 °C (95 °F) 40 °C (104 °F) 45 °C (113 °F) 50 °C (122 °F) 55 °C (131 °F) 60 °C (140 °F) 70 °C (158 °F) 75 °C (167 °F) 80 °C (176 °F) 130 °C (266 °F) 135 °C (275 °F) 140 °C (284 °F) 145 °C (293 °F) 150 °C (302 °F) >150 °C (>302 °F)

Electrical systems - Engine cooling system

Engine coolant temperature sensor - Overview C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

WE WE WE WE

1Z0O2004112136

Temperature sensors generally incorporate a thermistor. A thermistor is a resistor that changes its resistance according to temperature. There are two groups of thermistors: Negative temperature coefficient (NTC) and positive temperature coefficient (PTC). With NTCs, the higher the temperature, then the lower is the resistance. With PTC, the higher the temperature, then the higher the resistance. The NTC type is often used by sensors that indicate temperature change in fluids, like those contained in a hydraulic reservoir or in the engine coolant system. Often the signal provided to the controller is used by the controller to provide information to a display device which could display actual values or operate a warning indicator.

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Index Electrical systems - 55 Engine cooling system - 012 Engine coolant temperature sensor - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine coolant temperature sensor - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Electrical systems - 55 Hydrostatic drive control system - 019

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Electrical systems - 55 Hydrostatic drive control system - 019

FUNCTIONAL DATA Hydrostatic control solenoids Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Hydrostatic drive control sensors Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Hydrostatic control solenoids Remove - Right-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install - Right-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Remove - Left-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install - Left-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Hydrostatic drive control sensors Remove - Right-hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install - Right-hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Remove - Left-hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install - Left-hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Test - Swash plate angle sensor test and centering procedure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Electrical systems - Hydrostatic drive control system

Hydrostatic control solenoids - Overview C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

WE WE WE WE

1Z0O2004112134

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

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

Diagrams (1) to (3) show the normal operating range of the PWM valve, and diagram (4), shows the initial 12 volts programming and fill time only. The diagrams in column A show the voltage signal that is sent to the valve, whereas column B shows the relevant spring pressure and column B the reading on a voltmeter connected to the solenoid valve. Diagram (1) shows the OFF position: no signal is directed to the valve, which means no spring pressure in the valve at all and results in a zero voltage reading. Increasing the duty cycle causes some pressure to be made on the circuit (Diagram (2)), which results in a voltmeter reading increase. Diagram (3), shows the maximum signal that is used during the normal activity of the valve: its duty cycle is around 0.5, which results in a spring pressure for the half of its run and in an indication of a 6 volts average DC current. The electrical circuit to the solenoids can be checked by using a digital or analogue DC voltmeter, which will indicate the average voltage readings.

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Electrical systems - Hydrostatic drive control system

Hydrostatic drive control sensors - Overview WE WE WE WE

C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Rotary to linear actuators contain a potentiometer used to provide position information.

1Z0O2004112130

Like operator and mechanically controlled switches, checking the operation of potentiometers can be accomplished by disconnecting the potentiometer from the electrical circuit and using a multi-meter to measure resistances. Potentiometers are three-wire devices. Typically a source voltage is connected to one of the pins attached to the stationary (fixed contact) resistive component of the potentiometer and reference ground to the other while the signal is taken from the pin attached to the wiper (movable contact). First measure the resistance across the full range of the potentiometer, the pins attached to the stationary (fixed contact) resistive component of the potentiometer and then from either end to the pin attached to the wiper (movable contact). In the latter test the resistance value should change, continuously and smoothly, as the wiper is manually moved. As the resistance varies with temperature, the test specifications are usually given at 20 °C (68 °F). NOTE: Like switches a growing number of potentiometers, as well as other variable resistive devices, are incorporating electronics. These devices are referred to as Sensors rather than Potentiometers or Varistors and often cannot be continuity tested with a multi-meter.

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Electrical systems - Hydrostatic drive control system

Hydrostatic control solenoids - Remove - Right-hand side WE WE WE WE

C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

NOTE: This procedure covers how to remove the right-hand forward and right-hand reverse drive solenoids located on the electro-hydraulic hydrostatic pump. 1. Locate the electro-hydraulic hydrostatic pump (1).

931001814

2. Locate the drive solenoid that needs to be removed. The right-hand reverse (1) and right-hand forward (2) solenoids are located on the input shaft side of the hydrostatic pump.

3. Disconnect the connector (2) from the solenoid. Unscrew the cap (1).

4. Slide the solenoid off.

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Electrical systems - Hydrostatic drive control system

Hydrostatic control solenoids - Install - Right-hand side WE WE WE WE

C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

NOTE: This procedure covers how to install the right-hand forward and right-hand reverse drive solenoids located on the electro-hydraulic hydrostatic pump. 1. Place the solenoid on to the valve body. See picture for location of solenoids. The right-hand reverse (1) and right-hand forward (2) solenoids are located on the input shaft side of hydrostatic pump.

931001814

2. Screw the cap (1) onto valve body. Connect the connector (2) to the solenoid.

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Electrical systems - Hydrostatic drive control system

Hydrostatic control solenoids - Remove - Left-hand side WE WE WE WE

C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

NOTE: This procedure covers how to remove the left-hand forward and left-hand reverse drive solenoids located on the electro-hydraulic hydrostatic pump. 1. Locate the electro-hydraulic hydrostatic pump (1).

931001814

2. Locate the drive solenoid that needs to be removed. The left-hand forward (1) and left-hand reverse (2) solenoids are located near the auxiliary pump.

3. Disconnect the connector (1) from the solenoid. Unscrew the cap (2).

4. Slide the solenoid off.

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Electrical systems - Hydrostatic drive control system

Hydrostatic control solenoids - Install - Left-hand side WE WE WE WE

C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

NOTE: This procedure covers how to install the left-hand forward and left-hand reverse drive solenoids located on the electro-hydraulic hydrostatic pump. 1. Place the solenoid on to the valve body. See picture for location of solenoids. The left-hand reverse (1) and left-hand forward (2) solenoids are located near the auxiliary pump.

931001814

2. Screw the cap (1) onto valve body. Connect the connector (2) to the solenoid.

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Electrical systems - Hydrostatic drive control system

Hydrostatic drive control sensors - Remove - Right-hand swash plate sensor WE WE WE WE

C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

1. Locate the right-hand swash plate sensor on the bottom of the electro-hydraulic hydrostatic pump (1).

931001814

931001961

2. Label and disconnect the connector from the swash plate sensor. The right-hand swash plate sensor (1) is located on the input shaft side of the hydrostatic pump.

3. Remove the two screws (1) holding the swash plate shield (2) and sensor.

4. Remove the swash plate sensor.

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Electrical systems - Hydrostatic drive control system

Hydrostatic drive control sensors - Install - Right-hand swash plate sensor WE WE WE WE

C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

1. Install the right-hand swash plate sensor (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.

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Electrical systems - Hydrostatic drive control system

Hydrostatic drive control sensors - Remove - Left-hand swash plate sensor WE WE WE WE

C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

1. Locate the left-hand swash plate sensor on the bottom of the electro-hydraulic hydrostatic pump (1).

931001814

931001961

2. Label and disconnect the connector from the swash plate sensor. The left-hand swash plate sensor (1) is located near the auxiliary pump.

3. Remove the two screws (1) holding the swash plate shield (2) and sensor.

4. Remove the swash plate sensor.

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Electrical systems - Hydrostatic drive control system

Hydrostatic drive control sensors - Install - Left-hand swash plate sensor WE WE WE WE

C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

1. Install the left-hand swash plate sensor (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.

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Electrical systems - Hydrostatic drive control system

Hydrostatic drive control sensors - Test - Swash plate angle sensor test and centering procedure WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

Prior operation: Confirm that the joysticks are returning to the neutral position and there are no electrical issues with the joystick harness before checking the swash plate angle sensors. Prior operation: Place the machine on blocks or ensure that the machine is in an open area with adequate clearance to other objects. NOTE: This procedure is done using the Electronic Service Tool (EST) ‘monitor’ function.

RAPH16SSL0227GA

EST View Parameters List 1. Connect the EST diagnostic connector to the test port of the machine to monitor the four Electro-Hydraulic (EH) parameters shown in the right-hand column of Figure 1.

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Electrical systems - Hydrostatic drive control system

RAPH16SSL0228HA

Log Parameter Settings 2. To save the data you select, click on the ‘Log Parameter Selection’, and select the ‘Sampling Rate Selection’ to the 10 ms setting prior to recording. See Figure 2 for detail. 47683911 27/02/2015

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Electrical systems - Hydrostatic drive control system

Swash plate angle sensor voltage chart Neutral from Neutral from Neutral Dead-band Forward Reverse

Forward

LH Sensor 1 Voltage LH Sensor 2 Voltage RH Sensor 1 Voltage RH Sensor 2 Voltage 3. View live or record the data from the four noted parameters and use the chart to record and analyze the results. NOTE: The neutral reading changes depending upon whether the pump is returning to neutral from forward or from reverse driving direction. The difference between these values is called ‘neutral deadband’. Record the values in the chart above. 4. Slowly command the pumps from neutral to the forward direction. Forward specifications for the left-hand pump sensor: 1.

The left-hand swash plate angle Sensor 1 neutral voltage parameter specification is 2.4 V to 2.6 V and increasing voltage when commanded forward.

The left-hand swash plate angle Sensor 2 neutral voltage parameter specification is 2.6 V to 2.4 V and decreasing voltage when commanded forward.

Adding the forward voltages for the Sensor 1 and the Sensor 2 values from the left-hand sensors should equal between 4.9 V and 5.1 V.

Forward specifications for the right-hand pump sensor: 1.

The right-hand swash plate angle Sensor 1 neutral voltage parameter specification is 2.4 V to 2.6 V and increasing voltage when commanded forward.

The right-hand swash plate angle Sensor 2 neutral voltage parameter specification is 2.6 V to 2.4 V and decreasing voltage when commanded forward.

Adding the forward voltages for the Sensor 1 and the Sensor 2 values from the right-hand sensors should equal between 4.9 V and 5.1 V.

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Reverse

Sum of Sensor 1 & 2 - Forward

Sum of Sensor 1 & 2 - Reverse

Electrical systems - Hydrostatic drive control system

5. Slowly command the pumps from neutral to the reverse direction. Reverse specifications for the left-hand pump sensor: 1.

The left-hand swash plate angle Sensor 1 neutral voltage parameter specification is 2.4 V to 2.6 V and decreasing voltage when commanded reverse.

The left-hand swash plate angle Sensor 2 neutral voltage parameter specification is 2.6 V to 2.4 V and increasing voltage when commanded reverse.

Adding the reverse voltages for the Sensor 1 and the Sensor 2 values from the left-hand sensors should equal between 4.9 V and 5.1 V.

Reverse specifications for the right-hand pump sensor: 1.

The right-hand swash plate angle Sensor 1 neutral voltage parameter specification is 2.4 V to 2.6 V and decreasing voltage when commanded reverse.

The right-hand swash plate angle Sensor 2 neutral voltage parameter specification is 2.6 V to 2.4 V and increasing voltage when commanded reverse.

Adding the reverse voltages for the Sensor 1 and the Sensor 2 values from the right-hand sensors should equal between 4.9 V and 5.1 V.

6. If a sensor does not show the correct values in neutral, remove the angle sensor shield, loosen but do not remove the sensor mounting screws, and adjust the sensor to obtain approximately 2.5 V reading at the center of the neutral deadband. NOTE: Neutral readings must be between 2.4 - 2.6 V at the edges of the deadband. 7. Turn the sensor so that the reading moves toward 2.5 V attempting to center the readings within 0.05 V. 8. Tighten the mounting screws to 4.0 N·m (3.0 lb ft) and confirm the readings are still within the tolerance range. Repeat steps 4 and 5 to confirm the readings. 9. Once the readings are to specifications, install the angle sensor shield, and re-calibrate the Electro-Hydraulic (EH) ground drive system. See Servo control - Adjust (29.218) for procedure.

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Electrical systems - Hydrostatic drive control system

10. If a value for a noted parameter is not within the specification and adjustment of the sensor does not bring it within the specification, record the data with the EST for the following parameters in Figure 3 for ISO Pattern or Figure 4 for “H” Pattern control while repeating steps 4 and 5.

RAPH16SSL0229FA

Parameters to select for ISO Pattern

RAPH16SSL0230FA

Parameters to select for “H” Pattern 11. Install a new angle sensor and set the neutral sensor values as in step 6. Re-calibrate the ground drive system. See Servo control - Adjust (29.218) for procedure. Verify that the problem has been resolved.

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Electrical systems - Hydrostatic drive control system

12. Attach the recorded data to an ASIST incident and advise if the new sensor resolves the concern or if the values are all within specification and the concern still exists. Reference the ASIST incident number on the part return tag and in the warranty system.

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Index Electrical systems - 55 Hydrostatic drive control system - 019 Hydrostatic control solenoids - Install - Left-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydrostatic control solenoids - Install - Right-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydrostatic control solenoids - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydrostatic control solenoids - Remove - Left-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydrostatic control solenoids - Remove - Right-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydrostatic drive control sensors - Install - Left-hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . .

Hydrostatic drive control sensors - Install - Right-hand swash plate sensor (*) . . . . . . . . . . . . . . . . . .

Hydrostatic drive control sensors - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydrostatic drive control sensors - Remove - Left-hand swash plate sensor (*) . . . . . . . . . . . . . . . . .

Hydrostatic drive control sensors - Remove - Right-hand swash plate sensor (*) . . . . . . . . . . . . . . . .

Hydrostatic drive control sensors - Test - Swash plate angle sensor test and centering procedure (*)

(*) See content for specific models 47683911 27/02/2015

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Electrical systems - 55 Hydraulic system control - 036

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Electrical systems - 55 Hydraulic system control - 036

TECHNICAL DATA Hydraulic fluid temperature control sensor General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Hydraulic fluid temperature control sensor Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(*) See content for specific models 47683911 27/02/2015

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Electrical systems - Hydraulic system control

Hydraulic fluid temperature control sensor - General specification C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

WE WE WE WE

Conversion chart Sensor resistance >128318 Ω 128318 Ω 88806.4 Ω 63399.2 Ω 44472.7 Ω 32123.4 Ω 23479.7 Ω 17393.7 Ω 13020.7 Ω 9851.1 Ω 7528.2 Ω 5807.9 Ω 4521.3 Ω 3550 Ω 2810 Ω 2241.5 Ω

Oil temperature <-40 °C (<-40 °F) -40 °C (-40 °F) -35 °C (-31 °F) -30 °C (-22 °F) -25 °C (-13 °F) -20 °C (-4 °F) -15 °C (5 °F) -10 °C (14 °F) -5 °C (23 °F) -0 °C (32 °F) 5 °C (41 °F) 10 °C (50 °F) 15 °C (59 °F) 20 °C (68 °F) 25 °C (77 °F) 30 °C (86 °F)

Sensor resistance 1801.2 Ω 1457.5 Ω 1187.3 Ω 973.3 Ω 802.8 Ω 665.9 Ω 465.8 Ω 392.6 Ω 332.5 Ω 79.2 Ω 70 Ω 62 Ω 55.1 Ω 49.1 Ω > 49.1 Ω

Conversion chart Oil temperature <21 °C (<70 °F) 21 °C (70 °F) 37 °C (99 °F) 60 °C (140 °F) 82 °C (180 °F) 90 °C (194 °F) 98 °C (208 °F) 104 °C (219 °F) 110 °C (230 °F) >110 °C (>230 °F)

Instrument panel display 1 bar 1 bar 2 bars 3 bars 4 bars 5 bars 6 bars 7 bars 8 bars 8 bars

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Oil temperature 35 °C (95 °F) 40 °C (104 °F) 45 °C (113 °F) 50 °C (122 °F) 55 °C (131 °F) 60 °C (140 °F) 70 °C (158 °F) 75 °C (167 °F) 80 °C (176 °F) 130 °C (266 °F) 135 °C (275 °F) 140 °C (284 °F) 145 °C (293 °F) 150 °C (302 °F) >150 °C (>302 °F)

Electrical systems - Hydraulic system control

Hydraulic fluid temperature control sensor - Overview C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

WE WE WE WE

1Z0O2004112136

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Index Electrical systems - 55 Hydraulic system control - 036 Hydraulic fluid temperature control sensor - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic fluid temperature control sensor - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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Electrical systems - 55 Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls 051

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Electrical systems - 55 Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls - 051

FUNCTIONAL DATA Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Heating, Ventilation, and Air-Conditioning (HVAC) control system - Electrical schema . . . . . . . . . . . . . . . 4

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Electrical systems - Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls

Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls - Overview The HVAC system has several power inputs. One source power comes from the accessory relay to the HVAC box. This energizes the auxiliary relay for the coil for the fan motor (internal to HVAC Box). The accessory relay is powered from the instrument cluster when the ignition is on, which shuts the auxiliary relay for fan motor. The auxiliary relay for the power for the fan motor comes directly from the battery via the HVAC fuse. The auxiliary relay for fan motor is shut anytime the ignition is on, which provides power to the water valve, temperature control potentiometer, and blower switch. Power is provided to the A/C switch from the blower switch, anytime a fan speed is selected. The blower switch, A/C switch, and temperature control potentiometer are all located on the left console. Since the water valve and temperature control potentiometer are energized, cab heat is available anytime the ignition is on. When the A/C switch is turned “on” and an electric fan speed is selected, power is provided to the HVAC through the pressure switch (internal to HVAC box), through the thermostat (internal to HVAC box), out the HVAC box to the HVAC high pressure switch, and back into HVAC box to the compressor relay coil (internal to HVAC box), shutting the compressor relay next to HVAC box). When the compressor relay is shut, this allows battery power from the compressor fuse through the HVAC box to the compressor relay, and out of the HVAC box to the A/C compressor. When the A/C switch is turned “on” and an electric fan speed is selected, power is also applied to the condenser relay coil, shutting the condenser relay, and providing battery power via a fuse to the condenser fan. The blower switch, since energized, can provide four speed levels (off, low, medium, high) to the electric fan motor (internal to HVAC box). This is done through a resistor (internal to HVAC box).

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Electrical systems - Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls

Heating, Ventilation, and Air-Conditioning (HVAC) control system Electrical schema

HVACBOXSCHEMSL5

HVAC box schematic Components in the HVAC box Designation (1) (2) (3) (4) (5) (6) (7)

Component Compressor relay Auxiliary relay for fan motor Resistor Fan motor Thermostat Pressure switch HVAC connector

HVAC pin information (numbered from top to bottom on the schematic) Pin number 3 4 5 2 10

14 9 12

Wire description Power to the low speed portion of the resistor from the blower switch Power to the medium speed portion of the resistor from the blower switch High speed power to the fan motor from the blower switch Power to the compressor relay from the fuse Power to the blower switch, temperature control, potentiometer, and water valve from the auxiliary relay for the fan motor Power to the auxiliary relay for the fan motor from the HVAC fuse Ground path from the thermostat Power to the A/C compressor from compressor relay

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Electrical systems - Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls

11 6 1

13 8 7

Power to the auxiliary relay for the fan coil from the accessory relay Power to the pressure switch and thermostat from the A/C switch Ground for the compressor relay Ground for the auxiliary relay for fan coil Ground for the fan motor Not used Power to the compressor relay coil from the high pressure switch Power to the high pressure switch from the thermostat

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Index Electrical systems - 55 Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls - 051 Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls - Overview . . . . . . . . . . . . . . . . . . . .

Heating, Ventilation, and Air-Conditioning (HVAC) control system - Electrical schema . . . . . . . . . . .

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Electrical systems - 55 Harnesses and connectors - 100

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Electrical systems - 55 Harnesses and connectors - 100

FUNCTIONAL DATA Harnesses and connectors Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Wiring harnesses Electrical schematic sheet 01 - Power distribution and starting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (*) . . . . . . . . . . . . . . 32 Electrical schematic sheet 03 - Exhaust system and Controller Area Network (CAN) bus (*) . . . . . . . . . 34 Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (*) . . . . . . . . . . . . . . . . . . . 36 Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (*) . . . . . . . . . . . . . . . . . . . 38 Electrical schematic sheet 06 - Engine control and fuel injection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Electrical schematic sheet 01 Main Power Distribution (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Electrical schematic sheet 02 Accessory Power Distribution (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Electrical schematic sheet 03 Ignition Charging System (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Electrical schematic sheet 04 System Power and Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Electrical schematic sheet 05 Engine Power Distribution and Fuel Pump (*) . . . . . . . . . . . . . . . . . . . . . . . 50 Electrical schematic sheet 06 Engine F5C T4 (Vehicle) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Electrical schematic sheet 07 Engine F5C T4 (Engine) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Electrical schematic sheet 08 Throttle Sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Electrical schematic sheet 09 Control Valve Interlock & 2nd Aux Hydraulics (*) . . . . . . . . . . . . . . . . . . . . 58 Electrical schematic sheet 10 Cab to Chassis Interface (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Electrical schematic sheet 11 Cab Console Switches (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Electrical schematic sheet 12 Left-Hand Control Handle (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Electrical schematic sheet 13 Right-Hand Control Handle (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Electrical schematic sheet 14 Seat (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Electrical schematic sheet 15 Std Aux Hydraulics (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Electrical schematic sheet 16 Lamps (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Electrical schematic sheet 17 Indicators (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Electrical schematic sheet 18 Turn Signal and Work Lights (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Electrical schematic sheet 19 Roading Lights (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Electrical schematic sheet 20 Wipers and Washers (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Electrical schematic sheet 21 Instrument Cluster (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Electrical schematic sheet 22 HVAC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

(*) See content for specific models 47683911 27/02/2015

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Electrical schematic sheet 23 Radio (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Electrical schematic sheet 24 Multi-Function Loader Arm (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Electrical schematic sheet 25 Telematics (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Electrical schematic sheet 26 Case Front Lights (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Electrical schematic sheet 27 Diagnostic Connector (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Electrical schematic sheet 28 Fuel Filter Jumper (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Electrical schematic sheet 29 NH Front Lights (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Electrical schematic sheet 30 Boom Lock Valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Electrical schematic sheet 01 Main Power Distribution (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Electrical schematic sheet 02 Accessory Power Distribution (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Electrical schematic sheet 03 Ignition Charging System (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Electrical schematic sheet 04 System Power and Grounds (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Electrical schematic sheet 05 Engine F5C T4 (Vehicle) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Electrical schematic sheet 06 Engine F5C T4 (Engine) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Electrical schematic sheet 07 Engine Power Distribution and Fuel Pump (*) . . . . . . . . . . . . . . . . . . . . . . 114 Electrical schematic sheet 08 Throttle Sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Electrical schematic sheet 09 EH Pump/ Hydraulics (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Electrical schematic sheet 10 Hydraulic Interlocks (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Electrical schematic sheet 11 Loader Valve and Sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Electrical schematic sheet 12 Cab to Chassis Interface (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Electrical schematic sheet 13 Cab to Chassis Interface (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Electrical schematic sheet 14 Cab to Chassis Interface (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Electrical schematic sheet 15 Cab Console Switches (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Electrical schematic sheet 16 Left-Hand Control Handle (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Electrical schematic sheet 17 Right-Hand Control Handle (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Electrical schematic sheet 18 Seat Switch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Electrical schematic sheet 19 Unit Control Module (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Electrical schematic sheet 20 Unit Control Module (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Electrical schematic sheet 21 Lamps (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Electrical schematic sheet 22 Indicators (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Electrical schematic sheet 23 Turn Signal and Work Lights (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Electrical schematic sheet 24 Roading Lights (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Electrical schematic sheet 25 Wipers and Washers (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Electrical schematic sheet 26 Instrument Cluster (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Electrical schematic sheet 27 HVAC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Electrical schematic sheet 28 Radio (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Electrical schematic sheet 29 Case Front Lights (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Electrical schematic sheet 30 Multi-Function Loader Arm (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Electrical schematic sheet 31 Telematics (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Electrical schematic sheet 32 Enhanced High Flow (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 Electrical schematic sheet 33 Multi-Function ON/OFF (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

(*) See content for specific models 47683911 27/02/2015

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Electrical schematic sheet 34 2nd Aux (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Electrical schematic sheet 35 Diagnostic Connector (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Electrical schematic sheet 36 Fuel Filter Jumper (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Electrical schematic sheet 37 NH Front Lights (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

Wire connectors Component diagram 00 - Connectors X-9000 to X-9009 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Component diagram 01 - Connectors X-9010 to X-9019 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 Component diagram 02 - Connectors X-9020 to X-9029 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 Component diagram 03 - Connectors X-9030 to X-9039 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 Component diagram 04 - Connectors X-9040 to X-9049 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Component diagram 10 - Connectors X-9100 to X-9109 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 Component diagram 11 - Connectors X-9110 to X-9119 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 Component diagram 12 - Connectors X-9120 to X-9129 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 Component diagram 13 - Connectors X-9130 to X-9139 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Component localization - Deluxe cab (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 Component diagram 00 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 Component diagram 01 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242 Component diagram 02 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251 Component diagram 03 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252 Component diagram 05 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 Component diagram 07 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 Component diagram 11 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 Component diagram 20 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 Component diagram 23 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 Component diagram 25 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 Component diagram 27 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 Component diagram 30 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262 Component diagram 31 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265 Component diagram 32 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266 Component diagram 33 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 Component diagram 36 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268 Component diagram 40 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269 Component diagram 43 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 Component diagram 50 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 Component diagram 90 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 Component diagram - Connectors A - Z (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274 Component diagram - Grounds (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305 Component localization - Deluxe cab (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308 Component diagram 00 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323 Component diagram 01 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326 Component diagram 02 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

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Component diagram 03 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338 Component diagram 05 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339 Component diagram 09 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340 Component diagram 11 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342 Component diagram 20 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343 Component diagram 23 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344 Component diagram 25 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345 Component diagram 27 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346 Component diagram 30 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347 Component diagram 31 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 Component diagram 32 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351 Component diagram 33 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352 Component diagram 36 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354 Component diagram 40 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355 Component diagram 41 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358 Component diagram 50 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359 Component diagram 90 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361 Component diagram - Connectors A - Z (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363 Component diagram - Grounds (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405

Fuse and relay box Relay - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407 Fuse - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409 Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410 Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413 Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416

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Harnesses and connectors - Overview WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Electrical failure modes Short Circuit A short circuit is a connection of comparatively low resistance between two points in an electrical circuit. Typically, when a higher source (positive supply) short circuits to a ground circuit or a frame ground, it causes the circuit protection device, e.g. a fuse, to open and protect the wiring from damage. However, a short circuit can cause damage to the wiring and machine. This damage can occur if a circuit is not properly protected with a circuit protection device. The amount of current allowed to flow through a wire due to a short circuit can cause the wire to overheat. This heat melts the insulation around the wire, adjacent wires, and may lead to a fire. Proper fusing reduces or eliminates damage to the machine resulting from a short circuit. A short circuit may result when a cut, pinched or chafed wire makes contact with a grounded component of the vehicle.

Open Circuit An open circuit is a loss of connection between two points in a circuit. This condition creates infinite resistance between two circuits and usually results in the malfunction of an electrical component. An open circuit may result from: • Pinched/cut wire(s) • Terminal(s) improperly seated in a connector • Poor/improper crimping • Corroded terminal(s) • Improperly connected Faston connector/ring terminal

Intermittent Circuit An Intermittent circuit is a condition in the circuit that caused random or repeated failures, and is usually caused by repeatedly opens or shorts in the circuit. In other words, the circuit makes and breaks contact intermittently. An intermittent circuit may be caused by: • Pinched wire • Loose ring terminal • Improper seating of terminal(s) in a connector • Incomplete mating of connectors • Corroded terminals

Examples of common electrical problems Short circuit • The wires are pinched between two objects, e.g. a frame and bracket.

RAIL14SSL0590AA

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Open circuit • A cut or broken wire.

RAIL14SSL0589AA

RAIL14SSL0595AA

RAIL14SSL0600AA

RAIL14SSL0601AA

Open circuit • There is no contact between the wire(s) and the terminal due to the insulation not being properly removed or positioned when the terminal was fastened to the wire(s) .

Open circuit • Completely disconnected connectors do not make contact with the terminals.

Open circuit • The terminal is not positioned properly or did not stay inside the connector.

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Open circuit • A wire is missing from a connector.

RAIL14SSL0602AA

RAIL14SSL0603AA

RAIL14SSL0593AA

RAIL14SSL0594AA

Open circuit • A wire length that is shortened.

Intermittent circuit • The hardware used to secure the terminal is not completely tightened.

Intermittent circuit • The ring terminal is not secured with hardware.

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Intermittent circuit • The terminal is not crimped on the wire(s).

RAIL14SSL0596AA

RAIL14SSL0597AA

RAIL14SSL0598AA

RAIL14SSL0599AA

Intermittent circuit • Bent pins may cause a short circuit if the two terminals do not contact. • The male and female connectors may not make contact because of the bent pin.

Intermittent circuit • Corrosion on the pin(s) is Indicated by a layer of greenish-white powder appearing on the pins. • Corroded pins may overheat because of increased resistance due to corrosion.

Intermittent circuit • Partially disconnected connectors make contact with only some terminals.

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Intermittent circuit • Cracked, broken or melted connector cause improper connections.

RAIL14SSL0605AA

RAIL14SSL0606AA

RAIL14SSL0591AA

RAIL14SSL0592AA

Intermittent circuit • A ground terminal not fastened or loose on the machine.

Chaffed wire • A section of the wire’s insulation is rubbed away, exposing the bare wire.

Burned wire and/or melted insulation • If the wire(s) are located near a heat source or overheated because of continuous, excessive current, the insulation will be discolored and melt, exposing the wire(s).

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Cross connection • Terminals that are connected in the wrong cavity will result in system malfunction.

RAIL14SSL0604AA

RAIL14SSL0607AA

Incorrect routing • A wiring harness not routed properly can lead to problems.

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Prevention of common electrical problems In order to prevent common problems and to achieve a higher reliability, please follow the below procedures. Please use harness diagnostic and repair kit, part number 380040185, to assist you with repairs to wires, harnesses, and connectors.

Sealed connectors Sealed connectors are designed with weather-proof seals that protect the connector’s terminals from moisture and debris. This protection makes them ideal for use on the exterior. Two types of seals are available in these types of connectors: • A connector seal which provides an environmental seal between the mating connectors. • A cable seal which seals the area where each wire enters the connector.

RAIL14SSL0609AA

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Unsealed connectors Unsealed connectors are designed for the interior of the machine where connectors are free from contaminates. Do not replace sealed connectors with unsealed connectors. Usage of unsealed connectors in place of sealed connectors could lead to damage by environmental factors such as moisture and debris, and cause corrosion which can lead to a poor connection. Corroded terminals create high resistance in the connection, which can cause intermittent or open circuits.

RAIL14SSL0608AA

Assembly and disassembly of connectors: Crimping wires on the terminals The crimping procedure is the same for sealed and unsealed connectors. The differences are identified below. Sealed connector 1. Slide the wire seal (1) on the wires.

RAIL14SSL0610AA

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2. Remove approximately 10 mm (3/8 in) insulation from the wire ends. 3. Inspect wire strands for cuts and damage. Remove the stripped portion of wire and strip again if necessary.

RAIL14SSL0611AA

RAIL14SSL0613AA

RAIL14SSL0611AA

RAIL14SSL0612AA

4. Place the wire (1) on the terminal. Verify that the wire seal (2) rests on the insulation barrel (3). 5. Verify that the wire core (4) is exposed to the wire barrel (5).

Unsealed connector 1. Remove approximately 10 mm (3/8 in) insulation from the wire ends. 2. Inspect wire strands for cuts and damage. Remove the stripped portion of wire and strip again if necessary.

4. Place the wire (1) on the terminal. Verify that the insulation lies on the insulation barrel (2). 5. Verify that the wire core (3) is exposed to the wire barrel (4).

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Sealed and unsealed connectors 6. Use the appropriate tools to crimp the barrels. Follow these precautions while crimping: A. Do not bend or crack the terminal. B. Do not cut the wire strands with the barrel. C. Verify that all wire strands are contained inside the core barrel. D. Wires must not fall out of the barrels once they have been crimped.

RAIL14SSL0614AA

RAIL14SSL0615AA

7. Solder all hand-crimped terminals. 8. Check circuit for electrical continuity.

Installing terminals in the connectors NOTICE: Installing the terminals do not require any special tools. Do not use excessive force to insert a terminal. 1. Orient the terminal to its proper relationship with the connector body. 2. Insert the terminal into the correct connector cavity. 3. Push until the terminal “clicks” in place. 4. Gently pull the wire back to ensure the proper seating of the terminal. Verify that the terminal will not back out from the connector.

RAIL14SSL0616AA

RAIL14SSL0617AA

Wires are locked in place with a wire lock or a Terminal Position Assurance (TPA) lock. Wire locks or TPA locks are added in the connector to avoid damage to the wires as the exposed/loose wires are more prone to damage. Wire locks and TPA locks vary in size and shape, depending on the type of connector being used. Some connectors may not have wire or TPA locks. NOTE: Image shows connector without wire lock.

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Sealed connector - wire lock 1. Install the wire lock after all terminals have been seated in the connector. 2. Push the lock over the back of the connector until it locks onto the connector.

RAIL14SSL0619AA

RAIL14SSL0618AA

RAIL14SSL0620AA

Unsealed connector - TPA lock 1. Install the TPA lock after all terminals have been seated in the connector. 2. Push the lock into the back of the connector until it locks into place.

Hinged wire lock 1. On connectors with a hinged wire lock, snap the wire lock over back of the connector .

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Prior to mating the connectors, visually inspect the connectors for damage. Verify that the connector pins are straight.

RAIL14SSL0621AA

RAIL14SSL0622AA

RAIL14SSL0623AA

Bent pins will lead to damage to the connector and may cause a short circuit.

Once the terminals are installed and locked in place, apply dielectric grease to the connector and on the pins to avoid corrosion.

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1. Push the connectors together until the connector’s locks snaps into place. 2. If a manual latch is present, secure the manual latch. 3. Slightly pull the connectors to verify a proper connection. NOTICE: Do not test the connectors by pulling the wires.

RAIL14SSL0624AA

RAIL14SSL0625AA

RAIL14SSL0626AA

RAIL14SSL0627AA

Precautions to be followed while connecting a connector: • Verify that the connections are intact. Loose connections will lead to disconnection and corrosion damage.

• Rubber seals on the connector prevents contamination. Verify that the seal is present on the connectors before mating the connectors.

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• On connectors with a missing seal, the connection will not be intact and may cause intermittent or open circuit.

RAIL14SSL0628AA

RAIL14SSL0629AA

RAIL14SSL0630AA

RAIL14SSL0631AA

• Verify that the connectors without internal locks, the “T” on the pins are flush with the bottom of the mating connector to ensure a proper connection.

• Image 43 shows properly mated connector.

• In regards to Engine Control Unit (ECU) connectors, verify that the connector is properly locked. Moving the lever towards the controller locks the connector Moving the lever away from the controller unlocks the connector. When the connector is properly locked, you should be able to feel the lever “click” into place.

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• Install the secondary locks or connector position assurance (CPA) locks as required.

RAIL14SSL0632AA

RAIL14SSL0633AA

RAIL14SSL0634AA

RAIL14SSL0635AA

NOTICE: Missing and improperly installed secondary locks will lead to faulty connections.

Disconnecting connectors 1. Remove the secondary lock or CPA lock as follows: ○ Depress the tabs on either side of the lock ○ Pull the lock out of the connectors. 2. With your thumb and a small screwdriver or a pick, lift the connector’s lock and pull the connectors apart. NOTICE: Do not disconnect the connectors by pulling the wires.

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Unsealed connector – TPA lock removal 1. With a screwdriver or pick, depress the locking tabs of the TPA lock and pull the lock from the connector. NOTE: If the locks and connectors are to be used again, verify that the locking mechanisms are not bent or deformed.

RAIL14SSL0636AA

RAIL14SSL0637AA

Sealed connectors – Wire lock removal 1. With a screwdriver or pick, lift the secondary lock over the locking tabs on either side of the connector and remove the lock from the connector. NOTE: If the locks and connectors are to be used again, verify that the locking mechanisms are not bent or deformed.

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Removal of terminals from the connectors Special tools are required to remove the terminal without damaging it or the connector in which it is inserted. Please use harness diagnostic and repair kit, part number 380040185, to assist you with repairs to wires, harnesses, and connectors. Because connectors are designed to firmly retain terminals, it is sometimes difficult to remove the terminals. Different style terminals have different removal procedures, but the most common terminals can be removed by using the procedure below. A terminal removal tool (Ex: pick or safety pin) is required to remove a push-to-seat terminal from a connector. 1. Disconnect the mating connector. 2. Remove any wire or TPA lock. 3. Grasp the wire (3) and push the terminal to the foremost position in the cavity of the connector (2). Hold the terminal in this position. 4. The terminal locking tang should be separated from the ridge inside the connector cavity. This makes it easy for the terminal removal tool (1) to unseat the terminal. 5. Locate the terminal lock tang in the connector cavity channel by looking into the connector from the mating end.

RAIL14SSL0638AA

6. Insert an appropriately sized pick into the connector cavity from the mating end of the connector. 7. Depress the lock tang with the pick or pin to unseat the terminal. 8. Gently pull the wire to remove the terminal through the back of the connector. NOTICE: If force is required to remove the terminal, the locking tang has not been properly depressed. Forcing a terminal out of the connector can damage the cavity walls.

Splicing To ensure a reliable connection, CNHi does not recommend the use of Quicksplice, Scotchlock, wire nuts, and/or similar splicing devices. A crimp and seal splice sleeve is recommended for splicing two wires together. The advantages of using a crimp-and-seal splice sleeve are as follows: • Easy to use. • Only one part is required to complete the splice. • Does not require soldering. • Suitable for use in the interior and exterior of the machine. • The bond between the splice and the wire, in addition to the wire crimp, creates a very strong splice. When heated, these splices have a glue-lined sleeve that shrinks over the wires to seal them. For reliable splicing, always select properly sized splice sleeve as per the wire gauge of the wires to be spliced.

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Recommended splicing procedure Splicing single wires 1. Strip off approximately 10 mm (3/8 in) insulation from the wire ends.

RAIL14SSL0639AA

RAIL14SSL0640AA

RAIL14SSL0641AA

RAIL14SSL0642AA

2. Push the wire cores into the sleeve till they reach the stop at the center of the sleeve.

3. Individually crimp both the ends of the splice sleeve.

4. With a hot air gun, apply heat to the splice sleeve. 5. Heat will melt the glue and adds a firm seal. When the sleeve stops shrinking and glue appears at the ends of the sleeve, remove the heat source. 6. Allow the splice to cool.

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Electrical systems - Harnesses and connectors

Splicing multiple wires CNHi recommends the use of splice clip for splicing two or more wires together. Splice clips are similar to terminal core grip wings, except that the splice clips accept more than one wire. 1. Strip off approximately 10 mm (3/8 in) insulation from the wire ends.

RAIL14SSL0643AA

RAIL14SSL0644AA

RAIL14SSL0645AA

2. Place the stripped wires in the splice clip.

3. Crimp the splice clip. NOTICE: Do not crimp the insulation.

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4. Heat the splice clip with a soldering iron and apply solder to the splice clip. 5. Do not use too much solder. Too much solder might lead to wicking and makes the wire brittle, resulting in wire damage. 6. Check the continuity of the spliced wires. 7. Cover the splice with splice tape or heat shrink tubes.

RAIL14SSL0646AA

Harness routing guidelines Proper harness routing must be performed to ensure the electrical system reliability. Improper routing of the harness may lead to various electrical system malfunctions. When repairing or replacing wire harnesses, verify that the harnesses are routed in their original position. Observe the following safety precautions while routing the harness.

Location Verify that the harness: • Should not come in contact with any moving parts. • Should be placed at least 125 mm (5 in) away from sources of radiant heat • Should be away from any potentially damaging surfaces, such as sharp or abrasive objects, sheet metal holes, sharp metal flanges, etc. • Should be placed at least 75 mm (3 in) away from battery vents

RAIL14SSL0647BA

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Electrical systems - Harnesses and connectors

Verify that the bare wires (without conduit) do not contact the hydraulic tubes and hoses.

RAIL14SSL0648AA

RAIL14SSL0649AA

RAIL14SSL0650BA

Verify that the bare wires are not secured with cable ties.

Tension Verify that the harness is not under tension. Tension is when the strain on the harness between two fixing points (clamps, brackets, connectors, grommets, etc) is larger than the weight of the wiring harness. Verify that the slack between two fixing points is not going to cause interference with other objects/moving parts.

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When the harness are to be bent, verify that the bend radius is equal to or more than three time the harness diameter.

RAIL14SSL0651AA

RAIL14SSL0652AA

RAIL14SSL0653AA

Image 65 is an example of a correct bend radius.

Image 66 is an example of an incorrect bend radius.

Harness fastening guidelines The wiring harness must be fastened properly to avoid any possible harness damage such as incorrect routing, pinching, entrapment, and/or other conditions which would damage the wiring harness. When installing the harness, follow their original routing positions and locations. Follow the guidelines below to verify that the harness is fastened properly.

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Electrical systems - Harnesses and connectors

Use the double tie to secure the wiring harness to isolated points on the machine.

RAIL14SSL0654AA

RAIL14SSL0655AA

RAIL14SSL0657AA

RAIL14SSL0658AA

Use the dual clamp to secure the harnesses without any contact.

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Grounding guidelines A return path is necessary in an electrical circuit. In CNHi applications, the ground points are equivalent to the battery negative terminal. The electrical system should be properly grounded. Use plated ground fasteners (studs, ring terminals, etc.) for better corrosion resistance. The ground fasteners must be compatible with the ground terminals to reduce galvanic corrosion. Do not use rivets or sheet metal screws for grounding. Grounding surfaces must be free of sealants, paint and/or any non-conductive coatings. Whenever possible, use ring terminals with an anti-rotation feature. In case of terminals without an anti-rotation feature, use lock washers.

RAIL14SSL0701AA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 01 - Power distribution and starting C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Component identifier K-9102 K-9104 K-9107 K-9111

WE WE WE WE

Description Main relay Starter control relay Auxiliary main relay Selective Catalytic Reduction (SCR) relay

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Electrical systems - Harnesses and connectors

NHIL14ENG1288JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE WE

S-9102 Y-9102 Z-9101

Description Heater Control Unit (HCU) Lambda sensor (under 56 kW (76 Hp) engines only) Diagnostic connector Fuel filter heater relay Electric fuel pump relay (optional) Cold start bypass valve relay (Tractor Loader Backhoe (TLB) model applications only) Fuel filter heater Diesel Exhaust Fluid (DEF)/AdBlue® supply module suction line heater Diesel Exhaust Fluid (DEF)/AdBlue® supply module back flow line heater Diesel Exhaust Fluid (DEF)/AdBlue® supply module pressure line heater Water in fuel switch Coolant control valve (over 56 kW (76 Hp) engines only) Glow plug control module

NOTE: Under 56 kW (76 Hp) engine – circuit VE-9071 Over 56 kW (76 Hp) engine – circuit VE-9072 Z-9102

Diesel Exhaust Fluid (DEF)/AdBlue® Supply module

Component identifier A-9105 B-9123 J-9100 K-9100 K-9121 K-9122 R-9005 R-9102 R-9103 R-9104

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Electrical systems - Harnesses and connectors

NHIL14ENG1289JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 03 - Exhaust system and Controller Area Network (CAN) bus C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Component identifier A-9101 A-9102 A-9103 A-9104 B-9104 B-9106 B-9107 B-9110 B-9113 B-9126 B-9127 R-9101 Y-9103

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WE WE WE WE

Description NH₃ controller NOx sensor downstream NOx sensor upstream Diesel Exhaust Fluid (DEF)/AdBlue® temperature, level and quality sensor Selective Catalytic Reduction (SCR) catalyst temperature (downstream), (over 56 kW (76 Hp) engines only) Exhaust gas temperature upstream Diesel Oxidation Catalyst (DOC) sensor (over 56 kW (76 Hp) engines only) Selective Catalytic Reduction (SCR) catalyst temperature (upstream), (over 56 kW (76 Hp) engines only) NH₃ sensor Intake air temperature sensor Particulate Matter (PM) catalytic converter inlet temperature sensor (under 56 kW (76 Hp) engines only) Diesel Oxidation Catalyst (DOC) inlet temperature sensor (under 56 kW (76 Hp) engines only) Controller Area Network (CAN) termination resistor Diesel Exhaust Fluid (DEF)/AdBlue® dosing module

Electrical systems - Harnesses and connectors

NHIL14ENG1290JA

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Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Component identifier A-9000 NOTE: Under 56 kW (76 Hp) engine – circuit VE-9071, VE9119A, VE-9121A, VE-9147, and VE-9168 Over 56 kW (76 Hp) engine – circuit VE-9072, VE-9118A, VE-9120A, VE-9143, VE-9149, VE-9169, VE9170 and VE-9173

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WE WE WE WE

Description Engine Control Unit (ECU)

Electrical systems - Harnesses and connectors

NHIL14ENG1291JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Component identifier A-9000 NOTE: Under 56 kW (76 Hp) engines – circuit VE-9118 and VE-9120 Over 56 kW (76 Hp) engines – circuit VE-9119, VE-9121

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WE WE WE WE

Description Engine Control Unit (ECU)

Electrical systems - Harnesses and connectors

NHIL14ENG1292JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Component identifier B-9001 NOTE: Over 56 kW (76 Hp) engines – circuit EN-9104 B-9002 B-9003 B-9004 B-9005 NOTE: Under 56 kW (76 Hp) engines – circuit VE-9118, VE-9120, VE-9143A Over 56 kW (76 Hp) engines – circuit VE-9118A, VE-9120A, VE-9143 B-9007 B-9017 B-9018 NOTE: Under 56 kW (76 Hp) engines – circuit VE-9119A, VE-9121A Over 56 kW (76 Hp) engines – circuit VE-9119, VE-9121 R-9000 NOTE: Under 56 kW (76 Hp) engines – circuit EN-9174, EN-9175 R-9001 R-9002 R-9003 R-9004 S-9016 Y-9000 Y-9001 Y-9002 Y-9003 Y-9004 Y-9008 Z-9000 Z-9001

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WE WE WE WE

Description Intake manifold pressure and temperature sensor

Fuel temperature sensor Coolant temperature sensor Rail pressure sensor Exhaust gas pressure sensor

Crankshaft position sensor Camshaft speed sensor Exhaust manifold temperature sensor

Intake manifold temperature sensor (under 56 kW (76 Hp) engines only) Glow plug 1 Glow plug 2 Glow plug 3 Glow plug 4 Oil pressure switch Fuel metering unit Cylinder 1 injector (Bank 1 Injector 1) Cylinder 2 injector (Bank 2 Injector 2) Cylinder 3 injector (Bank 2 Injector 1) Cylinder 4 injector (Bank 1 Injector 2) Wastegate pressure modulator valve Exhaust Gas Recirculation (EGR) valve Throttle valve actuator

Electrical systems - Harnesses and connectors

NHIL14ENG1294JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 01 Main Power Distribution C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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WE WE WE WE

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0175JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 02 Accessory Power Distribution C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0176JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 03 Ignition Charging System C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0177JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 04 System Power and Ground C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0178JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 05 Engine Power Distribution and Fuel Pump C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0179JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 06 Engine F5C T4 (Vehicle) C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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WE WE WE WE

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0247JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 07 Engine F5C T4 (Engine) C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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WE WE WE WE

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0181JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 08 Throttle Sensor C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0182JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 09 Control Valve Interlock & 2nd Aux Hydraulics C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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WE WE WE WE

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0183JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 10 Cab to Chassis Interface C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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WE WE WE WE

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0184JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 11 Cab Console Switches C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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WE WE WE WE

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0185JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 12 Left-Hand Control Handle C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0186JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 13 Right-Hand Control Handle C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0187JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 14 Seat C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0188JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 15 Std Aux Hydraulics C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0189JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 16 Lamps C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0190JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 17 Indicators C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0191JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 18 Turn Signal and Work Lights C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0192JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 19 Roading Lights C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0193JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 20 Wipers and Washers C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0194JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 21 Instrument Cluster C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0195JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 22 HVAC C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0196JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 23 Radio C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0197JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 24 Multi-Function Loader Arm C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0198JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 25 Telematics C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0199JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 26 Case Front Lights C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0200JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 27 Diagnostic Connector C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0201JA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 28 Fuel Filter Jumper C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 96

WE WE WE WE

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0202JA

47683911 27/02/2015

55.8 [55.100] / 97

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 29 NH Front Lights C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 98

WE WE WE WE

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0203JA

47683911 27/02/2015

55.8 [55.100] / 99

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 30 Boom Lock Valve C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 100

WE WE WE WE

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0204JA

47683911 27/02/2015

55.8 [55.100] / 101

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 01 Main Power Distribution C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 102

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0210JA

47683911 27/02/2015

55.8 [55.100] / 103

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 02 Accessory Power Distribution C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 104

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0211JA

47683911 27/02/2015

55.8 [55.100] / 105

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 03 Ignition Charging System C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 106

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0212JA

47683911 27/02/2015

55.8 [55.100] / 107

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 04 System Power and Grounds C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 108

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0213JA

47683911 27/02/2015

55.8 [55.100] / 109

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 05 Engine F5C T4 (Vehicle) C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 110

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0214JA

47683911 27/02/2015

55.8 [55.100] / 111

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 06 Engine F5C T4 (Engine) C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 112

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0215JA

47683911 27/02/2015

55.8 [55.100] / 113

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 07 Engine Power Distribution and Fuel Pump C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 114

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0216JA

47683911 27/02/2015

55.8 [55.100] / 115

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 08 Throttle Sensors C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 116

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0217JA

47683911 27/02/2015

55.8 [55.100] / 117

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 118

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0218JA

47683911 27/02/2015

55.8 [55.100] / 119

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 10 Hydraulic Interlocks C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 120

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0219JA

47683911 27/02/2015

55.8 [55.100] / 121

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 122

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0220JA

47683911 27/02/2015

55.8 [55.100] / 123

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 12 Cab to Chassis Interface C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 124

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0221JA

47683911 27/02/2015

55.8 [55.100] / 125

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 13 Cab to Chassis Interface C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 126

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0222JA

47683911 27/02/2015

55.8 [55.100] / 127

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 14 Cab to Chassis Interface C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 128

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0223JA

47683911 27/02/2015

55.8 [55.100] / 129

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 15 Cab Console Switches C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 130

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0224JA

47683911 27/02/2015

55.8 [55.100] / 131

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 16 Left-Hand Control Handle C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 132

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0225JA

47683911 27/02/2015

55.8 [55.100] / 133

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 17 Right-Hand Control Handle C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 134

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0226JA

47683911 27/02/2015

55.8 [55.100] / 135

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 18 Seat Switch C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 136

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0227JA

47683911 27/02/2015

55.8 [55.100] / 137

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 19 Unit Control Module C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 138

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0228JA

47683911 27/02/2015

55.8 [55.100] / 139

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 20 Unit Control Module C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 140

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0229JA

47683911 27/02/2015

55.8 [55.100] / 141

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 21 Lamps C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 142

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0230JA

47683911 27/02/2015

55.8 [55.100] / 143

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 22 Indicators C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 144

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0231JA

47683911 27/02/2015

55.8 [55.100] / 145

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 23 Turn Signal and Work Lights C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 146

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0232JA

47683911 27/02/2015

55.8 [55.100] / 147

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 24 Roading Lights C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 148

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0233JA

47683911 27/02/2015

55.8 [55.100] / 149

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 25 Wipers and Washers C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 150

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0234JA

47683911 27/02/2015

55.8 [55.100] / 151

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 26 Instrument Cluster C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 152

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0235JA

47683911 27/02/2015

55.8 [55.100] / 153

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 27 HVAC C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 154

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0236JA

47683911 27/02/2015

55.8 [55.100] / 155

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 28 Radio C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 156

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0237JA

47683911 27/02/2015

55.8 [55.100] / 157

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 29 Case Front Lights C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 158

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0238JA

47683911 27/02/2015

55.8 [55.100] / 159

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 30 Multi-Function Loader Arm C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 160

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0239JA

47683911 27/02/2015

55.8 [55.100] / 161

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 31 Telematics C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 162

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0240JA

47683911 27/02/2015

55.8 [55.100] / 163

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 32 Enhanced High Flow C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 164

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0241JA

47683911 27/02/2015

55.8 [55.100] / 165

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 33 Multi-Function ON/OFF C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 166

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0242JA

47683911 27/02/2015

55.8 [55.100] / 167

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 34 2nd Aux C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 168

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0243JA

47683911 27/02/2015

55.8 [55.100] / 169

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 35 Diagnostic Connector C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 170

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0244JA

47683911 27/02/2015

55.8 [55.100] / 171

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 36 Fuel Filter Jumper C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 172

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0245JA

47683911 27/02/2015

55.8 [55.100] / 173

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 37 NH Front Lights C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

47683911 27/02/2015

55.8 [55.100] / 174

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Electrical systems - Harnesses and connectors

RAIL14SSL0246JA

47683911 27/02/2015

55.8 [55.100] / 175

Electrical systems - Harnesses and connectors

47683911 27/02/2015

55.8 [55.100] / 176

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 00 - Connectors X-9000 to X-9009 WE WE WE WE

C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

Connector X-9003 - Intake manifold pressure and temperature sensor Over 56kW engines PIN NUMBER 1 2 3 4

CONNECTOR X-9003 - Intake manifold pressure and temperature sensor WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME EN-9103 EN-9104 EN-9101 EN-9102

SHEET 06

Ground Temperature signal Supply Pressure signal

Under 56kW engines PIN NUMBER 1 2 3 4

CONNECTOR X-9003 - Intake manifold pressure and temperature sensor WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME EN-9103 EN-9101 EN-9102

Ground Supply Pressure signal

NHIS14ENG0977AA

SHEET 06 SHEET 06

Connector X-9003 is located on top of the engine.

NHIS14ENG0983AA

Connector X-9003 is located near the cylinder 2 injector.

47683911 27/02/2015

55.8 [55.100] / 177

Electrical systems - Harnesses and connectors

87709809

Connector X-9005 - Fuel temperature sensor CONNECTOR X-9005 - Fuel temperature sensor WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 EN-9117 2 EN-9116

Signal Ground

SHEET 06

NHIS14ENG0977AA

Connector X-9005 is located at the rear of the engine.

NHIS14ENG0988AA

Connector X-9005 is located above the fuel filter. Connector X-9006 - Coolant temperature sensor CONNECTOR X-9006 - Coolant temperature sensor PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 EN-9115 Signal SHEET 06 2 EN-9114 Ground

47683911 27/02/2015

55.8 [55.100] / 178

Electrical systems - Harnesses and connectors

NHIS14ENG0977AA

Connector X-9006 is located at the front of the engine.

NHIS14ENG0975AA

Connector X-9006 is located near the water pump. Connector X-9007 - Fuel metering unit PIN WIRE NUMBER NUMBER 1 EN-9137 2 EN-9136

CONNECTOR X-9007 - Fuel metering unit CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Supply Ground

SHEET 06

NHIS14ENG0977AA

Connector X-9007 is located on the front left-hand side of the engine.

47683911 27/02/2015

55.8 [55.100] / 179

Electrical systems - Harnesses and connectors

NHIS14ENG0987AA

Connector X-9007 is near the fuel pump.

87709798

Connector X-9008 - Camshaft speed sensor CONNECTOR X-9008 - Camshaft speed sensor PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 EN-9110 Ground SHEET 06 2 EN-9111 Signal 3 EN-9109 Supply

NHIS14ENG0977AA

Connector X-9008 is located at the front of the engine.

47683911 27/02/2015

55.8 [55.100] / 180

Electrical systems - Harnesses and connectors

NHIS14ENG0974AA

Connector X-9007 is located near the crank pulley. Connector X-9009 - Exhaust manifold temperature sensor CONNECTOR X-9009 - Exhaust manifold temperature sensor PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 EN-9121 Signal SHEET 06 2 EN-9119 Ground

NHIS14ENG0977AA

Connector X-9009 is located on top of the engine.

NHIS14ENG0983AA

Connector X-9009 is located near the cylinder 2 injector.

47683911 27/02/2015

55.8 [55.100] / 181

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 01 - Connectors X-9010 to X-9019 WE WE WE WE

C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

Connector X-9010 - Exhaust gas recirculation valve PIN NUMBER 1 2 3 4 5 6

CONNECTOR X-9010 - Exhaust gas recirculation valve WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME EN-9095 EN-9093 EN-9097 EN-9096 EN-9094

Actuator supply Signal Ground Actuator supply Sensor supply

NHIS14ENG0978AA

SHEET 06

Connector X-9010 is located at the top rear of the engine.

NHIS14ENG0982AA

Connector X-9010 is located near the cylinder 4 injector. Connector X-9011 - Throttle valve actuator PIN NUMBER 1 2 3 4 5 6

CONNECTOR X-9011 - Throttle valve actuator WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME EN-9098 EN-9135 EN-9100 EN-9099 EN-9134

Sensor supply Actuator supply Ground Signal Actuator supply 47683911 27/02/2015

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SHEET 06

Electrical systems - Harnesses and connectors

NHIS14ENG0977AA

Connector X-9011 is located at the top front of the engine.

NHIS14ENG0990AA

Connector X-9011 is located above the cylinder 1 injector. Connector X-9016 - Oil pressure switch PIN WIRE NUMBER NUMBER 1 EN-9105

CONNECTOR X-9016 - Oil pressure switch CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Signal

SHEET 06

NHIS14ENG0977AA

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Electrical systems - Harnesses and connectors

NHIS14ENG0988AA

Connector X9016 is located above the oil filter. Connector X-9018 - Exhaust gas pressure sensor CONNECTOR X-9018 - Exhaust gas pressure sensor PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 EN-9143 SHEET 06 Sensor supply 2 EN-9118 Sensor ground 3 EN-9120 Sensor signal

84146681

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 02 - Connectors X-9020 to X-9029 WE WE WE WE

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Connector X-9020 - Intake manifold temperature sensor CONNECTOR X-9020 - Intake manifold temperature sensor PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 EN-9175 Signal SHEET 06 2 EN-9174 Ground

NHIS14ENG0977AA

Connector X-9020 is located on top of the engine.

NHIS14ENG0983AA

Connector X-9020 is located near the cylinder 3 injector. Connector X-9021 - Crankshaft speed sensor CONNECTOR X-9021 - Crankshaft speed sensor PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 EN-9113 SHEET 06 Signal 2 EN-9112 Ground

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Electrical systems - Harnesses and connectors

NHIS14ENG0977AA

Connector X-9021 is located on the left-hand side of the engine.

NHIS14ENG0976AA

Connector X-9021 is located on the left-hand side of the engine block.

87709793

Connector X-9026 - Rail pressure sensor PIN WIRE NUMBER NUMBER 1 EN-9106 2 EN-9107 3 EN-9108

CONNECTOR X-9026 - Rail pressure sensor CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Ground Signal Supply

SHEET 06

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Electrical systems - Harnesses and connectors

NHIS14ENG0978AA

Connector X-9026 is located at the left, rear, top of the engine.

NHIS14ENG0989AA

Connector X-9026 is at the rear of the fuel rail.

84130322

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 03 - Connectors X-9030 to X-9039 C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE WE

Connector X-9030 - Cylinder 1 injector (Bank 1 Injector 1) CONNECTOR X-9030 - Cylinder 1 injector (Bank 1 Injector 1) PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 INJ-268 High side driver SHEET 06 2 INJ-269 Low side driver

NHIS14ENG0977AA

Connector X-9030 is located at the top, front of the engine.

NHIS14ENG0983AA

Connector X-9030 is connected to the cylinder 1 fuel injector. Connector X-9031 - Cylinder 3 injector (Bank 2 Injector 1) CONNECTOR X-9031 - Cylinder 3 injector (Bank 2 Injector 1) PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 INJ-270 High side driver SHEET 06 2 INJ-271 Low side driver

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Electrical systems - Harnesses and connectors

NHIS14ENG0977AA

Connector X-9031 is located on top of the engine.

NHIS14ENG0983AA

Connector X-9031 is connected to the cylinder 3 injector. Connector X-9032 - Cylinder 4 injector (Bank 1 Injector 2) CONNECTOR X-9032 - Cylinder 4 injector (Bank 1 Injector 2) PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 INJ-572 High side driver SHEET 06 2 INJ-573 Low side driver

NHIS14ENG0977AA

Connector X-9032 is located on top of the engine.

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Electrical systems - Harnesses and connectors

NHIS14ENG0982AA

Connector X-9032 is connected to the cylinder 4 injector. Connector X-9033 - Cylinder 2 injector (Bank 2 Injector 2) CONNECTOR X-9033 - Cylinder 2 injector (Bank 2 Injector 2) PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 INJ-574 High side driver SHEET 06 2 INJ-575 Low side driver

NHIS14ENG0977AA

Connector X-9033 is located on top of the engine.

NHIS14ENG0983AA

Connector X-9033 is connected to the cylinder 2 injector. Connector X-9034 - Glow plug 1 PIN WIRE NUMBER NUMBER 1 GP-9001

CONNECTOR X-9034 - Glow plug 1 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Control signal, Pulse Width Modulated (PWM) 47683911 27/02/2015

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SHEET 06

Electrical systems - Harnesses and connectors

NHIS14ENG0977AA

Connector X-9034 is located on top of the engine.

NHIS14ENG0981AA

Connector X-9034 is connected to the cylinder 1 glow plug. (Under 56 kW (76 Hp) shown; over 56 kW (76 Hp) cylinder 1 glow plug is on the side of the cylinder head.)

1-928-404-879

1-928-404-879 Connector X-9035 - Glow plug 2 PIN WIRE NUMBER NUMBER 1 GP-9002

CONNECTOR X-9035 - Glow plug 2 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Control signal, Pulse Width Modulated (PWM)

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SHEET 06

Electrical systems - Harnesses and connectors

NHIS14ENG0977AA

Connector X-9035 is located on top of the engine.

NHIS14ENG0980AA

Connector X-9035 is connected to the cylinder 2 glow plug. (Under 56 kW (76 Hp) shown; over 56 kW (76 Hp) cylinder 1 glow plug is on the side of the cylinder head.)

1-928-404-879

1-928-404-879 Connector X-9036 - Glow plug 3 PIN WIRE NUMBER NUMBER 1 GP-9003

CONNECTOR X-9036 - Glow plug 3 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Control signal, Pulse Width Modulated (PWM)

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Electrical systems - Harnesses and connectors

NHIS14ENG0977AA

Connector X-9036 is located on top of the engine.

NHIS14ENG0980AA

Connector X-9036 is connected to the cylinder 3 glow plug. (Under 56 kW (76 Hp) shown; over 56 kW (76 Hp) cylinder 1 glow plug is on the side of the cylinder head.)

1-928-404-879

1-928-404-879 Connector X-9037 - Glow plug 4 PIN WIRE NUMBER NUMBER 1 GP-9004

CONNECTOR X-9037 - Glow plug 4 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Control signal, Pulse Width Modulated (PWM)

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SHEET 06

Electrical systems - Harnesses and connectors

NHIS14ENG0977AA

Connector X-9037 is located on top of the engine.

NHIS14ENG0980AA

Connector X-9037 is connected to the cylinder 4 glow plug. (Under 56 kW (76 Hp) shown; over 56 kW (76 Hp) cylinder 1 glow plug is on the side of the cylinder head.)

1-928-404-879

1-928-404-879 Connector X-9038 - Wastegate pressure modulator valve CONNECTOR X-9038 - Wastegate pressure modulator valve PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 EN-9024 Actuator supply SHEET 06 2 EN-9133 Low side driver

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Electrical systems - Harnesses and connectors

NHIS14ENG0977AA

Connector X-9038 is located at the top front of the engine.

NHIS14ENG0991AA

Connector X-9038 is connected to the waste gate pressure modulator valve.

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 04 - Connectors X-9040 to X-9049 C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE WE

Connector X-9040 - Engine harness to glow plug harness CONNECTOR X-9040 - Engine harness to glow plug harness PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER A EN-9058 Supply voltage, cylinder 1 glow plug SHEET 06 GP-9001 B EN-9059 Supply voltage, cylinder 2 glow plug GP-9002 EN-9060 C Supply voltage, cylinder 3 glow plug GP-9003 D EN-9061 Supply voltage, cylinder 4 glow plug GP-9004

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 10 - Connectors X-9100 to X-9109 C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE WE

Connector X-9104 - Selective Catalytic Reduction (SCR) downstream exhaust gas temperature sensor CONNECTOR X-9104 - Selective Catalytic Reduction (SCR) downstream exhaust gas temperature sensor PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 VE-9149 Signal SHEET 03 2 VE-9169 Reference ground Connector X-9106 - Diesel Oxidation Catalyst (DOC) upstream exhaust gas temperature sensor CONNECTOR X-9106 - Diesel Oxidation Catalyst (DOC) upstream exhaust gas temperature sensor PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 VE-9145 SHEET 03 Signal 2 VE-9164 Reference ground Connector X-9107 - Selective Catalytic Reduction (SCR) upstream exhaust gas temperature sensor CONNECTOR X-9107 - Selective Catalytic Reduction (SCR) upstream exhaust gas temperature sensor PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 VE-9171 Signal SHEET 03 2 VE-9170 Reference ground Connector X-9108 - Diesel Exhaust Fluid (DEF)/AdBlue® supply module CONNECTOR X-9108 - DEF/AdBlue® supply module WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 2 VE-9165

VE-9031

VE-9092

5 6 7 8

VE-9083 VE-9122 VE-9124

VE-9123

VE-1923

11 12

VE-9086 VE-9091

Low Side Driver (LSD), Diesel SHEET 02 Exhaust Fluid (DEF)/AdBlue® pump motor control signal Supply, Diesel Exhaust Fluid (DEF)/AdBlue® pump motor Battery negative (for bonding purposes) Supply, back flow pump Ground, back flow pump SHEET 02 Reference ground, Diesel Exhaust Fluid (DEF)/AdBlue® pressure sensor Signal, Diesel Exhaust Fluid (DEF)/AdBlue® pressure sensor 5V supply, Diesel Exhaust Fluid (DEF)/AdBlue® pressure sensor Controlled supply, module heater Ground

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Electrical systems - Harnesses and connectors

84152570

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 11 - Connectors X-9110 to X-9119 WE WE WE WE

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Connector X-9110 -Diesel Exhaust Fluid (DEF)/AdBlue® dosing module CONNECTOR X-9110 -Diesel Exhaust Fluid (DEF)/AdBlue® dosing module PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 VE-9138 Low Side Driver (LSD) SHEET 06 2 VE-9139 High Side Driver (HSD)

87709798

Connector X-9111 - Heater Control Unit (HCU) CONNECTOR X-9111 -Heater Control Unit (HCU) PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER VE-9086 G1 Diesel Exhaust Fluid (DEF)/AdBlue® SHEET 02 supply module, heater supply VE-9084 G2 Diesel Exhaust Fluid (DEF)/AdBlue® tank supply and back-flow lines, heater supply G3 VE-9085 G4 Diesel Exhaust Fluid (DEF)/AdBlue® supply module pressure line, heater supply G5 87 VE-9025 Switched supply 31 VE-9087 Ground G6 D1 VE-9079 Controller Area Network (CAN) 2 low 30 VE-9054 Battery supply VE-9080 ST Controller Area Network (CAN) 2 high Connector X-9112 - Selective Catalytic Reduction (SCR) tank heating valve CONNECTOR X-9112 - Selective Catalytic Reduction (SCR) tank heating valve PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 VE-9082 SHEET 02 Supply 2 3 VE-9199 Low Side Driver (LSD)

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Electrical systems - Harnesses and connectors

84146685

Connector X-9113 - Glow plug control module Over 56kW (76hp) engines PIN NUMBER 1 2 3 4 5 6 7 8

CONNECTOR X-9113 - Glow plug control module WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME VE-9060 VE-9058 VE-9073 VE-9062 VE-9074 VE-9061 VE-9059 VE-0972

Controlled supply, glow plug 3 Controlled supply, glow plug 1 Feedback signal Battery supply Reference ground Controlled supply, glow plug 4 Controlled supply, glow plug 2 Control signal

SHEET 02

Under 56kW (76hp) engines PIN NUMBER 1 2 3 4 5 6 7 8

CONNECTOR X-9113 - Glow plug control module WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME VE-9060 VE-9058 VE-9073 VE-9062 VE-9074 VE-9061 VE-9059 VE-0971

Controlled supply, glow plug 3 Controlled supply, glow plug 1 Feedback signal Battery supply Reference ground Controlled supply, glow plug 4 Controlled supply, glow plug 2 Control signal

84356962

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SHEET 02

Electrical systems - Harnesses and connectors

Connector X-9114 - Diagnostic and monitoring connector PIN NUMBER A B C D E

CONNECTOR X-9114 - Diagnostic and monitoring connector WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME VE-9008 VE-9069 VE-9067 VE-9068 VE-9070

Ground SHEET 03 Battery voltage Controller Area Network (CAN) 1 high Controller Area Network (CAN) 1 low ISO K-line

47618613

Connector X-9115 - Fuel filter heater relay PIN NUMBER 86 85 30 87 87A

CONNECTOR X-9115 - Fuel filter heater relay WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME VE-9023 VE-9064 VE-9063 VE-9075 -

Supply Low Side Driver (LSD) Fused battery switched supply to heater -

SHEET 02

NOTE: Relay connector and conductor naming and numbering conventions are representative – used for engine diagnostics and schematic referencing. Use machine schematics for exact relay/wiring numbering and pinout. Connector X-9116 – Cold start bypass valve relay CONNECTOR X-9116 – Cold start bypass valve relay WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 86 85 30 87

VE-9298 VE-9299 see product schematics see product schematics

87A

SHEET 02 Supply Low Side Driver (LSD) From vehicle power distribution Switched supply to cold start bypass valve -

NOTE: Relay connector and conductor naming and numbering conventions are representative – used for engine diagnostics and schematic referencing. Use machine schematics for exact relay/wiring numbering and pinout. Connector X-9117 - Intake air temperature sensor CONNECTOR X-9117 - Intake air temperature sensor WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 VE-9144 2 VE-9162

Signal Reference ground 47683911 27/02/2015

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 12 - Connectors X-9120 to X-9129 WE WE WE WE

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Connector X-9120 - Starter control relay PIN WIRE NUMBER NUMBER 30 VE-9044 85 86 87 87A

VE-9057 VE-9056 VE-9055 -

CONNECTOR X-9120 - Starter control relay CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Controlled supply, vehicle controlled relay High Side Driver (HSD) Low Side Driver (LSD) Controlled signal, starter relay -

SHEET 01

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Electrical systems - Harnesses and connectors

Connector X-9121 - Engine Control Unit (ECU) connector A Over 56kW (76hp) engines PIN WIRE NUMBER NUMBER A01 VE-9128 A02

VE-9132

A03

VE-9138

A04

VE-9133

A05

VE-9124

A06 A07

VE-9105 VE-1923

A08

VE-9098

A09

VE-9094

A10

VE-9101

A11

VE-9108

A12

VE-9138

A13

VE-9109

A14 A15

VE-9111 VE-9137

A16

VE-9125

A17

VE-9129

A18

VE-9139

A19 A20

VE-9026

A21 A22

CONNECTOR X-9121 - ECU connector A CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME High Side Driver (HSD), bank 2 SHEET 05 injector 1 (cylinder 3) High Side Driver (HSD), bank 2 injector 2 (cylinder 2) Low Side Driver (LSD), Diesel Exhaust Fluid (DEF)/AdBlue® dosing valve Low side driver (LSD), waste gate pressure modulator valve Reference ground, Diesel Exhaust Fluid (DEF)/AdBlue® supply module pressure sensor Input signal, oil pressure switch +5 V sensor supply, Diesel Exhaust Fluid (DEF)/AdBlue® supply module pressure sensor +5 V sensor supply, Throttle Valve Actuator (TVA) position sensor +5 V sensor supply, Exhaust Gas Recirculation (EGR) valve position sensor +5 V sensor supply, intake manifold pressure sensor +5 V sensor supply, rail pressure sensor +5 V sensor supply, exhaust manifold temperature sensor +5 V sensor supply, camshaft speed sensor Input signal, camshaft speed sensor Switched voltage supply, fuel metering unit High Side Driver (HSD), bank 1 injector 1 (cylinder 1) High Side Driver (HSD), bank 1 injector 2 (cylinder 4) High Side Driver (HSD), Diesel Exhaust Fluid (DEF)/AdBlue® dosing valve Low side switch, Selective Catalytic SHEET 05 Reduction (SCR) main relay -

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CONNECTOR X-9121 - ECU connector A WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER A23 VE-9116 A24

VE-9097

A25

VE-9103

A26

VE-9106

A27

VE-9119

A28

VE-9110

A29 A30 A31

VE-9127

A32

VE-9126

A33 A34

VE-9135

A35

VE-9096

A36 A37

VE-9100

A38 A39

VE-9117 VE-9093

A40

VE-9102

A41 A42 A43

VE-9107 VE-9121

A44

VE-9112

A45

VE-9122

A46

VE-9131

A47 A48

VE-9130

A49

VE-9134

A50

VE-9095

A51

Reference ground, fuel temperature sensor Reference ground, Exhaust Gas Recirculation (EGR) valve position sensor Reference ground, intake manifold pressure sensor Reference ground, rail pressure sensor Reference ground, exhaust manifold temperature sensor Reference ground, camshaft speed sensor Low Side Driver (LSD), bank 2 injector 1 (cylinder 3) Low Side Driver (LSD), bank 1 injector 1 (cylinder 1) H-bridge Pulse-Width Modulated (PWM) supply, Throttle Valve Actuator (TVA) motor H-bridge Pulse-Width Modulated (PWM) supply, Exhaust Gas Recirculation (EGR) motor Reference ground, Throttle Valve Actuator (TVA) position sensor Input signal, fuel temperature sensor Input signal, Exhaust Gas Recirculation (EGR) position sensor Input signal, intake manifold pressure sensor Input signal, rail pressure sensor Input signal, exhaust manifold temperature sensor Input signal, negative, crankshaft position sensor Low Side Driver (LSD), Diesel Exhaust Fluid (DEF)/AdBlue® supply module purging solenoid Low Side Driver (LSD), Bank 2 Injector 2 (Cylinder 2) Low Side Driver (LSD), Bank 1 Injector 2 (Cylinder 4) H-bridge Pulse-Width Modulated (PWM) supply, Throttle Valve Actuator (TVA) motor H-bridge Pulse-Width Modulated (PWM) supply, Exhaust Gas Recirculation (EGR) motor 47683911 27/02/2015

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SHEET 05

Electrical systems - Harnesses and connectors

CONNECTOR X-9121 - ECU connector A WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER A52 A53 VE-9099 A54 A55

VE-9104

A56

VE-9123

A57

VE-9115

A58

VE-9114

A59

VE-9113

A60

VE-9136

Input signal, Throttle Valve Actuator SHEET 05 (TVA) position sensor Input signal, intake manifold temperature sensor Input signal, Diesel Exhaust Fluid SHEET 05 (DEF)/AdBlue® supply module pressure sensor Input signal, coolant temperature sensor Reference ground, coolant temperature sensor Input signal, positive, crankshaft position sensor Low Side Driver (LSD), fuel metering unit

Under 56kW (76hp) engines PIN WIRE NUMBER NUMBER A01 VE-9128 A02

VE-9132

A03

VE-9138

A04

VE-9133

A05

VE-9124

A06 A07

VE-9105 VE-1923

A08

VE-9098

A09

VE-9094

A10

VE-9101

A11

VE-9108

A12

CONNECTOR X-9121 - ECU connector A CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME High Side Driver (HSD), Bank 2 SHEET 05 Injector 1 (Cylinder 3) High Side Driver (HSD), Bank 2 Injector 2 (Cylinder 2) Low side driver (LSD), Diesel Exhaust Fluid (DEF)/AdBlue® dosing valve Low side driver (LSD), Waste gate pressure modulator valve Reference ground, Diesel Exhaust Fluid (DEF)/AdBlue® supply module pressure sensor Input signal, Oil pressure switch +5 V sensor supply, Diesel Exhaust Fluid (DEF)/AdBlue® supply module pressure sensor +5 V sensor supply, Throttle Valve Actuator (TVA) position sensor +5 V sensor supply, Exhaust Gas Recirculation (EGR) valve position sensor +5 V sensor supply, Intake manifold pressure sensor +5 V sensor supply, Rail pressure sensor -

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Electrical systems - Harnesses and connectors

CONNECTOR X-9121 - ECU connector A WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER A13 VE-9109 A14 A15

VE-9111 VE-9137

A16

VE-9125

A17

VE-9129

A18

VE-9139

A19 A20

VE-9026

A21 A22 A23

VE-9116

A24

VE-9097

A25

VE-9103

A26

VE-9106

A27

VE-9118

A28

VE-9110

A29 A30 A31

VE-9127

A32

VE-9126

A33 A34

VE-9135

A35

VE-9096

A36 A37

VE-9100

A38 A39

VE-9117 VE-9093

A40

VE-9102

A41 A42

VE-9107 -

+5 V sensor supply, Camshaft speed sensor Input signal, Camshaft speed sensor Switched voltage supply, Fuel metering unit High Side Driver (HSD), Bank 1 Injector 1 (Cylinder 1) High Side Driver (HSD), Bank 1 Injector 2 (Cylinder 4) High Side Driver (HSD), Diesel Exhaust Fluid (DEF)/AdBlue® dosing valve Low side switch, Selective Catalytic Reduction (SCR) main relay Reference ground, Fuel temperature sensor Reference ground, Exhaust Gas Recirculation (EGR) valve position sensor Reference ground, Intake manifold pressure sensor Reference ground, Rail pressure sensor Reference ground, Exhaust manifold pressure sensor Reference ground, Camshaft speed sensor Low Side Driver (LSD), Bank 2 Injector 1 (Cylinder 3) Low Side Driver (LSD), Bank 1 Injector 1 (Cylinder 1) H-bridge Pulse-Width Modulated (PWM) supply, Throttle Valve Actuator (TVA) motor H-bridge Pulse-Width Modulated (PWM) supply, Exhaust Gas Recirculation (EGR) motor Reference ground, Throttle Valve Actuator (TVA) position sensor Input signal, Fuel temperature sensor Input signal, Exhaust Gas Recirculation (EGR) position sensor Input signal, Intake manifold pressure sensor Input signal, Rail pressure sensor -

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SHEET 05

Electrical systems - Harnesses and connectors

CONNECTOR X-9121 - ECU connector A WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER A43 VE-9120 A44

VE-9112

A45

VE-9122

A46

VE-9131

A47 A48

VE-9130

A49

VE-9134

A50

VE-9095

A51 A52 A53

VE-9099

A54 A55

VE-9104

A56

VE-9123

A57

VE-9115

A58

VE-9114

A59

VE-9113

A60

VE-9136

Input signal, Exhaust manifold pressure sensor Input signal, negative, Crankshaft position sensor Low Side Driver (LSD), Diesel Exhaust Fluid (DEF)/AdBlue® supply module purging solenoid Low Side Driver (LSD), Bank 2 Injector 2 (Cylinder 2) Low Side Driver (LSD), Bank 1 Injector 2 (Cylinder 4) H-bridge Pulse-Width Modulated (PWM) supply, Throttle Valve Actuator (TVA) motor H-bridge Pulse-Width Modulated (PWM) supply, Exhaust Gas Recirculation (EGR) motor Input signal, Throttle Valve Actuator (TVA) position sensor Input signal, Intake manifold temperature sensor Input signal, Diesel Exhaust Fluid (DEF)/AdBlue® supply module pressure sensor Input signal, Coolant temperature sensor Reference ground, Coolant temperature sensor Input signal, positive, Crankshaft position sensor Low Side Driver (LSD), Fuel metering unit

84474053

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SHEET 05

Electrical systems - Harnesses and connectors

Connector X-9122 - Engine Control Unit (ECU) connector K Over 56kW (76hp) engines PIN WIRE NUMBER NUMBER K01 VE-9017 K02

VE-9158

K03

VE-9141

K04

VE-9159

K05

VE-9142

K06

VE-9160

K07

VE-9161

K08 K09 K10 K11 K12 K13 K14 K15 K16 K17 K18

VE-9048 VE-9143

K19

VE-9144

K20

VE-9162

K21 K22

VE-9073

K23

VE-9150

K24

VE-9068

K25

VE-9067

K26 K27

VE-9072 VE-9056

K28 K29 K30 K31 k32 K33 K34 K35 K36

VE-9018 VE-9077 -

CONNECTOR X-9122 - ECU connector K CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Main relay switched fused supply, independent source Ground, Battery minus (negative) terminal Main relay switched fused supply, shared source (K05) Ground, Battery minus (negative) terminal Main relay switched fused supply, shared source (K03) Ground, Battery minus (negative) terminal Low Side Driver (LSD), Diesel Exhaust Fluid (DEF)/AdBlue® tank heating valve Input signal, Key switch start position +5 V sensor supply, Exhaust manifold pressure sensor Input signal, Intake air temperature sensor Reference ground, Intake air temperature sensor Input signal, Glow-plug Control Unit (GCU) feedback CAN 2 High, Selective Catalytic Reduction (SCR) devices CAN 1 High, Diagnostic and maintenance connector CAN 1 Low, Diagnostic and maintenance connector Low Side Driver (LSD), GCU relay Low Side Driver (LSD), Starter control relay Low Side Driver (LSD), Main relay Input signal, Water in fuel switch -

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Electrical systems - Harnesses and connectors

CONNECTOR X-9122 - ECU connector K WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER K37 VE-9118A K38 K39 K40 K41

VE-9074

K42 K43 K44 K45

VE-9151

K46 K47 K48 K49 K50 K51 K52 K53

VE-9057

K54

VE-9053

K55 K56

VE-9145

K57

VE-9120A

K58 K59 K60 K61 K62 K63 K64 K65

VE-9164

K66 K67 K68

VE-9070

K69 K70

VE-9064

K71 K72

VE-9166

K73 K74 K75 K76

VE-9167

Reference ground, Exhaust manifold pressure sensor Reference ground, Glowplug Control Unit (GCU) CAN 2 Low, Selective Catalytic Reduction (SCR) devices High Side Driver (HSD), Starter control relay Input signal, Key switch ON/ACC position Input signal, Upstream Diesel Oxidation Catalyst (DOC) exhaust gas temperature sensor Input signal, Exhaust manifold pressure sensor Reference ground, upstream Diesel Oxidation Catalyst (DOC) exhaust gas temperature sensor ISO-K Interface, Diagnostic and monitoring connector K-line Low Side Driver (LSD), Fuel filter heating relay Low Side Driver (LSD), Diesel Exhaust Fluid (DEF)/AdBlue® supply module pump motor Input signal, Diesel Exhaust Fluid (DEF)/AdBlue® supply module pump motor and temperature data 47683911 27/02/2015

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SHEET 04

Electrical systems - Harnesses and connectors

CONNECTOR X-9122 - ECU connector K WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER K77 K78 K79 VE-9169

K80

VE-9149

K81

VE-9170

K82

VE-9171

K83 K84 K85 K86 K87 K88 K89 K90 K91 K92 K93 K94

Reference ground, Downstream Selective Catalytic Reduction(SCR) temperature sensor Input signal, Downstream Selective Catalytic Reduction(SCR)temperature sensor Reference ground, Upstream Selective Catalytic Reduction(SCR) temperature sensor Input signal, Upstream Selective Catalytic Reduction(SCR) temperature sensor -

SHEET 04

Under 56kW (76hp) engines PIN WIRE NUMBER NUMBER K01 VE-9017 K02

VE-9158

K03

VE-9141

K04

VE-9159

K05

VE-9142

K06

VE-9160

K07

VE-9161

K08 K09 K10 K11 K12 K13 K14 K15 K16 K17

VE-9048 -

CONNECTOR X-9122 - ECU connector K CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Main relay switched fused supply, SHEET 04 independent source Ground, Battery minus (negative) terminal Main relay switched fused supply, shared source (K05) Ground, Battery minus (negative) terminal Main relay switched fused supply, shared source (K03) Ground, Battery minus (negative) terminal Low Side Driver (LSD), Diesel Exhaust Fluid (DEF)/AdBlue® tank heating valve Input signal, Key switch start position 47683911 27/02/2015

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CONNECTOR X-9122 - ECU connector K WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER K18 K19 VE-9144 K20

VE-9162

K21 K22

VE-9073

K23

VE-9150

K24

VE-9068

K25

VE-9067

K26 K27

VE-9056

K28 K29 K30 K31 k32 K33 K34 K35 K36 K37

VE-9018 VE-9077 VE-9118A

K38 K39 K40 K41

VE-9074

K42 K43 K44 K45

VE-9151

K46 K47 K48 K49 K50 K51 K52 K53

VE-9071 VE-9057

K54

VE-9053

K55 K56

VE-9145

K57

VE-9120A

Input signal, Intake air temperature sensor Reference ground, Intake air temperature sensor Input signal, Glow-plug Control Unit (GCU) feedback CAN 2 High, Selective Catalytic Reduction (SCR) devices CAN 1 High, Diagnostic and maintenance connector CAN 1 Low, Diagnostic and maintenance connector Low Side Driver (LSD), Starter control relay Low Side Driver (LSD), Main relay Input signal, Water in fuel switch Reference ground, Exhaust manifold pressure sensor Reference ground, Glowplug Control Unit (GCU) CAN 2 Low, Selective Catalytic Reduction(SCR) devices Low Side Driver (LSD), GCU relay High Side Driver (HSD), Starter control relay Input signal, Key switch ON/ACC position Input signal, Upstream Diesel Oxidation Catalyst (DOC) exhaust gas temperature sensor Input signal, Exhaust manifold pressure sensor

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SHEET 04

Electrical systems - Harnesses and connectors

CONNECTOR X-9122 - ECU connector K WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER K58 K59 K60 K61 K62 K63 K64 K65

VE-9164

K66 K67 K68

VE-9070

K69 K70

VE-9064

K71 K72

VE-9166

K73 K74 K75 K76

VE-9167

K77 K78 K79

VE-9168

K80

VE-9147

K81

VE-9119A

K82

VE-9121A

K83

VE-9153

K84

-VE-9152

K85 K86 K87 K88 K89 K90 K91

VE-9066

K92 K93 K94

Reference ground, upstream Diesel Oxidation Catalyst (DOC) exhaust gas temperature sensor ISO-K Interface, Diagnostic and monitoring connector K-line Low Side Driver (LSD), Fuel filter heating relay Low Side Driver (LSD), Diesel Exhaust Fluid (DEF)/AdBlue® supply module pump motor Input signal, Diesel Exhaust Fluid (DEF)/AdBlue® supply module pump motor and temperature data Reference ground, Particulate Matter (PM) Catalyst inlet temperature sensor Input signal, Particulate Matter (PM) Catalyst inlet temperature sensor Reference ground, exhaust manifold temperature sensor Input signal, exhaust manifold temperature sensor Reference ground, Diesel Oxidation Catalyst (DOC) inlet temperature sensor Input signal, Diesel Oxidation Catalyst (DOC) inlet temperature sensor Low Side Driver (LSD), fuel pump relay (on some applications) -

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SHEET 04

Electrical systems - Harnesses and connectors

84474047

Connector X-9123 - Lambda (Universal Heated Exhaust Gas Oxygen (UHEGO)) sensor CONNECTOR X-9123 - Lambda (Universal Heated Exhaust Gas Oxygen (UHEGO)) sensor PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 VE-9154 SHEET 03 Current pump 2 VE-9155 Ground 3 VE-9200 Low Side Driver (LSD), heater 4 VE-9081 Supply, heater 5 VE-9157 Current adjust 6 VE-9156 Nernst voltage Connector X-9124 - Auxiliary main relay CONNECTOR X-9124 - Auxiliary main relay WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 30 VE-9001 85

VE-9011

86 87

VE-9020 VE-9014

87A

Battery supply, Battery plus / positive SHEET 01 terminal Ground, Battery minus / negative terminal Switched control signal, Main relay Supply voltage, Selective Catalytic Reduction (SCR) sensors -

NOTE: Relay connector and conductor naming and numbering conventions are representative – used for engine diagnostics and schematic referencing. Use machine schematics for exact relay/wiring numbering and pinout. Connector X-9125 - Water in fuel switch CONNECTOR X-9125 - Water in fuel switch (black connector on sensor housing) PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 VE-9077 SHEET 02 Signal 2 VE-9078 Ground 3 VE-9076 Supply, from key switch Connector X-9126 -Particulate Matter (PM) catalytic converter inlet temperature sensor CONNECTOR X-9126 -Particulate Matter (PM) catalytic converter inlet temperature sensor PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 VE-9168 SHEET 03 Signal 2 VE-9147 Ground

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Connector X-9127 -Diesel Oxidation Catalyst (DOC) inlet temperature sensor CONNECTOR X-9127 -Diesel Oxidation Catalyst (DOC) inlet temperature sensor WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 VE-9152 2 VE-9153

Signal Ground

SHEET 03

Connector X-9128 - Selective Catalytic Reduction (SCR) main relay CONNECTOR X-9128 - Selective Catalytic Reduction (SCR) main relay PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 30 VE-9010 Battery supply, Battery plus / positive SHEET 01 terminal 85 VE-9026 Low Side Driver (LSD), Engine Control Unit (ECU) 86 VE-9021 Switched supply, Main relay 87 VE-9027 Supply voltage, Diesel Exhaust Fluid (DEF)/AdBlue® supply module and tank heater valve 87A NOTE: Relay connector and conductor naming and numbering conventions are representative – used for engine diagnostics and schematic referencing. Use machine schematics for exact relay/wiring numbering and pinout. Connector X-9129 - Main relay PIN WIRE NUMBER NUMBER 30 VE-9901 85

VE-9018

VE-9002

VE-9003

87A

CONNECTOR X-9129 - Main relay CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Battery supply, Battery plus / positive SHEET 01 terminal Low Side Driver (LSD), Engine Control Unit (ECU) Battery supply, Battery plus / positive terminal Supply voltage, Engine Control Unit (ECU) and engine devices -

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 13 - Connectors X-9130 to X-9139 WE WE WE WE

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Connector X-9130 - Electric fuel pump relay (optional) CONNECTOR X-9130 - Electric fuel pump relay (optional) PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 30 VE-9065 Controlled supply, battery disconnect SHEET 02 switch 85 VE-9066 Low Side Driver (LSD), Engine Control Unit (ECU) 86 VE-9022 Controlled supply, main relay switched 87 See product schematics Controlled source, electric fuel pump motor 87A Connector X-9131 - Diesel Exhaust Fluid (DEF)/AdBlue® temperature, level and quality sensor CONNECTOR X-9131 - Diesel Exhaust Fluid (DEF)/AdBlue® temperature, level and quality sensor PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 VE-9176 Controlled supply, auxiliary main SHEET 03 relay switched 2 VE-9177 Ground 3 4 VE-9174 SHEET 03 CAN 2 low 5 VE-9175 CAN 2 high

87688719

Connector X-9132 - NH3 sensor controller PIN NUMBER 1 2 3 4

CONNECTOR X-9132 - NH3 sensor controller WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME VE-9178 VE-9188 VE-9187 VE-9179

SHEET 03

Supply CAN high CAN low Ground

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84146686

Connector X-9133 - Diesel Oxidation Catalyst (DOC) upstream NOx sensor PIN NUMBER 1 2 3 4 5

CONNECTOR X-9133 - Diesel Oxidation Catalyst (DOC) upstream NOx sensor WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME VE-9184 VE-9183 VE-9191 VE-9192 VE-9182

Supply Ground CAN low CAN high Ground

SHEET 03

47514978

Connector X-9134 - Selective Catalytic Reduction (SCR) downstream NOx sensor PIN NUMBER 1 2 3 4 5

CONNECTOR X-9134 - SCR downstream NOx sensor WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME VE-9180 VE-9181 VE-9195 VE-9196 -

Supply Ground CAN low CAN high -

SHEET 03

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47514978

Connector X-9135 - Controller Area Network (CAN) terminator CONNECTOR X-9135 - Controller Area Network (CAN) terminator WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 VE-9197 2 VE-9198

CAN 2 low CAN 2 high

84539353

Connector X-9136 - DEF/AdBlue® supply module suction line heater CONNECTOR X-9136 -DEF/AdBlue® supply module suction line heater PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 VE-9084 Heater supply SHEET 02 2 VE-9088 Series supply for heater R-9103. Connector X-9137 - NH3 sensor controller PIN NUMBER 1 2 3 4 5 6 7 8

CONNECTOR X-9137 - NH3 sensor controller WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NH3-1 NH3-2 NH3-3 NH3-4 NH3-5 NH3-6 NH3-7 NH3-8

(PU) (YE) (YE) (BK) (WH) (GN) (BR) (GY)

Heater supply Trim resistor supply Trim resistor ground EMF 2 Heater ground Temperature signal Signal ground EMF 1

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SHEET 03

Electrical systems - Harnesses and connectors

Connector X-9138 - Engine interface 1 Over 56kW (76hp) engines PIN WIRE NUMBER NUMBER 1 VE-9137 EN-9137 2 VE-9136 EN-9136 3 VE-9105 EN-9105 4 VE-9111 EN-9111 5 VE-9106 EN-9106 6 VE-9107 EN-9107 7 VE-9108 EN-9108 8 VE-9110 EN-9110 9 VE-9113 EN-9113 10 VE-9112 EN-9112 11 12 VE-9109 EN-9109 13 VE-9114 EN-9114 14 VE-9115 EN-9115 15 VE-9116 EN-9116 16 VE-9117 EN-9117 17 VE-9101 EN-9101 18 VE-9102 EN-9102 19 VE-9103 EN-9103 20 VE-9104 EN-9104 21 VE-9143 EN-9143 22 VE-9118A EN-9118 23 VE-9120A EN-9120 24

CONNECTOR X-9138 - Engine interface 1 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SHEET 06 Switched voltage supply, fuel metering unit Low Side Driver (LSD), fuel metering unit Input signal, oil pressure switch Input signal, camshaft speed sensor Reference ground, rail pressure sensor Input signal, rail pressure sensor +5 V sensor supply, rail pressure sensor Reference ground, camshaft speed sensor Input signal, positive, crankshaft position sensor Input signal, negative, crankshaft position sensor +5 V sensor supply, camshaft speed SHEET 06 sensor Reference ground, coolant temperature sensor Input signal, coolant temperature sensor Reference ground, fuel temperature sensor Input signal, fuel temperature sensor +5 V sensor supply, intake manifold pressure sensor Input signal, intake manifold pressure sensor Reference ground, intake manifold pressure sensor Input signal, intake manifold temperature sensor +5 V sensor supply, exhaust manifold pressure sensor Reference ground, exhaust manifold pressure sensor Input signal, exhaust manifold pressure sensor

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CONNECTOR X-9138 - Engine interface 1 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 25 VE-9119 EN-9119 26 VE-9121 EN-9121 27 VE-9133 EN-9133 28 VE-9024 EN-9024 29 VE-9095 EN-9095 30

VE-9096 EN-9096

31 32 33

VE-9094 EN-9094

VE-9093 EN-9093

VE-9097 EN-9097

36 37

VE-9134 EN-9134

VE-9135 EN-9135

39 40 41

VE-9098 EN-9098 VE-9099 EN-9099 VE-9100 EN-9100 -

42 43 44 45 46 47 48 49 50 51 52 53 54 55 56

Reference ground, exhaust manifold temperature sensor Input signal, exhaust manifold temperature sensor Low Side Driver (LSD), wastegate pressure modulator valve Main relay switched supply, wastegate pressure modulator valve H-bridge Pulse-Width Modulated (PWM) supply, Exhaust Gas Recirculation (EGR) motor H-bridge Pulse-Width Modulated (PWM) supply, Exhaust Gas Recirculation (EGR) motor +5 V sensor supply, Exhaust Gas Recirculation (EGR) valve position sensor Input signal, Exhaust Gas Recirculation (EGR) position sensor Reference ground, Exhaust Gas Recirculation (EGR) valve position sensor H-bridge Pulse-Width Modulated (PWM) supply, Throttle Valve Actuator (TVA) motor H-bridge Pulse-Width Modulated (PWM) supply, Throttle Valve Actuator (TVA) motor +5 V sensor supply, Throttle Valve Actuator (TVA) position sensor Input signal, Throttle Valve Actuator (TVA) position sensor Reference ground, Throttle Valve Actuator (TVA) position sensor -

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SHEET 06

Electrical systems - Harnesses and connectors

CONNECTOR X-9138 - Engine interface 1 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 57 VE-9061 EN-9061 58 VE-9060 EN-9060 59 60 VE-9059 EN-9059 61 VE-9058 EN-9058 62

Glow plug control module controlled supply, glow plug 4 Glow plug control module controlled supply, glow plug 3 Glow plug control module controlled supply, glow plug 2 Glow plug control module controlled supply, glow plug 1 -

SHEET 06

Under 56kW (76hp) engines PIN WIRE NUMBER NUMBER 1 VE-9137 EN-9137 2 VE-9136 EN-9136 3 VE-9105 EN-9105 4 VE-9111 EN-9111 5 VE-9106 EN-9106 6 VE-9107 EN-9107 7 VE-9108 EN-9108 8 VE-9110 EN-9110 9 VE-9113 EN-9113 10 VE-9112 EN-9112 11

CONNECTOR X-9138 - Engine interface 1 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Switched voltage supply, fuel SHEET 06 metering unit Low Side Driver (LSD), fuel metering unit Input signal, oil pressure switch Input signal, camshaft speed sensor Reference ground, rail pressure sensor Input signal, rail pressure sensor +5 V sensor supply, rail pressure sensor Reference ground, camshaft speed sensor Input signal, positive, crankshaft position sensor Input signal, negative, crankshaft position sensor -

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Electrical systems - Harnesses and connectors

CONNECTOR X-9138 - Engine interface 1 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 12 VE-9109 EN-9109 13 VE-9114 EN-9114 14 VE-9115 EN-9115 15 VE-9116 EN-9116 16 VE-9117 EN-9117 17 VE-9101 EN-9101 18 VE-9102 EN-9102 19 VE-9103 EN-9174 20 VE-9104 EN-9175 21 VE-9143A EN-9143 22 VE-9118 EN-9118 23 VE-9120 EN-9120 24 25 VE-9119A EN-9119 26 VE-9121A EN-9121 27 VE-9133 EN-9133 28 VE-9024 EN-9024 29 VE-9095 EN-9095 30

VE-9096 EN-9096

31 32 33

VE-9094 EN-9094

VE-9093 EN-9093

VE-9097 EN-9097

+5 V sensor supply, camshaft speed SHEET 06 sensor Reference ground, coolant temperature sensor Input signal, coolant temperature sensor Reference ground, fuel temperature sensor Input signal, fuel temperature sensor +5 V sensor supply, intake manifold pressure sensor Input signal, intake manifold pressure sensor Reference ground, intake manifold pressure sensor Input signal, intake manifold temperature sensor +5 V sensor supply, exhaust manifold pressure sensor Reference ground, exhaust manifold pressure sensor Input signal, exhaust manifold pressure sensor Reference ground, exhaust manifold SHEET 06 temperature sensor Input signal, exhaust manifold temperature sensor Low Side Driver (LSD), wastegate pressure modulator valve Main relay switched supply, wastegate pressure modulator valve H-bridge Pulse-Width Modulated (PWM) supply, Exhaust Gas Recirculation (EGR) motor H-bridge Pulse-Width Modulated (PWM) supply, Exhaust Gas Recirculation (EGR) motor SHEET 06 +5 V sensor supply, Exhaust Gas Recirculation (EGR) valve position sensor Input signal, Exhaust Gas Recirculation (EGR) position sensor Reference ground, Exhaust Gas Recirculation (EGR) valve position sensor -

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Electrical systems - Harnesses and connectors

CONNECTOR X-9138 - Engine interface 1 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 37 VE-9134 EN-9134 38

VE-9135 EN-9135

39 40 41

VE-9098 EN-9098 VE-9099 EN-9099 VE-9100 EN-9100 VE-9061 EN-9061 VE-9060 EN-9060 VE-9059 EN-9059 VE-9058 EN-9058 -

42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62

H-bridge Pulse-Width Modulated (PWM) supply, Throttle Valve Actuator (TVA) motor H-bridge Pulse-Width Modulated (PWM) supply, Throttle Valve Actuator (TVA) motor +5 V sensor supply, Throttle Valve Actuator (TVA) position sensor Input signal, Throttle Valve Actuator (TVA) position sensor Reference ground, Throttle Valve Actuator (TVA) position sensor Glow plug control module controlled supply, glow plug 4 Glow plug control module controlled supply, glow plug 3 Glow plug control module controlled supply, glow plug 2 Glow plug control module controlled supply, glow plug 1 -

NHIS14ENG0977AA

SHEET 06

Connector X-9138 is located on top of the engine.

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Electrical systems - Harnesses and connectors

NHIS14ENG0985AA

Connector X-9138 is located above the fuel filter housing.

84154701

Connector X-9139 - Engine interface 2 PIN WIRE NUMBER NUMBER A VE-9125 INJ-268 B VE-9126 INJ-269 VE-9127 C INJ-271 D VE-9128 INJ-270 E VE-9129 INJ-572 F VE-9130 INJ-573 VE-9131 G INJ-575 H VE-9132 INJ-574 J K

CONNECTOR X-9139 - Engine interface 2 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME High Side Driver (HSD), Bank 1 Injector 1 (Cylinder 1) Low Side Driver (LSD), Bank 1 Injector 1 (Cylinder 1) Low Side Driver (LSD), Bank 2 Injector 1 (Cylinder 3) High Side Driver (LSD), Bank 2 Injector 1 (Cylinder 3) High Side Driver (LSD), Bank 1 Injector 2 (Cylinder 4) Low Side Driver (LSD), Bank 1 Injector 2 (Cylinder 4) Low Side Driver (LSD), Bank 2 Injector 2 (Cylinder 2) High Side Driver (LSD), Bank 2 Injector 2 (Cylinder 2)

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SHEET 06

Electrical systems - Harnesses and connectors

NHIS14ENG0977AA

Connector X-9139 is located on top of the engine.

NHIS14ENG0985AA

Connector X-9139 is located above the oil fill tube.

87698254

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Electrical systems - Harnesses and connectors

Wire connectors - Component localization - Deluxe cab C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE WE

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

NOTE: Deluxe cab shown

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controls controls controls controls

Electrical systems - Harnesses and connectors

RAPH12SSL0478KA

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

RAPH12SSL0479GA

Detail 1 Connector title X-30

Component Cab/right hand jumper interface

X-9

Ignition switch

X-C23

Instrument cluster

X-365

Park brake switch

X-CTS X-311 X-20A

Turn signal switch Light selector switch Hand throttle

X-502

Door wiper motor

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Pin information Wire connectors - Component diagram 03 (55.100) Wire connectors - Component diagram 00 (55.100) Wire connectors - Component diagram - Connectors A - Z (55.100) Wire connectors - Component diagram 36 (55.100) Not available Not available Wire connectors - Component diagram 02 (55.100) Wire connectors - Component diagram 50 (55.100)

Electrical systems - Harnesses and connectors

RAPH12SSL0480GA

Detail 2 Connector title X-31

Component Cab/left hand jumper interface

X-252

Temperature control switch

X270 X-275

Blower fan switch A/C switch

X-155B X-157B X175B X-300

Turn signal (right) Turn signal (left) Turn indicator (ground) Hydraulic coupler switch

X-310

Two speed indicator

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Pin information Wire connectors - Component diagram 03 (55.100) Wire connectors - Component diagram 25 (55.100) Not available Wire connectors - Component diagram 27 (55.100) Not available Not available Not available Wire connectors - Component diagram 30 (55.100) Wire connectors - Component diagram 31 (55.100)

Electrical systems - Harnesses and connectors

X-301

Beacon switch

X-302

Hazard switch

X-317 X-303

Self level switch Hi flow switch

X-113 X-503

FE #2 switch Wiper/washer switch

X-306

Loader lockout switch

X-ACC X-505

Accessory power switch Cab/door switch interface

RAPH12SSL0481GA

Wire connectors - Component diagram 30 (55.100) Wire connectors - Component diagram 30 (55.100) Not available Wire connectors - Component diagram 30 (55.100) Not available Wire connectors - Component diagram 50 (55.100) Wire connectors - Component diagram 30 (55.100) Not available Not available

Detail 3 Connector title X-2SPD X-DIAG

Component Two speed valve solenoid CAN Diagnostic connector

X-BRK

Brake valve solenoid

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Pin information Not available Wire connectors - Component diagram - Connectors A - Z (55.100) Not available

Electrical systems - Harnesses and connectors

CHS_GND_FRT

Ground

X-CO2A

Cab/chassis option 2

X-42 X-CAB_GNDA

Mechanical backup switch Ground

X-CAB_GNDB

Ground

FUSE1

Fuse box

X-271

Water valve

X-20A

Foot throttle sensor

RAPH12SSL0482GA

Detail 4

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Wire connectors - Component diagram - Grounds (55.100) Wire connectors - Component diagram - Connectors A - Z (55.100) Not available Wire connectors - Component diagram - Grounds (55.100) Wire connectors - Component diagram - Grounds (55.100) Wire connectors - Component diagram - Connectors A - Z (55.100) Wire connectors - Component diagram 27 (55.100) Wire connectors - Component diagram 02 (55.100)

Electrical systems - Harnesses and connectors

Connector title X-CO2A

Component Cab/chassis option 2

X-CO1A

Cab/chassis option 1

X-42 X-CC3A

Mechanical backup switch Cab/chassis 3

X-CC7A X-CC2A

Cab/chassis 7 Cab/chassis 2

X-CC1A

Cab/chassis 1

RAPH12SSL0483GA

Detail 5

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Pin information Wire connectors - Component diagram - Connectors A - Z (55.100) Wire connectors - Component diagram - Connectors A - Z (55.100) Not available Wire connectors - Component diagram - Connectors A - Z (55.100) Not available Wire connectors - Component diagram - Connectors A - Z (55.100) Wire connectors - Component diagram - Connectors A - Z (55.100)

Electrical systems - Harnesses and connectors

Connector title X-HVC1

Component Cab/HVAC interconnect

X-111

Condenser relay

X-42

Mechanical backup switch

RAPH12SSL0484GA

Pin information Wire connectors - Component diagram - Connectors A - Z (55.100) Wire connectors - Component diagram 11 (55.100) Not available

Detail 6 Connector title X-RDCTRL X-318 X-PORT_LK X-OILTMP X-402 X-43 X-432 X-433 X-TELE

Component Ride control valve solenoid Self level valve Port lock Hydraulic oil temperature sender Right hand handle interconnect park/ride/brake control Mechanical backup switch Proportional auxiliary valve retract Proportional auxiliary valve extend Telematics

X-430

Auxiliary PWM controller

X-405

Left hand handle interlock horn/two speed

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Pin information Not available Not available Not available Not available Wire connectors - Component diagram 40 (55.100) Not available Not available Not available Wire connectors - Component diagram - Connectors A - Z (55.100) Wire connectors - Component diagram 43 (55.100) Wire connectors - Component diagram 40 (55.100)

Electrical systems - Harnesses and connectors

RAPH12SSL0485GA

Detail 7 Connector title X-195 X-001

Component GCU fuse Engine relay box

X-5A X-126 X-013

Alternator Starter GCU

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Pin information Not available Wire connectors - Component diagram 00 (55.100) Not available Not available Wire connectors - Component diagram 01 (55.100)

Electrical systems - Harnesses and connectors

RAPH12SSL0486GA

Detail 8 Connector title X-004 X-007 X-508 X-005

Component Air temperature sensor Exhaust gas temperature sensor 2 Air filter Differential pressure sensor

X-178 X-HORN_PWR x-HORN_GND X-77 X-502A

Beacon lamp socket Horn power Horn ground Side lamp socket Rear window wiper motor

X-006 X-014

Exhaust gas temperature sensor 1 Lambda sensor

X-902

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Pin information Not available Not available Not available Wire connectors - Component diagram 00 (55.100) Not available Not available Not available Not available Wire connectors - Component diagram 50 (55.100) Not available Wire connectors - Component diagram 01 (55.100) Wire connectors - Component diagram 90 (55.100)

Electrical systems - Harnesses and connectors

RAPH12SSL0487GA

Detail 9 Connector title X-331 X–330 X-332 X-333 X-97 X-30

Component Right speaker Right speaker Left speaker Left speaker Cab/dome lamp jumper Cab/right hand lamp jumper interface

X-9

Ignition switch

X-335

Radio connector

X-104

Lap bar switch

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Pin information Not available Not available Not available Not available Not available Wire connectors - Component diagram 03 (55.100) Wire connectors - Component diagram 00 (55.100) Wire connectors - Component diagram 33 (55.100) Not available

Electrical systems - Harnesses and connectors

RAPH12SSL0488GA

Detail 10 Connector title X-012

Component ECU

X-016

ECU

X-11 X-CHS_GND_RR

Ground

X-015

Electric valve

X-NEG_TERM_A

Ground

ECU_GND

Ground

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Pin information Wire connectors - Component diagram 01 (55.100) Wire connectors - Component diagram 01 (55.100) Wire connectors - Component diagram 01 (55.100) Wire connectors - Component diagram - Grounds (55.100) Wire connectors - Component diagram 01 (55.100) Wire connectors - Component diagram - Grounds (55.100) Wire connectors - Component diagram - Grounds (55.100)

Electrical systems - Harnesses and connectors

X-017

Engine interface

X-001

Engine relay box

X-018 X-14

Fuel filter heater Fuel level sender

RAPH12SSL0489GA

Wire connectors - Component diagram 01 (55.100) Wire connectors - Component diagram 00 (55.100) Not available Not available

Detail 11 Connector title BKUP-GND BKUP-PWR X-RRJMPRA

Component Backup alarm (ground) Backup alarm (power) Chassis/rear lamp jumper interface

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Pin information Not available Not available Wire connectors - Component diagram - Connectors A - Z (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 00 C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE WE

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

CONNECTOR X-001 - ENGINE RELAY BOX PIN NUMBER A30 A85 A86 A87 C85 C86 C87

CONNECTOR X-001 - ENGINE RELAY BOX WIRE NUMBER CIRCUIT REFERENCE 256 (RD) CRANK RELAY FUSE POWER 161 (YE) CRANK ENABLE FROM ECU 121 (YE) CRANK ENABLE FROM ECU 520 (WH) STARTER MOTOR POWER 112 (BL) ECU MAIN RELAY ENABLE FROM ECU BATT+ 527C (RD) 528A (OR) ECU RELAY OUTPUT TO FUSE

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Electrical systems - Harnesses and connectors

CONNECTOR X-005 - DIFFERENTIAL PRESSURE SENSOR PIN NUMBER 1 2 3

CONNECTOR X-005 - DIFFERENTIAL PRESSURE SENSOR WIRE NUMBER CIRCUIT REFERENCE 269 (YE) DIFF PRESSURE SUPPLY 266 (BK/WH) DIFF PRESSURE SENSOR GND 268 (YE) DIFF PRESSURE SENSOR SIGNAL

87747172

CONNECTOR X-9 - IGNITION SWITCH PIN NUMBER 1 2 3 6

CONNECTOR X-9 - IGNITION SWITCH WIRE NUMBER CIRCUIT REFERENCE 140 (RD) KEY SW POWER 624 (WH) KEY START TO CLUSTER 132 (OR) KEY IGNITION TO CLUSTER 138 (OR) KEY ACCESSORY

87693713

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 01 WE WE WE WE

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

CONNECTOR X-011 - WATER IN FUEL SWITCH PIN NUMBER 1 2 3

CONNECTOR X-011 - WATER IN FUEL SWITCH WIRE NUMBER CIRCUIT REFERENCE 150 (YE) WATER IN FUEL LEVEL SENSOR SIGNAL 908E (BK) WIF GND 133E (OR) WIF POWER

87709663

CONNECTOR X-012 - ECU PIN NUMBER 1 2 3 4 5 6 7 8

WIRE NUMBER 110 (OR) 908B (BK) 155B (OR) 908C (BK) 155C (OR) 908D (BK) 242 (YE) 622 (WH)

14 19 20 22 24 25 27 28

269 (YE) 257 (YE) 254 (BK/WH) 235 (YE) 503C (YE) 504C (GN) 121 (YE) 112 (BL)

150 (YE)

36 41 52

266 (BK/WH) 239 (BK) 216 (YE)

53 54 58 68 70

161 (YE) 133D (OR) 268 (YE) 248 (YE) 347 (BL)

CONNECTOR X-012 - ECU CIRCUIT REFERENCE ECU FUSE 1 POWER ECU GND 1 BATTERY +B VIA MAIN RELAY ECU GND 2 BATTERY +C VIA MAIN RELAY ECU GND 3 LAMBDA SENSOR HEATING CRANK SIGNAL FROM CLUSTER TO ECU DIFF PRESSURE SUPPLY AIR TEMP SENSOR SIGNAL AIR TEMP GND GLOW PLUG FEEDBACK SIGNAL

CRANK ENABLE FROM ECU ECU MAIN RELAY ENABLE FROM ECU WATER IN FUEL LEVEL SENSOR SIGNAL DIFF PRESSURE SENSOR GND GLOW PLUG UNIT GND GLOW PLUG UNIT COMMAND SIGNAL CRANK ENABLE FROM ECU TERMINAL 15 SW BATT+ DIFF PRESSURE SENSOR SIGNAL EGR ECU K-LINE FUEL FILTER HEATER GROUND 47683911 27/02/2015

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ELECTRICAL SCHEMATIC FRAME

Electrical systems - Harnesses and connectors

PIN NUMBER 79 80 81 82 83 84 85 86

WIRE NUMBER 270 271 265 263 272 273 252 249

(BK/WH) (YE) (BK/WH) (YE) (BK/WH) (YE) (BK) (YE)

CONNECTOR X-012 - ECU CIRCUIT REFERENCE EXHAUST GAS TEMP GND EXHAUST GAS TEMP SIGNAL INLET TURBINE TEMP GND INLET TURBINE TEMP SIGNAL EXHAUST GAS TEMP GND 2 EXHAUST GAS TEMP SIGNAL 2

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ELECTRICAL SCHEMATIC FRAME

Electrical systems - Harnesses and connectors

CONNECTOR X-013 - GCU PIN NUMBER 1 2 3 4 5 6 7 8

CONNECTOR X-013 - GCU WIRE NUMBER CIRCUIT REFERENCE 1112 (WH) GLOW PLUG 1110 (WH) GLOW PLUG 235 (YE) GLOW PLUG FEEDBACK SIGNAL 212 (OR) GCU B+ 239A (BK) GLOW PLUG UNIT GND 1113 (WH) GLOW PLUG 1111 (WH) GLOW PLUG 216 (YE) GLOW PLUG UNIT COMMAND SIGNAL

84356962

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Electrical systems - Harnesses and connectors

CONNECTOR X-014 - LAMBDA SENSOR PIN NUMBER 1 2 3 4 5 6

CONNECTOR X-014 - LAMBDA SENSOR WIRE NUMBER CIRCUIT REFERENCE 245 (YE) 252 (BK) 242 (YE) LAMBDA SENSOR HEATING 241B (OR) LAMBDA POWER 249 (YE) 253 (PK)

84301132

CONNECTOR X-015 - ELECTRIC VALVE PIN NUMBER A B C D E F G H

CONNECTOR X-015 - ELECTRIC VALVE WIRE NUMBER CIRCUIT REFERENCE 274 (WH) INJECTOR 1 HIGH BANK 1 275 (GY) INJECTOR 1 LOW BANK 1 276 (GY) INJECTOR 1 LOW BANK 2 277 (WH) INJECTOR 1 HIGH BANK 2 278 (WH) INJECTOR 2 HIGH BANK 1 279 (GY) INJECTOR 2 LOW BANK 1 280 (GY) INJECTOR 2 LOW BANK 2 281 (WH) INJECTOR 2 HIGH BANK 2

87698252

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Electrical systems - Harnesses and connectors

CONNECTOR X-016 - ECU PIN NUMBER 1 2 4 6 8 9 10 11 12 13 14 15 16 17 23 24 25 26 27 28 31 32 34 35 37 38 39 40 41 43 44 46 48 49 50 53 54 55 57 58 59 60

CONNECTOR X-016 - ECU WIRE NUMBER CIRCUIT REFERENCE 277 (WH) 281 (WH) 294 (GY) BOOST PRESSURE ACTUATOR 1 658 (YE) 340 (PK) TVA POSITION SENSOR SUPPLY 318 (PK) EGR POSITION SENSOR SUPPLY 343 (PK) BOOST PRESSURE SENSOR SUPPLY 284 (PK) RAIL PRESSURE SENSOR SUPPLY 295 (PK) EXHAUST GAS PRESSURE SENSOR SUPPLY (UPSTREAM TURBINE PRESSURE) P3 289 (PK) SEGMENT(CAMSHAFT) SPEED SENSOR SUPLY 287 (YE) SEGMENT(CAMSHAFT) SPEED SENSOR SIGNAL 299 (WH) 274 (WH) 278 (WH) 292 (BL) FUEL TEMPERATURE SENSOR GROUND 337 (BK/WH) EGR POSITION SENSOR GROUND 345 (BK/WH) BOOST PRESURE SENSOR GROUND 282 (YE) 296 (BK/WH) EXHAUST GAS PRESSURE SENSOR GROUND P3 (UPSTREAM TURBINE PRESSURE) 288 (BL) SEGMENT(CAMSHAFT) SPEED SENSOR GROUND 276 (GY) 275 (GY) 339 (GY) 322 (GY) 342 (BK/WH) TVA POSITION SENSOR GROUND 293 (YE) FUEL TEMPERATURE SENSOR SIGNAL 327 (YE) EGR POSITION SENSOR SIGNAL 344 (YE) BOOST PRESSURE SENSOR SIGNAL 283 (YE) 297 (YE) EXHAUST GAS PRESSURE SENSOR SIGNAL P3 (UPSTREAM TURBINE PRESSURE) 286 (YE) 280 (GY) 279 (GY) 338 (WH) 321 (WH) 341 (YE) TVA POSITION SENSOR SIGNAL 346 (YE) BOOST PRESSURE TEMPERATURE SENSOR SIGNAL 291 (YE) COOLANT TEMPERATURE SENSOR SIGNAL 290 (BL) COOLANT TEMPERATURE SENSOR GROUND 285 (YE) 298 (GY)

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

CONNECTOR X-017 - ENGINE INTERFACE PIN NUMBER 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 33 34 35 37 38 41 42 43 57 58 60 61

CONNECTOR X-017 - ENGINE INTERFACE WIRE NUMBER CIRCUIT REFERENCE 299 (WH) 298 (GY) 658 (YE) 287 (YE) SEGMENT(CAMSHAFT) SPEED SENSOR SIGNAL 282 (YE) 283 (YE) 284 (PK) RAIL PRESSURE SENSOR SUPPLY 288 (BL) SEGMENT(CAMSHAFT) SPEED SENSOR GROUND 285 (YE) 286 (YE) 289 (PK) SEGMENT(CAMSHAFT) SPEED SENSOR SUPLY 290 (BL) COOLANT TEMPERATURE SENSOR GROUND 291 (YE) COOLANT TEMPERATURE SENSOR SIGNAL 292 (BL) FUEL TEMPERATURE SENSOR GROUND 293 (YE) FUEL TEMPERATURE SENSOR SIGNAL 343 (PK) BOOST PRESSURE SENSOR SUPPLY 344 (YE) BOOST PRESSURE SENSOR SIGNAL 345 (BK/WH) BOOST PRESURE SENSOR GROUND 346 (YE) BOOST PRESSURE TEMPERATURE SENSOR SIGNAL 295 (PK) EXHAUST GAS PRESSURE SENSOR SUPPLY (UPSTREAM TURBINE PRESSURE) P3 296 (BK/WH) EXHAUST GAS PRESSURE SENSOR GROUND P3 (UPSTREAM TURBINE PRESSURE) 297 (YE) EXHAUST GAS PRESSURE SENSOR SIGNAL P3 (UPSTREAM TURBINE PRESSURE) 265 (BK/WH) INLET TURBINE TEMP GND 263 (YE) INLET TURBINE TEMP SIGNAL 294 (GY) BOOST PRESSURE ACTUATOR 1 241C (OR) ELECTRIC VALVE POWER 321 (WH) 322 (GY) 318 (PK) EGR POSITION SENSOR SUPPLY 327 (YE) EGR POSITION SENSOR SIGNAL 337 (BK/WH) EGR POSITION SENSOR GROUND 338 (WH) 339 (GY) 340 (PK) TVA POSITION SENSOR SUPPLY 341 (YE) TVA POSITION SENSOR SIGNAL 342 (BK/WH) TVA POSITION SENSOR GROUND 1113 (WH) GLOW PLUG 1112 (WH) GLOW PLUG 1111 (WH) GLOW PLUG 1110 (WH) GLOW PLUG

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Electrical systems - Harnesses and connectors

84154706

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Electrical systems - Harnesses and connectors

CONNECTOR X-11 - X-11 PIN NUMBER 1 2 3

CONNECTOR X-11 - X-11 WIRE NUMBER CIRCUIT REFERENCE 833 (WH) THERMOSTAT TO PRES SW 834 (WH) PRES SW TO COMP RLY 841 (WH) A/C COMP RLY PIN 87 POWER

87382911

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 02 WE WE WE WE

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

CONNECTOR X-20 - FOOT THROTTLE SENSOR PIN NUMBER A B C

CONNECTOR X-20 - FOOT THROTTLE SENSOR WIRE NUMBER CIRCUIT REFERENCE 545 (YE) FOOT THROTTLE SIGNAL 1066 (BK/WH) FOOT THROTTLE SENSOR GND 211 (PK) FOOT THROTTLE SENSOR SUPPLY

CONNECTOR X-20A - HAND TROTTLE PIN NUMBER A B C

CONNECTOR X-20A - HAND TROTTLE WIRE NUMBER CIRCUIT REFERENCE 544 (YE) HAND THROTTLE SIGNAL 1071 (BK/WH) HAND THROTTLE SENSOR GND 260 (PK) HAND THROTTLE SENSOR SUPPLY

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 03 C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE WE

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

CONNECTOR X-30 - CAB/RH LAMP JUMPER INTERFACE PIN NUMBER 1 2 3 4

CONNECTOR X-30 - CAB/RH LAMP JUMPER INTERFACE WIRE NUMBER CIRCUIT REFERENCE 798 (VT) RH WORK LAMP POWER 793 (VT) RH SIDE LAMP POWER 779 (VT) RH CAB TURN SIGNAL POWER 926 (BK) RH CAB LAMPS GROUND

87694154

CONNECTOR X-31 - CAB/LH LAMP JUMPER INTERFACE PIN NUMBER 1 2 3 4

CONNECTOR X-31 - CAB/LH LAMP JUMPER INTERFACE WIRE NUMBER CIRCUIT REFERENCE 799 (VT) LH WORK LAMP POWER 794 (VT) LH SIDE LAMP POWER 773 (VT) LH CAB TURN SIGNAL POWER 927 (BK) LH CAB LAMPS GND

87694154

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 05 C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE WE

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

CONNECTOR X-58 - CAB/SEAT INTERFACE PIN NUMBER 1 2 3 4

CONNECTOR X-58 - CAB/SEAT INTERFACE WIRE NUMBER CIRCUIT REFERENCE 756 (OR) SEAT ACCESSORY POWER 933 (BK) SEAT ACCESSORY GROUND 315 (RD) SEAT SW UNSWITCHED POWER 323 (YE) SEAT SW CLUSTER INPUT

87694154

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 07 C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE WE

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

CONNECTOR X-079 - X-079 PIN NUMBER A B

WIRE NUMBER 600 (OR) 600A (OR)

CONNECTOR X-079 - X-079 CIRCUIT REFERENCE FUEL PUMP FUEL PUMP

87695580

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 11 WE WE WE WE

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

CONNECTOR X-111 - CONDENSER RELAY [CAB] PIN NUMBER 1 2 3 5

CONNECTOR WIRE NUMBER 839 (RD) 840 (WH) 237 (WH) 1087 (BK)

X-111 - CONDENSER RELAY [CAB] CIRCUIT REFERENCE CONDENSER RELAY PIN 30 POWER CONDENSER RELAY PIN 86 SIGNAL HVAC COND FAN POWER CONDENSER RELAY GROUND

CONNECTOR X-113 - FE #2 SWITCH PIN NUMBER D E F

CONNECTOR X-113 - FE #2 SWITCH WIRE NUMBER CIRCUIT REFERENCE 425 (VT) CONSOLE SWITCH MF #2 UP 359 (OR) CONSOLE SWITCH MF #2 POWER 427 (RD) CONSOLE SWITCH MF #2 DN

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Electrical systems - Harnesses and connectors

CONNECTOR X-114 - LH HANDLE INTERCONNECT PIN NUMBER 1 2 3 6 7 8 9 10 11 12 13 14

CONNECTOR WIRE NUMBER 558 (OR) 554 (WH) 552 (WH) 768 (VT) 765 (VT) 246 (OR) 857 (WH) 358 (OR) 424 (VT) 426 (RD) 418 (GY) 419 (LG)

X-114 - LH HANDLE INTERCONNECT CIRCUIT REFERENCE 2ND AUX SWITCH POWER 2ND AUX EXTEND 2ND AUX RETRACT LH GRIP LH TURN SIGNAL OUTPUT SIGNAL LH GRIP RH TURN SIGNAL OUTPUT SIGNAL AUX ELEC ON/OFF SWITCH IN AUX ELEC ON/OFF SWITCH SIGNAL LH HANDLE MF #2/#3 POWER LH HANDLE MULTIFUNCTION #2 UP LH HANDLE MULTIFUNCTION #2 DOWN LH HANDLE MULTIFUNCTION #3 UP LH HANDLE MULTIFUNCTION #3 DOWN

87382926

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Electrical systems - Harnesses and connectors

CONNECTOR X-117 - RH HANDLE INTERCONNECT PIN NUMBER 1 2 3 5 6 9 10

CONNECTOR WIRE NUMBER 352 (OR) 410 (WH) 411 (TN) 412 (VT) 413 (RD) 247 (OR) 858 (WH)

X-117 - RH HANDLE INTERCONNECT CIRCUIT REFERENCE RH HANDLE MF #1/#2 POWER RH HANDLE MULTIFUNCTION #1 UP RH HANDLE MULTIFUNCTION #1 DOWN RH HANDLE MULTIFUNCTION #2 UP RH HANDLE MULTIFUNCTION #2 DOWN AUX ELEC ON/OFF SWITCH IN AUX ELEC ON/OFF SWITCH SIGNAL

87382924

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 20 C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE WE

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

CONNECTOR X-200 - CHASSIS/REAR LAMP JUMPER INTERFACE PIN NUMBER 1 2 3 4 5 6

CONNECTOR X-200 - CHASSIS/REAR LAMP JUMPER INTERFACE WIRE NUMBER CIRCUIT REFERENCE 766 (VT) LH REAR TURN SIGNAL POWER 763 (VT) RH REAR TURN SIGNAL POWER 717 (VT) LH REAR POSITION LAMP 718 (VT) RH REAR POSITION LAMP 725 (VT) BRAKE LAMP SIGNAL POWER 975 (BK) REAR LAMPS GROUND

87382918

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 23 C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE WE

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

CONNECTOR X-230 - CHASSIS OPTIONS/LH BOOM LIGHTS INTERCONNECT CONNECTOR X-230 - CHASSIS OPTIONS/LH BOOM LIGHTS INTERCONNECT PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE A 712 (VT) LH BOOM ROAD LAMPS SIGNAL B 767 (VT) LH BOOM TURN SIGNAL POWER D 979 (BK) LH BOOM LAMPS GROUND

CONNECTOR X-231 - CHASSIS OPTION/RH BOOM LIGHTS INTERCONNECT CONNECTOR X-231 - CHASSIS OPTION/RH BOOM LIGHTS INTERCONNECT PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE A 713 (VT) RH BOOM ROAD LAMPS SIGNAL B 764 (VT) RH BOOM TURN SIGNAL POWER D 980 (BK) RH BOOM LAMPS GROUND

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 25 C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE WE

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

CONNECTOR X-252 - TEMP CONTROL SW PIN NUMBER 1 2 3

CONNECTOR X-252 - TEMP CONTROL SW WIRE NUMBER CIRCUIT REFERENCE 912 (BK) HVAC TEMPERATURE SW GROUND 824 (YE) HVAC TEMP CTRL SIG 823 (PK) HVAC TEMP SW POWER

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 27 C232 TIER 4B (FINAL) [NFM402195 - ] L228

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-271 - WATER VALVE PIN NUMBER A C D

CONNECTOR X-271 - WATER VALVE WIRE NUMBER CIRCUIT REFERENCE 822 (OR) HVAC WATER VALVE POWER 1013 (BK) WATER GROUND 824 (YE) HVAC TEMP CTRL SIG

CONNECTOR X-275 - A/C SW PIN NUMBER A B C

CONNECTOR X-275 - A/C SW WIRE NUMBER CIRCUIT REFERENCE 825 (OR) HVAC CLUTCH 913 (BK) HVAC COMPRESSOR CLUTCH SW GROUND 829 (WH) A/C SWITCH OUT

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 30 C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE WE

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

CONNECTOR X-300 - HYD COUPLER SW PIN NUMBER 1 2 3 9

CONNECTOR X-300 - HYD COUPLER SW WIRE NUMBER CIRCUIT REFERENCE 751 (OR) HYD COUPLER SWITCH POWER 752 (WH) HYDRAULIC COUPLER SIGNAL 918 (BK) HYDRAULIC COUPLER SWITCH INDICATOR GROUND

CONNECTOR X-301 - BEACON SW PIN NUMBER A D E

CONNECTOR X-301 - BEACON SW WIRE NUMBER CIRCUIT REFERENCE 919 (BK) BEACON SW INDICATOR GROUND 761 (VT) BEACON SW OUTPUT 796 (VT) BEACON POWER

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CONNECTOR X-302 - HAZARD SW PIN NUMBER A B C E F

CONNECTOR X-302 - HAZARD SW WIRE NUMBER CIRCUIT REFERENCE 776 (VT) HAZARD SW LH TURN SIGNAL OUTPUT 784 (OR) LH HAZARD FLASHER POWER IN 920 (BK) HAZARD SW INDICATOR GROUND 785 (OR) RH HAZARD FLASHER POWER IN 778 (VT) HAZARD SW RH TURN SIGNAL OUTPUT

CONNECTOR X-303 - HI FLOW SW PIN WIRE NUMBER NUMBER B 753 (OR) C 750 (WH) E 921 (BK)

CONNECTOR X-303 - HI FLOW SW CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME HIGH FLOW SWITCH POWER STANDARD HIGH FLOW SIGNAL HIGH FLOW SW INDICATOR GND

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Electrical systems - Harnesses and connectors

CONNECTOR X-306 - LOADER LOCKOUT SW PIN NUMBER A B E

CONNECTOR X-306 - LOADER LOCKOUT SW WIRE NUMBER CIRCUIT REFERENCE 312 (WH) LOADER LOCK SWITCH OUT 311 (WH) LOADER LOCKOUT SWITCH IN 924 (BK) LOADER LOCK SW INDICATOR GND

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 31 C232 TIER 4B (FINAL) [NFM402195 - ] L228

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-310 - 2SPD INDICATOR PIN NUMBER 7 9

CONNECTOR X-310 - 2SPD INDICATOR WIRE NUMBER CIRCUIT REFERENCE 565 (VT) 2 SPEED INDICATOR 917 (BK) 2 SPEED INDICATOR GROUND

CONNECTOR X-317 - SELF LEVEL SW PIN NUMBER A B E

CONNECTOR X-317 - SELF LEVEL SW WIRE NUMBER CIRCUIT REFERENCE 404 (WH) SELF LEVEL SW OUT 405 (OR) SELF LEVEL SW POWER 922 (BK) SELF LEVEL SW INDICATOR GROUND

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 32 C232 TIER 4B (FINAL) [NFM402195 - ] L228

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-323 - CHASSIS OPTION/MULTIFUNCTION INTERCONNECT

1 2 3 4 5 6 7 8 9

CONNECTOR X-323 - CHASSIS OPTION/MULTIFUNCTION INTERCONNECT PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE 419 (LG) LH HANDLE MULTIFUNCTION #3 DOWN 418 (GY) LH HANDLE MULTIFUNCTION #3 UP 410 (WH) RH HANDLE MULTIFUNCTION #1 UP 411 (TN) RH HANDLE MULTIFUNCTION #1 DOWN 416 (VT) HANDLE MULTIFUNCTION #2 UP 417 (RD) HANDLE MULTIFUNCTION #2 DOWN 982 (BK) MULTIFUNCTION GROUND 856 (WH) AUX ELEC ON/OFF SWITCH SIGNAL 420 (OR) FE HOT FUSE POWER

87382922

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 33 C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE Mechanical hydraulic controls WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-335 - RADIO CONNECTOR PIN NUMBER 2 4 5 6 7 9

CONNECTOR X-335 - RADIO CONNECTOR WIRE NUMBER CIRCUIT REFERENCE 452 (BL) LEFT SPEAKER (-) 451 (WH) RIGHT SPEAKER (+) 450 (BL) RIGHT SPEAKER (-) 453 (WH) LEFT SPEAKER (+) 934 (BK) RADIO GROUND 130 (OR) RADIO POWER

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 36 C232 TIER 4B (FINAL) [NFM402195 - ] L228

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-365 - NH PARK BRAKE SW PIN NUMBER 2 3

CONNECTOR X-365 - NH PARK BRAKE SW WIRE NUMBER CIRCUIT REFERENCE 305 (YE) RH CONSOLE PARK BRAKE SW 306 (YE) RH CONSOLE PARK BRAKE SW OUT

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 40 C232 TIER 4B (FINAL) [NFM402195 - ] L228

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-402 - RH HANDLE INTERCONNECT PARK BRAKE/RIDE CONTROL CONNECTOR X-402 - RH HANDLE INTERCONNECT PARK BRAKE/RIDE CONTROL PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE 1 324 (OR) RH GRIP PARK BRAKE SWITCH POWER 2 307 (YE) RH PARK BRAKE SW OUT 4 832 (OR) RIDE CONTROL VALVE FUSED POWER 5 831 (WH) RIDE CONTROL VALVE SOLENOID SIGNAL 8 699 (PK) EH AUX PROPORTIONAL SWITCH SIGNAL OUTPUT 9 1010 (BK/WH) EH AUX PROPORTIONAL SWITCH GROUND 10 331 (OR) EH AUX PROPORTIONAL SWITCH REFERENCE VOLTAGE

87382922

CONNECTOR X-405 - LH HANDLE INTERCONNECT HORN/TWO SPEED PIN NUMBER A B D

CONNECTOR X-405 - LH HANDLE INTERCONNECT HORN/TWO SPEED WIRE NUMBER CIRCUIT REFERENCE 891 (OR) LH GRIP HORN / 2 SSPEED SWITCH POWER 892 (WH) HORN POWER SIGNAL 563 (WH) 2 SPEED SWITCH OUTPUT SIGNAL

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Wire connectors - Component diagram 43 WE Mechanical hydraulic controls WE Mechanical hydraulic controls

C232 TIER 4B (FINAL) [NFM402195 - ] L228

CONNECTOR X-430 - EH AUX PWM CONTROLLER PIN NUMBER 1 2 3 4 5 6 7 8

CONNECTOR WIRE NUMBER 319 (OR) 901 (BK/WH) 889 (WH) 890 (WH) 1009 (BL) 699 (PK) 1010 (BK/WH) 331 (OR)

X-430 - EH AUX PWM CONTROLLER CIRCUIT REFERENCE EH AUX POWER AUX PWN CLEAN GROUND EH AUX RETRACT SIGNAL EH AUX RETRACT SIGNAL EH AUX VALVE SIGNAL RETURN EH AUX PROPORTIONAL SWITCH SIGNAL OUTPUT EH AUX PROPORTIONAL SWITCH GROUND EH AUX PROPORTIONAL SWITCH REFERENCE VOLTAGE

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 50 C232 TIER 4B (FINAL) [NFM402195 - ] L228

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-502 - DOOR WIPER MOTOR PIN NUMBER A B C D

CONNECTOR X-502 - DOOR WIPER MOTOR WIRE NUMBER CIRCUIT REFERENCE 227 (WH) DOOR WIPER MOTOR SIGNAL 929 (BK) DOOR WIPER MOTOR GROUND 231 (OR) DOOR WIPER MOTOR PARK 220 (YE) DOOR SW BYPASS

CONNECTOR X-502A - REAR WINDOW WIPER MOTOR PIN NUMBER A B C

CONNECTOR X-502A - REAR WINDOW WIPER MOTOR WIRE NUMBER CIRCUIT REFERENCE 228 (WH) REAR WINDOW WIPER MOTOR SIGNAL 930 (BK) REAR WINDOW WIPER MOTOR GND 232 (OR) REAR WINDOW WIPER MOTOR PARK

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Electrical systems - Harnesses and connectors

CONNECTOR X-503 - WIPER/WASHER SW PIN NUMBER 1 2 3 5 6 7 8

CONNECTOR X-503 - WIPER/WASHER SW WIRE NUMBER CIRCUIT REFERENCE 931 (BK) SW GROUND 225 (WH) WIPER &amp; INDICATOR POWER 229 (OR) WIPER/INDICATOR POWER IN 224 (WH) WASHER PUMP SIGNAL 230 (OR) WASHER MOTOR POWER IN 226 (VT) WIPER/WASHER LAMP SIGNAL 932 (BK) WIPER/WASHER SW IND GND

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Wire connectors - Component diagram 90 C232 TIER 4B (FINAL) [NFM402195 - ] L228

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-902 - X-902 PIN NUMBER A B C D

WIRE NUMBER 1095 (BK) 1098 (BK) 1094 (BK) 947 (BK)

CONNECTOR X-902 - X-902 CIRCUIT REFERENCE OPTION RELAY COIL GROUND OPTION RELAY COIL GROUND CAB GND B MAIN POWER RELAY COIL GROUND

CONNECTOR X-903 - FUSE HOLDER PIN NUMBER A B

CONNECTOR X-903 - FUSE HOLDER WIRE NUMBER CIRCUIT REFERENCE 1092 (BK) OPTION RELAY COIL GROUND 1097 (BK) OPTION RELAY COIL GROUND

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram - Connectors A - Z WE Mechanical hydraulic controls WE Mechanical hydraulic controls

C232 TIER 4B (FINAL) [NFM402195 - ] L228

CONNECTOR X-C23 - INSTRUMENT CLUSTER PIN NUMBER 2 3 5 6 7 8 9 10 11 12 13 16 17 19 20 21 22 24 25 26 28 29 30 32 33 34

CONNECTOR X-C23 - INSTRUMENT CLUSTER WIRE NUMBER CIRCUIT REFERENCE 261 HYDRAULIC OIL FILTER 624 KEY START TO CLUSTER 505 CAN LO 500 CAN HI 301 CLUSTER SW POWER 302 CLUSTER SW POWER 313 CLUSTER UNSW POWER 132 KEY IGNITION TO CLUSTER AIR FILTER/ENGINE 267 MALFUNCTION 323 SEAT SW CLUSTER INPUT 205C TELEMATICS CRANK DISABLE 264 HYDRAULIC OIL TEMP SENDER 259 THROTTLE SENSOR SUPPLY 251 DOOR SW SIGNAL LAP BAR/SEAT BELT CLUSTER 314 INPUT 754 PARK BRAKE SW 543 THROTTLE SIGNAL 234 FUEL LEVEL SENDER 1070 THROTTLE SENSOR GND 319 EH AUX POWER 258 PARK BRAKE VALVE SIGNAL 137 ACCESSORY RELAY SIGNAL 303 HYD LOADER INTERLOCK SIGNAL CRANK SIGNAL FROM CLUSTER 622 TO ECU 133 MAIN POWER RELAY SIGNAL 1011 INSTRUMENT CLUSTER GND

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

CONNECTOR X-CC1A - CAB/CHASSIS 1 PIN NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14

CONNECTOR X-CC1A - CAB/CHASSIS 1 WIRE NUMBER CIRCUIT REFERENCE 797 FRONT WORK LAMP FUSE PWR 795 SIDE LAMP POWER SIGNAL 248 EGR ECU K-LINE 503A CAN HI 791 LAMP SW ROAD LAMP SIGNAL 205C TELEMATICS CRANK DISABLE 910 CLUSTER GROUND 234 FUEL LEVEL SENDER 319 EH AUX POWER 115 ACC/BEACON FUSE POWER 264 HYDRAULIC OIL TEMP SENDER 310 UNSW BAT FUSE POWER 545 FOOT THROTTLE SIGNAL 790 LAMP SW WORK LAMP SIGNAL

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Electrical systems - Harnesses and connectors

CONNECTOR CC2A - CAB/CHASSIS 2 PIN NUMBER

CONNECTOR CC2A - CAB/CHASSIS 2 WIRE NUMBER

134

3 4 5 6

258 309 303 261

267

1066

843

622

11 12

133 139

211

822

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CIRCUIT REFERENCE ACCESSORY RELAY FUSE POWER PARK BRAKE VALVE SIGNAL CLUSTER FUSE POWER HYD LOADER INTERLOCK SIGNAL HYDRAULIC OIL FILTER AIR FILTER/ENGINE MALFUNCTION FOOT THROTTLE SENSOR GND HVAC FUSE TO HVAC BOX - VOLTAGE DROP PARALLEL CIRCUIT CRANK SIGNAL FROM CLUSTER TO ECU MAIN POWER RELAY SIGNAL ACCESSORY RELAY SIGNAL FOOT THROTTLE SENSOR SUPPLY HVAC WATER VALVE POWER

Electrical systems - Harnesses and connectors

CONNECTOR X-CC3A - CAB/CHASSIS 3 PIN NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14

CONNECTOR X-CC3A - CAB/CHASSIS 3 WIRE NUMBER CIRCUIT REFERENCE 404 SELF LEVEL SW OUT 565 2 SPEED INDICATOR 824 HVAC TEMP CTRL SIG 504 CAN LO 792 LAMP SW WORK/SIDE SIG 841 A/C COMP RLY PIN 87 POWER 833 THERMOSTAT TO PRES SW HVAC FUSE TO HVAC BOX 844 - VOLTAGE DROP PARALLEL CIRCUIT 307 RH PARK BRAKE SW OUT 123 LAMP SW POWER 237 HVAC COND FAN POWER COMPRESSOR/CONDENSER FAN 836 FUSE POWER 834 PRES SW TO COMP RLY 233 WIPER/WASHER SW PWR

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Electrical systems - Harnesses and connectors

CONNECTOR CN1A - UCM CN1A PIN NUMBER 1 7 8 9 13 14 16 19

CONNECTOR CN1A - UCM CN1A WIRE NUMBER 1075 1076 202 200 1018 525 124 1022

189

1020

515

240

82016219

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CIRCUIT REFERENCE 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 POWER PROPORTIONAL AUX RETURN PROPORTIONAL AUX RETRACT SIGNAL 5V REF SUPPLY FUSE

Electrical systems - Harnesses and connectors

CONNECTOR CN1B - UCM CN1B PIN NUMBER 1 9 13 15 26 27 29 30 31 32

CONNECTOR CN1B - UCM CN1B WIRE NUMBER 1026 1025 560 521 128 126 580 579 166 201

514

87410946

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CIRCUIT REFERENCE UCM GROUND 1B.34 UCM GROUND 1B.26 RH UA2 Y SENSOR OUTPUT CONTROL PATTERN NEUTRAL SW POWER PROP AUX EXTEND SW POWER 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

Electrical systems - Harnesses and connectors

CONNECTOR CN2A - UCM CN2A PIN NUMBER 2 3 4 5 7 8 9 13 14 20 23 25 26

CONNECTOR CN2A (2) - UCM CN2A WIRE NUMBER CIRCUIT REFERENCE 164 LEFT PUMP REVERSE POWER 165 RIGHT PUMP REVERSE POWER 536 LOADER PILOT INTERLOCK 537 LOADER PORT LOCK SWITCHED POWER PORT/PILOT 159 LOCK 518 PUMP RIGHT REVERSE HYDRAULIC CHARGE PRESSURE 262 SWITCH SWITCHED POWER PORT/PILOT 163 LOCK 517 PUMP LEFT REVERSE 1077 UCM GROUND 2A.20 PATTERN INDICATOR H LS 1024 OUTPUT 750 STANDARD HIGH FLOW SIGNAL 1027 UCM GROUND 2A.26

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

CONNECTOR CN2B - UCM CN2B PIN NUMBER 1

CONNECTOR CN2B (2) - UCM CN2B WIRE NUMBER 503E

1023

7 8

1019 1099

154

10 13 14

504E 535 562

158

20 21 22

522 523 754

398

532

25 26 27

1021 1028 531

547

31 32 33 34

568 576 575 1029

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CIRCUIT REFERENCE CAN HI PATTERN INDICATOR ISO LS OUTPUT LOADER RETURN EHF RETURN SWITCHED POWER LOADER CONTROL CAN LO 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) START SIGNAL FROM CLUSTER TO UCM 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

Electrical systems - Harnesses and connectors

RAPH12SSL0240AA

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Electrical systems - Harnesses and connectors

CONNECTOR CN3A - UCM CN3A PIN NUMBER 2 3 4 6 7 9 10 11 13 19 20 21 22 23 25 26

CONNECTOR CN3A (3) - UCM CN3A WIRE NUMBER CIRCUIT REFERENCE 168 SWITCHED POWER PARK BRAKE 169 SWITCHED POWER PARK BRAKE 258 PARK BRAKE VALVE SIGNAL 430 EHF RETRACT SIGNAL 170 SWITCHED POWER TWO SPEED 574 LH PUMP ANGLE #1 573 LH PUMP ANGLE #2 548 RH UA2 X SENSOR OUTPUT 171 SWITCHED POWER TWO SPEED 431 EHF EXTEND SIGNAL 1030 UCM GROUND 3A.20 120 PUMP FORWARD FUSE POWER 512 LOADER LOWER SIGNAL HYDRAULIC LOADER INTERLOCK 303 SIGNAL 2 SPEED VALVE SOLENOID 564 SIGNAL 1031 UCM GROUND 3A.26

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Electrical systems - Harnesses and connectors

RAPH12SSL0240AA

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Electrical systems - Harnesses and connectors

CONNECTOR CN3B - UCM CN3B PIN NUMBER

CONNECTOR CN3B (3) - UCM CN3B WIRE NUMBER

167

6 8 9

513 142 147

755

570

571

572

17 18

510 895

312

1032

554

526

552

32 33 34

519 516 1033

CNH_84130760AAO

CIRCUIT REFERENCE UCM BACKUP ALARM FUSE POWER LOADER RAISE SIGNAL SW POWER BUCKET CONTROL SW POWER BUCKET CONTROL HIGH PERFORMANCE HIGH FLOW SIGNAL CONTROL VALVE BUCKET POSITION SENSOR CONTROL VALVE LOADER POSITION SENSOR CONTROL VALVE AUX POSITION SENSOR BUCKET RETRACT SIGNAL BACKUP ALARM SIGNAL LOADER LOCK SWITCH N.C. OUTPUT (VALVE ON) UCM GROUND 3B.26 2ND AUX EXTEND SWITCH OUTPUT SEAT SWITCH OPERATOR INTERLOCK 2ND AUX RETRACT SIGNAL POWER PUMP RIGHT FORWARD PUMP LEFT FORWARD UCM GROUND 3B.34

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

CONNECTOR CN4A - UCM CN4A PIN NUMBER 1 8

CONNECTOR CN4A (4) - UCM CN4A WIRE NUMBER 0060 0061

524

17 18 19 20 24 25 26

561 569 511 1034 549 567 1035

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CIRCUIT REFERENCE SW POWER BUCKET CONTROL SW 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

Electrical systems - Harnesses and connectors

CONNECTOR CN4B - UCM CN4B PIN NUMBER 13 15

CONNECTOR CN4B (4) - UCM CN4B WIRE NUMBER 423 541

546

27 34

1036 1037

82028495

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CIRCUIT REFERENCE EHF INTERLOCK 2 SPEED UCM INPUT PROPORTIONAL AUX SWITCH OUTPUT SIGNAL #1 UCM GROUND 4B.27 UCM GROUND 4B.34

Electrical systems - Harnesses and connectors

CONNECTOR X-CO1A - CAB/CHASSIS OPTIONS 1 PIN NUMBER 1 2 5 6 7 10

CONNECTOR X-CO1A - CAB/CHASSIS OPTIONS 1 WIRE NUMBER CIRCUIT REFERENCE 782 FLASHER POWER OUTPUT LH TURN SIGNAL CHASSIS 774 POWER 311 LOADER LOCKOUT SW IN RH TURN SIGNAL CHASSIS 780 POWER 312 LOADER LOCK SW OUT 141 CLUSTER OPT RELAYS SIGNAL

SL57_87382924

CONNECTOR X-CO2A - CAB/CHASSIS OPTIONS 2 PIN NUMBER 1 2 3 4 5 7 8

CONNECTOR X-CO2A - CAB/CHASSIS OPTIONS 2 WIRE NUMBER CIRCUIT REFERENCE 425 CONSOLE SWITCH MF #2 UP 359 CONSOLE SWITCH MF #2 POWER 427 CONSOLE SWITCH MF#2 DN 751 HYDRAULIC COUPLER SW IN 752 HYDRAULIC COUPLER SIGNAL 753 HIGH FLOW SW IN 750 STANDARD HIGH FLOW SIGNAL

84257541

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Electrical systems - Harnesses and connectors

CONNECTOR X-DIAG - CAN DIAGNOSTIC CONNECTOR CONNECTOR X-DIAG - CAN DIAGNOSTIC CONNECTOR PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE A 961 DIAG CONNECTOR GND B 162 UNSWITCHED BATTERY POWER 501 C CAN HI D 506 CAN LO E 248 EGR ECU K-LINE

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Electrical systems - Harnesses and connectors

CONNECTOR ECC1B - CHASSIS/CAB INTERFACE 1 PIN NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14

CONNECTOR ECC1B - CHASSIS/CAB INTERFACE 1 WIRE NUMBER CIRCUIT REFERENCE FRONT WORK LAMP FUSE 798 POWER 795 SIDE LAMP POWER SIGNAL 248 EGR ECU K-LINE 503A CAN HI 791 ROAD LAMP SIGNAL 205A TELEMATICS CRANK DISABLE 910 INSTRUMENT CLUSTER GROUND 234 UNSWITCHED BATTERY POWER 319 EH AUX POWER 115 ACC/BEACON FUSE POWER 264 HYDRAULIC OIL TEMP SENDER UNSWITCHED BATTERY FUSE 310 POWER 545 FOOT THROTTLE SIGNAL LAMP SWITCH WORK LAMP 790 SIGNAL

87382927

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Electrical systems - Harnesses and connectors

RAPH12SSL0251AA

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Electrical systems - Harnesses and connectors

CONNECTOR ECC2B - CHASSIS/CAB INTERFACE 2 PIN NUMBER 1 3 4 5 6 7 8 9 10 11 12 13 14

CONNECTOR ECC2B - CHASSIS/CAB INTERFACE 2 WIRE NUMBER CIRCUIT REFERENCE ACCESSORY RELAY FUSE 134 POWER 258 PARK BRAKE VALVE SIGNAL 309 CLUSTER FUSE POWER 303 HYD INTLCK SIG 261 HYDRAULIC OIL FILTER AIR FILTER / ENGINE 267 MALFUNCTION FOOT THROTTLE SENSOR 1066 GROUND HVAC FUSE POWER - VOLTAGE 843 DROP PARALLEL CIRCUIT CRANK SIGNAL FROM CLUSTER 622 TO ECU 133A MAIN POWER RELAY SIGNAL 139 ACCESSORY RELAY SIGNAL FOOT THROTTLE SENSOR 211 SUPPLY 822 HVAC WATER VALVE POWER

87382926

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Electrical systems - Harnesses and connectors

RAPH12SSL0251AA

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Electrical systems - Harnesses and connectors

CONNECTOR ECC3B - CHASSIS/CAB INTERFACE 3 PIN NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14

CONNECTOR ECC3B - CHASSIS/CAB INTERFACE 3 WIRE NUMBER CIRCUIT REFERENCE SELF LEVEL SWITCH OUTPUT 404 POWER 565 2 SPEED INDICATOR 824 HVAC TEMP CONTROL SIGNAL 504A CAN LO LAMP SWITCH WORK AND SIDE 792 LAMP SIGNAL A/C COMPRESSOR RELAY PIN 87 841 POWER THERMOSTAT TO BINARY 833 PRESSURE SWITCH HVAC FUSE POWER - VOLTAGE 844 DROP PARALLEL CIRCUIT RH GRIP PARK BRAKE SWITCH 307 OUTPUT ACC RELAY OUTPUT TO LAMP 123 SWITCH 237 HVAC CONDENSER FAN POWER COMPRESSOR/CONDENSER FAN 836 FUSE POWER PRESSURE SWITCH TO 834 COMPRESSOR RELAY PIN 86 233 WIPER / WASHER FUSE POWER

84394890

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Electrical systems - Harnesses and connectors

RAPH12SSL0251AA

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Electrical systems - Harnesses and connectors

CONNECTOR FUSE1 - POWER DISTRIBUTION-CHASSIS CONNECTOR FUSE1 - POWER DISTRIBUTION-CHASSIS PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE A1 830 HVAC RELAY FUSE IN A2 820 HVAC FUSE POWER A3 528B ECU FUSE 1 IN A4 110 ECU FUSE 1 POWER A5 528C ECU FUSE 2 IN A6 155A ECU FUSE 2 POWER LIGHT RELAY #2 SIDE & REAR A7 707 WORK LAMP OUT A9 945 COIL GROUND A10 116 B+ TO LIGHT RELAY #1 PIN 87 A11 710 STD LAMP CONFIG CONTROL A12 946 COIL GROUND ACC RELAY OUTPUT TO B1 243 WIPER/WASHER B2 233 WIPER / WASHER FUSE POWER B3 528D ENGINE SENSORS FUSE IN B4 241A ENGINE SENSORS FUSE POWER B7 709 SIDE LAMP FUSE OUT B9 113 LIGHT RELAY #2 B+ B10 325 LIGHT RELAY #1 SWITCH SIGNAL LIGHT RELAY #1 PIN 30 TO FUSE B12 788 (FRONT WORK LAMP POWER) 135 C1 ACC FUSE IN ACCESSORY RELAY FUSE 134 C2 POWER 350 C3 IGNITION FUSE IN 351 C4 IGNITION FUSE POWER 835 C5 COMPRESSOR RELAY FUSE IN COMPRESSOR/CONDENSER FAN 836 C6 FUSE POWER 136 C7 MAIN POWER RELAY OUT MAIN POWER RELAY COIL 947 C9 GROUND 125 C10 ACC RELAY OUT 948 C12 COIL GROUND D1 160 UNSWITCHED B+ UNSWITCHED BATTERY FUSE D2 310 POWER D3 326 INSTRUMENT CLUSTER FUSE IN INSTRUMENT CLUSTER FUSE D4 300 POWER D5 114 ACC/BEACON B+ D6 196 ACC/BEACON FUSE POWER D7 144 MAIN POWER RELAY SIGNAL D9 118 MAIN POWER RELAY B+ D10 139 ACCESSORY RELAY SIGNAL D12 117 ACCESSORY RELAY B+ LIGHT RELAY #1 PIN 30 TO FUSE E1 788 (FRONT WORK LAMP POWER) LIGHT RELAY #1 FRONT WORK E2 797 LAMP POWER LAMP SWITCH WORK AND SIDE E3 792 LAMP SIGNAL E4 708 SIDE LAMP FUSE POWER E5 705 REAR WORK LAMP FUSE IN 47683911 27/02/2015

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Electrical systems - Harnesses and connectors

E6 E7 E8 E9 E10 E11 E12

706 701 703 700 704 255 256

84255438

REAR WORK LAMP FUSE POWER LH TAIL LAMP FUSE IN LH TAIL LAMP FUSE POWER RH TAIL LAMP FUSE IN RH TAIL LAMP FUSE POWER CRANK RELAY FUSE IN CRANK RELAY FUSE POWER

CONNECTOR X-HVC1 - CAB/HVAC INTERCONNECT PIN NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 14

CONNECTOR X-HVC1 - CAB/HVAC INTERCONNECT WIRE NUMBER CIRCUIT REFERENCE 935 HVAC GND COMPRESSOR RELAY PIN 30 838 POWER 828 HVAC FAN LOW 827 HVAC FAN MEDIUM 850 HVAC FAN HIGH A/C SW COMPRESSOR RELAY 837 PIN 86 VIA PRESSURE SW 833 THERMOSTAT TO PRES SW 834 PRES SW TO COMP RLY 1012 HVAC THERMOSTAT CLEAN GND HVAC RELAY PIN 87 OUTPUT 842 POWER 143 HVAC KEYED POWER 841 A/C COMP RLY PIN 87 POWER 845 HVAC RELAY FUSE POWER

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Electrical systems - Harnesses and connectors

87382926

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Electrical systems - Harnesses and connectors

CONNECTOR RRJMPRA - CHASSIS/REAR LAMP JUMPER INTERFACE CONNECTOR RRJMPRA - CHASSIS/REAR LAMP JUMPER INTERFACE PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE 1 706 REAR WORK LAMP FUSE POWER 2 704 RH TAIL LAMP FUSE POWER 3 703 LH TAIL LAMP FUSE POWER 4 950 REAR LAMP GROUND

87382914

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Electrical systems - Harnesses and connectors

CONNECTOR TELE - TELEMATICS PIN NUMBER

CONNECTOR TELE - TELEMATICS WIRE NUMBER

336

802

244

E H L M S

308 925 503D 504D 205A

87696550

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CIRCUIT REFERENCE TELEMATICS UNSWITCHED BATTERY TELEMATICS IGNITION POWER ALTERNATOR LAMP TELEMATICS ENGINE ON VEHICLE WORKING CONDITION TELEMATICS GROUND TELEMATICS CAN HI TELEMATICS CAN LO TELEMATICS CRANK DISABLE

Electrical systems - Harnesses and connectors

CONNECTOR X-UJML - UJM LH PIN NUMBER 1 2 3 4 7 8 9 10

CONNECTOR X-UJML - UJM LH WIRE NUMBER 215 567 569 1045 218 562 568 1046

SL57_87694583

CIRCUIT REFERENCE LH UB1 X-Y SENSOR VOLTAGE LH UA1 X SENSOR OUTPUT LH UA1 Y SENSOR OUTPUT LH OV1 X-Y SENSOR GROUND LH UB2 X-Y SENSOR VOLTAGE LH UA2 X SENSOR OUTPUT LH UA2 Y SENSOR OUTPUT LH OV2 X-Y SENSOR GROUND

CONNECTOR X-UJMR - UJM RH PIN NUMBER 1 2 3 4 7 8 9 10

CONNECTOR X-UJMR - UJM RH WIRE NUMBER 219 549 561 1047 217 548 560 1048

SL57_87694583

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CIRCUIT REFERENCE RH UB1 X-Y SENSOR VOLTAGE RH UA1 X SENSOR OUTPUT RH UA1 Y SENSOR OUTPUT RH OV1 X-Y SENSOR GROUND RH UB2 X-Y SENSOR VOLTAGE RH UA2 X SENSOR OUTPUT RH UA2 Y SENSOR OUTPUT RH OV2 X-Y SENSOR GROUND

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram - Grounds C232 TIER 4B (FINAL) [NFM402195 - ] L228

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

Ground locations Grounds NEG_TERM_A Main chassis ECU

(1) (2) (3)

RAPH12SSL0239AA

Ground location for the ECU, NEG_TERM_A, and the main chassis Grounds X-CAB_GNDA X-CAB_GNDB

(1) (2)

RAPH12SSL0248AA

Ground location for X-CAB_GNDA and X-CAB_GNDB

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Electrical systems - Harnesses and connectors

Grounds CHS_GND_RR OPT_GND_RR

(1) (2)

RAPH12SSL0252AA

Ground location for CHS_GND_RR and OPT_GND_RR Grounds UCM_GND CHS_GND_FRT OPT_GND_FRT

(1) (2) (3)

RAPH12SSL0251AA

Ground location for UCM_GND, CHS_GND_FRT, and OPT_GND_FRT

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire connectors - Component localization - Deluxe cab C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE WE

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

NOTE: Deluxe cab shown.

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controls controls controls controls

Electrical systems - Harnesses and connectors

RAPH12SSL0466KA

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

RAPH15SSL0199GA

Detail 1 Connector title X-9

Component Ignition switch

X-C23

Instrument cluster

X-365

Park brake switch

X-95

Drive pattern selector switch

X-CTS X-311 X-20A

Turn signal switch Lamp selector switch Hand throttle

X-502

Door wiper motor

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Pin information Wire connectors - Component diagram 00 (55.100) Wire connectors - Component diagram - Connectors A - Z (55.100) Wire connectors - Component diagram 36 (55.100) Wire connectors - Component diagram 01 (55.100) Not available Not available Wire connectors - Component diagram 02 (55.100) Wire connectors - Component diagram 50 (55.100)

Electrical systems - Harnesses and connectors

RAPH12SSL0468GA

Detail 2 Connector title X-270 X-275

Component Blower fan switch A/C switch

X-155B X-156B X-157B X-300

Turn signal indicator (right) Turn signal indicator (left) Turn signal indicator (ground) Hydraulic coupler switch

X-310

2SPD indicator

X-301

Beacon lamp switch

X-302

Hazard lamp switch

X-317

Self level switch 47683911 27/02/2015

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Pin information Not available Wire connectors - Component diagram 27 (55.100) Not available Not available Not available Wire connectors - Component diagram 30 (55.100) Wire connectors - Component diagram 31 (55.100) Wire connectors - Component diagram 30 (55.100) Wire connectors - Component diagram 30 (55.100) Not available

Electrical systems - Harnesses and connectors

X-303

Hi flow switch

X-113

Fe #2 switch

X-503

Wiper/washer switch

X-306

Loader lockout switch

X-ACC X-505

Accessory power outlet Cab/door switch interface

RAPH12SSL0469GA

Wire connectors - Component diagram 30 (55.100) Wire connectors - Component diagram 11 (55.100) Wire connectors - Component diagram 50 (55.100) Wire connectors - Component diagram 30 (55.100) Not available Not available

Detail 3 Connector title X-CN1A

Component UCM

X-CN1B

UCM

X-CN2A

UCM

X-CN2B

UCM

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Electrical systems - Harnesses and connectors

X-CN3A

UCM

X-CN3B

UCM

X-CN4A

UCM

X-CN4B

UCM

X- F1

Fuse 1

X-F2

Fuse 2

X-AUX_RET X-AUX_EXT X-271

2nd auxiliary retract 2nd auxiliary extend Water valve

X-20

Foot throttle sensor

X-DIAG

CAN Diagnostic connector

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Wire connectors - Component diagram - Connectors A - Z (55.100) Wire connectors - Component diagram - Connectors A - Z (55.100) Wire connectors - Component diagram - Connectors A - Z (55.100) Wire connectors - Component diagram - Connectors A - Z (55.100) Wire connectors - Component diagram - Connectors A - Z (55.100) Wire connectors - Component diagram - Connectors A - Z (55.100) Not available Not available Wire connectors - Component diagram 27 (55.100) Wire connectors - Component diagram 02 (55.100) Wire connectors - Component diagram - Connectors A - Z (55.100)

Electrical systems - Harnesses and connectors

RAPH12SSL0470GA

Detail 4 Connector title X-ECC6B

Component

X-ECC5B X-ECC4B X-ECC3B

Chassis/cab interface

X-ECC2B

Chassis/cab interface

X-ECC1B

Chassis/cab interface

CHS_GND_FRT

Ground

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Pin information Wire connectors - Component diagram - Connectors A - Z (55.100) Wire connectors - Component diagram - Connectors A - Z (55.100) Wire connectors - Component diagram - Connectors A - Z (55.100) Wire connectors - Component diagram - Connectors A - Z (55.100) Wire connectors - Component diagram - Connectors A - Z (55.100) Wire connectors - Component diagram - Connectors A - Z (55.100) Wire connectors - Component diagram - Grounds (55.100)

Electrical systems - Harnesses and connectors

OPT_GND_FRT

Ground

X-BRKPRS X-PLTLK X-BRK X-CHGPRS X-2SPD

Brake pressure switch Pilot interlock Brake valve solenoid Hydraulic charge pressure switch 2 speed valve solenoid

RAPH12SSL0471GA

Wire connectors - Component diagram - Grounds (55.100) Not available Not available Not available Not available Not available

Detail 5 Connector title X-HVC1

Component Cab/HVAC interconnect

X-UJML

UJM left hand

X-408

left hand handle interconnect

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Pin information Wire connectors - Component diagram - Connectors A - Z (55.100) Wire connectors - Component diagram - Connectors A - Z (55.100) Wire connectors - Component diagram 40 (55.100)

Electrical systems - Harnesses and connectors

X-58

Cab/seat interface

RAPH12SSL0472GA

Wire connectors - Component diagram 05 (55.100)

Detail 6 Connector title X-93 X-318 X-403 X-UJMRH X-506 X-401 X-406 X-OILTMP

Component Right swash plate sensor

Pin information Wire connectors - Component diagram 09 (55.100) Not available Self level Right hand interconnect Wire connectors - Component FE/proportional auxiliary/float diagram 40 (55.100) UJM right hand Wire connectors - Component diagram - Connectors A - Z (55.100) Front washer pump Not available Right hand handle interconnect FE Not available Right hand handle interconnect park Wire connectors - Component brake/ride control diagram 40 (55.100) Hydraulic oil temperature sensor Not available 47683911 27/02/2015

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Electrical systems - Harnesses and connectors

X-13

Left, drive, forward

X-16

Left, drive, reverse

X-CPLR X-94

Hydraulic coupler Left swash plate sensor

X-TELE

Telematics

X-PORT_LK

Port lock

RAPH12SSL0473GA

Wire connectors - Component diagram 01 (55.100) Wire connectors - Component diagram 01 (55.100) Not available Wire connectors - Component diagram 09 (55.100) Wire connectors - Component diagram - Connectors A - Z (55.100) Not available

Detail 7 Connector title X-195 X-013

Component GCU fuse GCU

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Pin information Not available Wire connectors - Component diagram 01 (55.100)

Electrical systems - Harnesses and connectors

X-001

Engine relay box

X-126 X-318 X-93

Starter Self level valve Right hand swash plate sensor

X-RDCTRL

Ride control valve solenoid

RAPH12SSL0474GA

Wire connectors - Component diagram 00 (55.100) Not available Not available Wire connectors - Component diagram 09 (55.100) Not available

Group 8 Connector title ECU_GND NED_TERM_A X-OILFLT SIDE LAMP BEACON LAMP SOCKET X-HORN_PWR X-HORN_GND REAR WIPER MOTOR

Component Ground

Pin information Wire connectors - Component diagram - Grounds (55.100) Ground Wire connectors - Component diagram - Grounds (55.100) Not available Hydraulic oil filter switch Side lamp dealer installed accessory Not available Beacon lamp socket dealer installed Not available accessory Horn power Not available Horn ground Not available Rear wiper motor dealer installed Not available accessory 47683911 27/02/2015

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Electrical systems - Harnesses and connectors

X-230 X-323

Chassis options/left hand boom lights interconnect Chassis options/multifunction interconnect

RAPH12SSL0475GA

Wire connectors - Component diagram 23 (55.100) Wire connectors - Component diagram 32 (55.100)

Group 9 Connector title X-104 X-330 X-311 X-332 X-333 X-97 X-30

Component Lap bar switch Right speaker Right speaker Left speaker Left speaker Cab/dome lamp jumper Cab/right hand jumper interface

X-9

Ignition switch

X-335

Radio connector

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Pin information Not available Not available Not available Not available Not available Not available Wire connectors - Component diagram 03 (55.100) Wire connectors - Component diagram 00 (55.100) Wire connectors - Component diagram 33 (55.100)

Electrical systems - Harnesses and connectors

RAPH12SSL0476GA

Group 10 Connector title X-231 X-14 NEG_TERM_A ECU_GND X-15 NEG_TERM_A ECU_GND ECU_POS1 ECU_POS2

Component Pin information Chassis option right hand boom lights Wire connectors - Component diagram 23 (55.100) Fuel level sensor Not available Ground Wire connectors - Component diagram - Grounds (55.100) Ground Wire connectors - Component diagram - Grounds (55.100) Electrical valve Wire connectors - Component diagram 01 (55.100) Ground Wire connectors - Component diagram - Grounds (55.100) Ground Wire connectors - Component diagram - Grounds (55.100) Battery power Not available Battery power Not available 47683911 27/02/2015

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Electrical systems - Harnesses and connectors

X-001

Engine relay box

X-012

ECU

RAPH12SSL0477GA

Wire connectors - Component diagram 00 (55.100) Wire connectors - Component diagram 01 (55.100)

Group 11 Connector title X-BKUP_PWR X-BKUP_GND X-200

Component Backup alarm power Backup alarm ground Chassis/rear jumper interface

X-RRJMPRA

Chassis/rear lamp jumper interface

NEG_TERM_A

Ground

ECU-GND

Ground

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Pin information Not available Not available Wire connectors - Component diagram 20 (55.100) Wire connectors - Component diagram - Connectors A - Z (55.100) Wire connectors - Component diagram - Grounds (55.100) Wire connectors - Component diagram - Grounds (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 00 C232 TIER 4B (FINAL) [NFM402195 - ] L228

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-001 - ENGINE RELAY BOX PIN NUMBER A30 A85 A86 A87 B30 B85 B86 B87 C30 C85 C86 C87 A87A B87A C87A

CONNECTOR X-001 - ENGINE RELAY BOX WIRE NUMBER CIRCUIT REFERENCE 256 (RD) CRANK FUSE POWER 161 (YE) CRANK ENABLE FROM ECU 121 (YE) CRANK ENABLE FROM ECU 520 (WH) STARTER MOTOR POWER 527B (RD) ECU RELAY B+ 112 (BL) ECU MAIN RELAY 527C (RD) ECU RELAY COIL B+ 528A (OR) ECU RELAY OUTPUT TO ECU FUSES -

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Electrical systems - Harnesses and connectors

CONNECTOR X-005 - DIFFERENTIAL PRESSURE SENSOR PIN NUMBER 1 2 3

CONNECTOR X-005 - DIFFERENTIAL PRESSURE SENSOR WIRE NUMBER CIRCUIT REFERENCE 269 (YE) DIFF PRESSURE SENSOR SUPPLY 266 (BK/WH) DIFF PRESSURE SENSOR GND 268 (YE) DIFF PRESSURE SENSOR SIGNAL

87747172

CONNECTOR X-5A - ALTERNATOR PIN NUMBER 1 2 3

CONNECTOR X-5A - ALTERNATOR WIRE NUMBER CIRCUIT REFERENCE 244 (YE) ALTERNATOR LAMP TELEMATICS ENGINE ON 127 (OR) ALTERNATOR EXCITE 124 (YE) ENGINE RPM SIGNAL

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Electrical systems - Harnesses and connectors

CONNECTOR X-9 - IGNITION SWITCH PIN NUMBER 1 2 3 6

CONNECTOR X-9 - IGNITION SWITCH WIRE NUMBER CIRCUIT REFERENCE 140 (RD) KEY SWITCH INPUT POWER 624 (WH) KEY START OUTPUT 132 (OR) KEY IGNITION 138 (OR) KEY ACCESSORY

87693713

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 01 WE Electro hydraulic controls WE Electro hydraulic controls

C232 TIER 4B (FINAL) [NFM402195 - ] L228

CONNECTOR X-011 - WATER IN FUEL SWITCH PIN NUMBER 1 2 3

CONNECTOR X-011 - WATER IN FUEL SWITCH WIRE NUMBER CIRCUIT REFERENCE 150 (YE) WIF LEVEL SENSOR SIGNAL 908E (BK) WIF GROUND 133E (OR) WIF SENSOR POWER

87709663

CONNECTOR X-012 - ECU PIN NUMBER 1 2 3 4 5 6 7 8 14 19 20 22 24 25 27 28 30 36 41 52 53 54 58 63 64 68 70 79 80 81 82

WIRE NUMBER 110 (OR) 908B (BK) 155B (OR) 908C (BK) 155C (OR) 908D (BK) 242 (YE) 626 (WH) 269 (YE) 257 (YE) 254 (BK/WH) 235 (YE) 503C (YE) 504C (GN) 121 (YE) 112 (BL) 150 (YE) 266 (BK/WH) 239 (BK) 216 (YE) 161 (YE) 133D (OR) 268 (YE) 253 (PK) 245 (YE) 248 (YE) 347 (BL) 270 (BK/WH) 271 (YE) 265 (BK/WH) 263 (YE)

CONNECTOR X-012 - ECU CIRCUIT REFERENCE ECU FUSE 1 POWER ECU GROUND 1 BATTERY +B VIA MAIN RELAY ECU GROUND 2 BATTERY +C VIA MAIN RELAY ECU GROUND 3 LAMBDA SENSOR HEATING START SIGNAL FROM CLUSTER TO ECU DIFF PRESSURE SENSOR SUPPLY AIR TEMP SENSOR SIGNAL AIR TEMP GND GLOW PLUG FEEDBACK SIGNAL

CRANK ENABLE FROM ECU ECU MAIN RELAY WIF LEVEL SENSOR SIGNAL DIFF PRESSURE SENSOR GND GLOW PLUG UNIT GND GLOW PLUG UNIT COMMAND SIGNAL CRANK ENABLE FROM ECU EGR ECU SWITCHED BATTERY POWER DIFF PRESSURE SENSOR SIGNAL

EGR ECU K-LINE FUEL FILTER HEATER GROUND EXHAUST GAS TEMP GND EXHAUST GAS TEMP SIGNAL INLET TURBINE TEMP GND INLET TURBINE TEMP SIGNAL 47683911 27/02/2015

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Electrical systems - Harnesses and connectors

PIN NUMBER 83 84 85 86

CONNECTOR X-012 - ECU WIRE NUMBER CIRCUIT REFERENCE 272 (BK/WH) EXHAUST GAS TEMP GND 2 273 (YE) EXHAUST GAS TEMP SIGNAL 2 252 (BK) 249 (YE)

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Electrical systems - Harnesses and connectors

CONNECTOR X-013 - GCU PIN NUMBER 1 2 3 4 5 6 7 8

84356962

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Electrical systems - Harnesses and connectors

CONNECTOR X-014 - LAMBDA SENSOR PIN NUMBER 1 2 3 4 5 6

CONNECTOR X-014 - LAMBDA SENSOR WIRE NUMBER CIRCUIT REFERENCE 245 (YE) 252 (BK) 242 (YE) LAMBDA SENSOR HEATING 241B (OR) LAMBDA SENSOR POWER 249 (YE) 253 (PK)

84301132

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Electrical systems - Harnesses and connectors

CONNECTOR X-015 - ELECTRIC VALVE PIN NUMBER A B C D E F G H

CONNECTOR X-015 - ELECTRIC VALVE WIRE NUMBER CIRCUIT REFERENCE 274 (WH) 275 (GY) 276 (GY) 277 (WH) 278 (WH) 279 (GY) 280 (GY) 281 (WH)

87698252

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Electrical systems - Harnesses and connectors

CONNECTOR X-016 - ECU PIN NUMBER 1 2 4 6 8 9 10 11 12 13 14 15 16 17 23 24 25 26 27 28 31 32 34 35 37 38 39 40 41 43 44 46 48 49 50 53 55 57 58 59 60

CONNECTOR X-016 - ECU WIRE NUMBER CIRCUIT REFERENCE 277 (WH) 281 (WH) 294 (GY) 658 (YE) 340 (PK) TVA POSITION SENSOR SUPPLY 318 (PK) EGR POSITION SENSOR SUPPLY 343 (PK) BOOST PRESSURE SENSOR SUPPLY 284 (PK) RAIL PRESSURE SENSOR SUPPLY 295 (PK) EXHAUST GAS PRESSURE SENSOR SUPPLY (UPSTREAM TURBINE PRESSURE) P3 289 (PK) SEGMENT(CAMSHAFT) SPEED SENSOR SUPLY 287 (YE) SEGMENT(CAMSHAFT) SPEED SENSOR SIGNAL 299 (WH) 274 (WH) 278 (WH) 292 (BL) FUEL TEMPERATURE SENSOR GROUND 337 (BK/WH) EGR POSITION SENSOR GROUND 345 (BK/WH) BOOST PRESURE SENSOR GROUND 282 (BL) 296 (BK/WH) EXHAUST GAS PRESSURE SENSOR GROUND P3 (UPSTREAM TURBINE PRESSURE) 288 (BL) SEGMENT(CAMSHAFT) SPEED SENSOR GROUND 276 (GY) 275 (GY) 339 (GY) 322 (GY) 342 (BK/WH) TVA POSITION SENSOR GROUND 293 (YE) FUEL TEMPERATURE SENSOR SIGNAL 327 (YE) EGR POSITION SENSOR SIGNAL 344 (YE) BOOST PRESSURE SENSOR SIGNAL 283 (YE) 297 (YE) EXHAUST GAS PRESSURE SENSOR SIGNAL P3 (UPSTREAM TURBINE PRESSURE) 286 (YE) 280 (GY) 279 (GY) 338 (WH) 321 (WH) 341 (YE) TVA POSITION SENSOR SIGNAL 346 (YE) BOOST PRESSURE TEMPERATURE SENSOR SIGNAL 291 (YE) COOLANT TEMPERATURE SENSOR SIGNAL 290 (BL) COOLANT TEMPERATURE SENSOR GROUND 285 (YE) 298 (GY)

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CONNECTOR X-017 - ENGINE INTERFACE PIN NUMBER 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 21 22 23 25 26 27 28 29 30 33 34 35 37 38 41 42 43 57 58 60 61

CONNECTOR X-017 - ENGINE INTERFACE WIRE NUMBER CIRCUIT REFERENCE 299 (WH) 298 (GY) 658 (YE) 287 (YE) SEGMENT(CAMSHAFT) SPEED SENSOR SIGNAL 282 (BL) 283 (YE) 284 (PK) RAIL PRESSURE SENSOR SUPPLY 288 (BL) SEGMENT(CAMSHAFT) SPEED SENSOR GROUND 285 (YE) 286 (YE) 289 (PK) SEGMENT(CAMSHAFT) SPEED SENSOR SUPLY 290 (BL) COOLANT TEMPERATURE SENSOR GROUND 291 (YE) COOLANT TEMPERATURE SENSOR SIGNAL 292 (BL) FUEL TEMPERATURE SENSOR GROUND 293 (YE) FUEL TEMPERATURE SENSOR SIGNAL 343 (PK) BOOST PRESSURE SENSOR SUPPLY 344 (YE) BOOST PRESSURE SENSOR SIGNAL 345 (BK/WH) BOOST PRESURE SENSOR GROUND 346 (YE) BOOST PRESSURE TEMPERATURE SENSOR SIGNAL 295 (PK) EXHAUST GAS PRESSURE SENSOR SUPPLY (UPSTREAM TURBINE PRESSURE) P3 296 (BK/WH) EXHAUST GAS PRESSURE SENSOR GROUND P3 (UPSTREAM TURBINE PRESSURE) 297 (YE) EXHAUST GAS PRESSURE SENSOR SIGNAL P3 (UPSTREAM TURBINE PRESSURE) 265 (BK/WH) INLET TURBINE TEMP GND 263 (YE) INLET TURBINE TEMP SIGNAL 294 (GY) 241C (OR) 321 (WH) 322 (GY) 318 (PK) EGR POSITION SENSOR SUPPLY 327 (YE) EGR POSITION SENSOR SIGNAL 337 (BK/WH) EGR POSITION SENSOR GROUND 338 (WH) 339 (GY) 340 (PK) TVA POSITION SENSOR SUPPLY 341 (YE) TVA POSITION SENSOR SIGNAL 342 (BK/WH) TVA POSITION SENSOR GROUND 1113 (WH) GLOW PLUG 1112 (WH) GLOW PLUG 1111 (WH) GLOW PLUG 1110 (WH) GLOW PLUG

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84154706

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CONNECTOR X-10 - CHASSIS/ LOADER INTERFACE PIN NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14

CONNECTOR X-10 - CHASSIS/ LOADER INTERFACE WIRE NUMBER CIRCUIT REFERENCE 510 (WH) BUCKET RETRACT SIGNAL 1018 (BL) BUCKET RETURN 511 (WH) BUCKET EXTEND SIGNAL 570 (YE) CONTROL VALVE BUCKET POSITION SENSOR 512 (WH) LOADER LOWER SIGNAL 1019 (BL) LOADER RETURN 513 (WH) LOADER RAISE SIGNAL 571 (YE) CONTROL VALVE LOADER POSITION SENSOR 1060 (BK/WH) CONTROL VALVE SENSOR GROUNDS 515 (WH) PROPORTIONAL AUX RETRACT SIGNAL 1020 (BL) PROPORTIONAL AUX RETURN 514 (WH) PROPORTIONAL AUX EXTEND SIGNAL 572 (YE) CONTROL VALVE AUX POSITION SENSOR 236 (PK) CONTROL VALVE SENSOR REFERENCE VOLTAGE

87382926

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Electrical systems - Harnesses and connectors

CONNECTOR X-11 - A/C COMPRESSOR PIN NUMBER 1 2 3

CONNECTOR X-11 - A/C COMPRESSOR WIRE NUMBER CIRCUIT REFERENCE 833 (WH) THERMOSTAT TO BINARY PRESSURE SW 834 (WH) BINARY PRESSURE SW TO COMPRESSOR RELAY PIN 86 841 (WH) A/C COMPRESSOR RELAY PIN 87 POWER

87382911

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 02 WE Electro hydraulic controls WE Electro hydraulic controls

C232 TIER 4B (FINAL) [NFM402195 - ] L228

CONNECTOR X-20 - FOOT THROTTLE SENSOR PIN NUMBER A B C

CONNECTOR X-20 - FOOT THROTTLE SENSOR WIRE NUMBER CIRCUIT REFERENCE 545 (YE) FOOT THROTTLE SIGNAL 1066 (BK/WH) FOOT THROTTLE SENSOR GROUND 211 (PK) FOOT THROTTLE SENSOR SUPPLY

CONNECTOR X-20A - HAND THROTTLE PIN NUMBER A B C

CONNECTOR X-20A - HAND THROTTLE WIRE NUMBER CIRCUIT REFERENCE 544 (YE) HAND THROTTLE SIGNAL 1071 (BK/WH) HAND THROTTLE SENSOR GROUND 260 (PK) HAND THROTTLE SENSOR SUPPLY

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 03 C232 TIER 4B (FINAL) [NFM402195 - ] L228

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-30 - CAB/RH LAMP JUMPER INTERFACE PIN NUMBER 1 2 3 4

CONNECTOR X-30 - CAB/RH LAMP JUMPER INTERFACE WIRE NUMBER CIRCUIT REFERENCE 798 (VT) RH WORK LAMP POWER 793 (VT) RH SIDE LAMP POWER 779 (VT) RH CAB TURN SIGNAL POWER 926 (BK) RH CAB LAMPS GROUND

87694154

CONNECTOR X-31 - CAB/LH LAMP JUMPER INTERFACE PIN NUMBER 1 2 3 4

CONNECTOR X-31 - CAB/LH LAMP JUMPER INTERFACE WIRE NUMBER CIRCUIT REFERENCE 799 (VT) LH WORK LAMP POWER 794 (VT) LH SIDE LAMP POWER 773 (VT) LH CAB TURN SIGNAL POWER 927 (BK) LH CAB LAMPS GROUND

87694154

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 05 C232 TIER 4B (FINAL) [NFM402195 - ] L228

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-58 - CAB/SEAT INTERFACE PIN NUMBER 1 2 3 4

CONNECTOR X-58 - CAB/SEAT INTERFACE WIRE NUMBER CIRCUIT REFERENCE 756 (OR) SEAT ACCESSORY POWER 933 (BK) SEAT ACCESSORY GROUND 315 (RD) SEAT SW UNSWITCHED POWER 323 (YE) SEAT SW CLUSTER INPUT

87694154

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 09 C232 TIER 4B (FINAL) [NFM402195 - ] L228

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-93 - RH PUMP SWASH PLATE SENSOR PIN NUMBER 1 2 3 4 5 6

CONNECTOR X-93 - RH PUMP SWASH PLATE SENSOR WIRE NUMBER CIRCUIT REFERENCE 1055 (BK/WH) RH PUMP ANGLE SENSOR GROUND 223 (PK) RH PUMP ANGLE SENSOR REFERENCE 575 (YE) RH PUMP ANGLE #2 576 (YE) RH PUMP ANGLE #1 221 (PK) RH PUMP ANGLE SENSOR REFERENCE 1074 (BK/WH) RH PUMP ANGLE SENSOR GROUND #2

87694112

CONNECTOR X-94 - LH PUMP SWASH PLATE SENSOR PIN NUMBER 1 2 3 4 5 6

CONNECTOR X-94 - LH PUMP SWASH PLATE SENSOR WIRE NUMBER CIRCUIT REFERENCE 1054 (BK/WH) LH PUMP ANGLE SENSOR GROUND 222 (PK) LH PUMP ANGLE SENSOR REFERENCE 574 (YE) LH PUMP ANGLE #1 573 (YE) LH PUMP ANGLE #2 209 (PK) LH PUMP ANGLE SENSOR REFERENCE 1073 (BK/WH) LH PUMP ANGLE SENSOR GROUND #2

87694112

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Electrical systems - Harnesses and connectors

CONNECTOR X-95 - DRIVE PATTERN SELECTOR SWITCH PIN NUMBER 1 3 5 6 7 8 9 10

CONNECTOR X-95 - DRIVE PATTERN SELECTOR SWITCH WIRE NUMBER CIRCUIT REFERENCE 522 (YE) CONTROL PATTERN H 521 (YE) CONTROL PATTERN NEUTRAL 199 (OR) CONTROL PATTERN SW INPUT POWER 523 (YE) CONTROL PATTERN ISO 197 (OR) PATTERN INDICATOR H POWER 1024 (BL) PATTERN INDICATOR H LS OUTPUT 1023 (BL) PATTERN INDICATOR ISO LS OUTPUT 198 (OR) PATTERN INDICATOR ISO POWER

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 11 WE Electro hydraulic controls WE Electro hydraulic controls

C232 TIER 4B (FINAL) [NFM402195 - ] L228

CONNECTOR X-111 - CONDENSER RELAY [CAB] PIN NUMBER 1 2 3 5

CONNECTOR WIRE NUMBER 839 (RD) 840 (WH) 237 (WH) 1087 (BK)

X-111 - CONDENSER RELAY [CAB] CIRCUIT REFERENCE CONDENSER RELAY PIN 30 POWER CONDENSER RELAY PIN 86 SIGNAL HVAC CONDENSER FAN POWER CONDENSER RELAY GROUND

CONNECTOR X-113 - FE #2 SWITCH PIN NUMBER D E F

CONNECTOR X-113 - FE #2 SWITCH WIRE NUMBER CIRCUIT REFERENCE 425 (VT) CAB CONSOLE MULTIFUNCTION #2 UP 359 (OR) CAB CONSOLE MULTIFUNCTION #2/#3 POWER 427 (RD) CAB CONSOLE MULTIFUNCTION #2 DOWN

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Wire connectors - Component diagram 20 C232 TIER 4B (FINAL) [NFM402195 - ] L228

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-200 - CHASSIS/REAR LAMP JUMPER INTERFACE PIN NUMBER 1 2 3 4 5 6

CONNECTOR X-200 - CHASSIS/REAR LAMP JUMPER INTERFACE WIRE NUMBER CIRCUIT REFERENCE 766 (VT) LH REAR TURN SIGNAL POWER 763 (VT) RH REAR TURN SIGNAL POWER 717 (VT) LH REAR POSITION LAMP 718 (VT) RH REAR POSITION LAMP 721 (VT) BRAKE LAMP SIGNAL POWER 975 (BK) REAR LAMPS GROUND

87382918

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 23 C232 TIER 4B (FINAL) [NFM402195 - ] L228

WE Electro hydraulic controls WE Electro hydraulic controls

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 25 WE Electro hydraulic controls WE Electro hydraulic controls

C232 TIER 4B (FINAL) [NFM402195 - ] L228

CONNECTOR X-252 - TEMP CONTROL SWITCH PIN NUMBER 1 2 3

CONNECTOR X-252 - TEMP CONTROL SWITCH WIRE NUMBER CIRCUIT REFERENCE 912 (BK) HVAC TEMPERATURE SWITCH GROUND 824 (YE) HVAC TEMPERATURE CONTROL SIGNAL 823 (PK) HVAC TEMPERATURE SW POWER

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Wire connectors - Component diagram 27 C232 TIER 4B (FINAL) [NFM402195 - ] L228

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-271 - WATER VALVE PIN NUMBER A B C D

CONNECTOR X-271 - WATER VALVE WIRE NUMBER CIRCUIT REFERENCE 822 (OR) HVAC WATER VALVE POWER 1013 (BK) WATER VALVE GROUND 824 (YE) HVAC TEMPERATURE CONTROL SIGNAL

CONNECTOR X-275 - A/C SWITCH PIN NUMBER A B C

CONNECTOR X-275 - A/C SWITCH WIRE NUMBER CIRCUIT REFERENCE 825 (OR) HVAC CLUTCH 913 (BK) HVAC COMPRESSOR CLUTCH SW GROUND 829 (WH) A/C SW OUT

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 30 WE Electro hydraulic controls WE Electro hydraulic controls

C232 TIER 4B (FINAL) [NFM402195 - ] L228

CONNECTOR X-300 - HYDRAULIC COUPLER SWITCH PIN NUMBER 1 2 3 9

CONNECTOR X-300 - HYDRAULIC COUPLER SWITCH WIRE NUMBER CIRCUIT REFERENCE 751 (OR) HYDRAULIC COUPLER SW IN 752 (WH) HYDRAULIC COUPLER SIGNAL 918 (BK) HYD COUPLER IND GND

CONNECTOR X-301 - BEACON LAMP SWITCH PIN NUMBER A D E

CONNECTOR X-301 - BEACON LAMP SWITCH WIRE NUMBER CIRCUIT REFERENCE 919 (BK) BEACON SW IND GND 761 (VT) BEACON SW OUTPUT 796 (VT) BEACON POWER

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Electrical systems - Harnesses and connectors

CONNECTOR X-302 - HAZARD LAMP SWITCH PIN NUMBER A B C E F

CONNECTOR X-302 - HAZARD LAMP SWITCH WIRE NUMBER CIRCUIT REFERENCE 776 (VT) HAZARD SW LH TURN SIGNAL OUTPUT 784 (OR) LH HAZARD FLASHER POWER IN 920 (BK) HAZARD SW INDICATOR GROUND 785 (OR) RH HAZARD FLASHER POWER IN 778 (VT) HAZARD SW RH TURN SIGNAL OUTPUT

CONNECTOR X-303 - HI FLOW SWITCH PIN NUMBER A B C E

CONNECTOR X-303 - HI FLOW SWITCH WIRE NUMBER CIRCUIT REFERENCE 755 (WH) HIGH PERFORMANCE HIGH FLOW SIGNAL 753 (OR) HIGH FLOW SW IN 750 (WH) STANDARD HIGH FLOW SIGNAL 921 (BK) HIGH FLOW SW INDICATOR GROUND

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Electrical systems - Harnesses and connectors

CONNECTOR X-306 - LOADER LOCKOUT SWITCH PIN NUMBER A B C E

CONNECTOR WIRE NUMBER 312 (YE) 311 (OR) 398 (YE) 924 (BK)

X-306 - LOADER LOCKOUT SWITCH CIRCUIT REFERENCE LOADER LOCK SW N.C. OUTPUT (VALVE ON) LOADER LOCKOUT SW PWR LOADER LOCKOUT SW N.O. OUTPUT (VALVE OFF) LOADER LOCK SW INDICATOR GROUND

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 31 C232 TIER 4B (FINAL) [NFM402195 - ] L228

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-310 - 2 SPD INDICATOR PIN NUMBER 7 9

CONNECTOR X-310 - 2 SPD INDICATOR WIRE NUMBER CIRCUIT REFERENCE 565 (VT) 2 SPEED INDICATOR 917 (BK) 2 SPEED INDICATOR GROUND

CONNECTOR X-317 - SELF LEVEL SWITCH PIN NUMBER A B E

CONNECTOR X-317 - SELF LEVEL SWITCH WIRE NUMBER CIRCUIT REFERENCE 404 (WH) SELF LEVEL SW OUTPUT POWER 405 (OR) SELF LEVEL SW POWER 922 (BK) SELF LEVEL SW IND GROUND

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 32 C232 TIER 4B (FINAL) [NFM402195 - ] L228

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-323 - CHASSIS OPTION/MULTIFUNCTION INTERCONNECT CONNECTOR X-323 - CHASSIS OPTION/MULTIFUNCTION INTERCONNECT PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE 1 419 (LG) LH HANDLE MULTIFUNCTION #3 DOWN 2 418 (GY) LH HANDLE MULTIFUNCTION #3 UP 3 410 (WH) RH HANDLE MULTIFUNCTION #1 UP 4 411 (TN) RH HANDLE MULTIFUNCTION #1 DOWN 5 416 (VT) MULTIFUNCTION #2 UP 6 417 (RD) MULTIFUNCTION #2 DOWN 7 982 (BK) MULTIFUNCTION GROUND 8 856 (WH) AUX ELEC ON/OFF SW SIGNAL 9 420 (OR) MULTIFUNCTION FUSE POWER 10 423 (YE) EHF INTERLOCK

87382922

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 33 C232 TIER 4B (FINAL) [NFM402195 - ] L228

WE Electro hydraulic controls WE Electro hydraulic controls

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Electrical systems - Harnesses and connectors

CONNECTOR X-335 - RADIO CONNECTOR PIN NUMBER 2 4 5 6 7 9

84257494

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 36 WE Electro hydraulic controls WE Electro hydraulic controls

C232 TIER 4B (FINAL) [NFM402195 - ] L228

CONNECTOR X-365 - NH PARK BRAKE SWITCH PIN NUMBER 2 3

CONNECTOR X-365 - NH PARK BRAKE SWITCH WIRE NUMBER CIRCUIT REFERENCE 194 (OR) RH CONSOLE PARK BRAKE SW PWR 306 (YE) RH CONSOLE PARK BRAKE SW OUT

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 40 C232 TIER 4B (FINAL) [NFM402195 - ] L228

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-403 - RH HANDLE INTERCONNECT FE/PROPORTIONAL AUX/FLOAT

1 2 3 5 6 7 8 9 10 11 12 13 14

CONNECTOR X-403 - RH HANDLE INTERCONNECT FE/PROPORTIONAL AUX/FLOAT PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE 213 (PK) PROPORTIONAL AUX SW #2 REFERENCE 547 (YE) PROPORTIONAL AUX SW OUTPUT SIGNAL #2 1052 (BK/WH) PROPORTIONAL AUX SW #2 GROUND 352 (OR) RH HANDLE MULTIFUNCTION #1/#2 POWER 410 (WH) RH HANDLE MULTIFUNCTION #1 UP 411 (TN) RH HANDLE MULTIFUNCTION #1 DOWN 412 (VT) RH HANDLE MULTIFUNCTION #2 UP 413 (RD) RH HANDLE MULTIFUNCTION #2 DOWN 214 (PK) PROPORTIONAL AUX SW #1 REFERENCE 546 (YE) PROPORTIONAL AUX SW OUTPUT SIGNAL #1 1053 (BK/WH) PROPORTIONAL AUX SW #1 GROUND 406 (OR) FLOAT SW INPUT VOLTAGE 531 (YE) LOADER FLOAT SW INPUT

87382928

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Electrical systems - Harnesses and connectors

CONNECTOR X-406 - RH HANDLE INTERCONNECT PARK BRAKE/RIDE CTRL CONNECTOR X-406 - RH HANDLE INTERCONNECT PARK BRAKE/RIDE CTRL PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE A 324 (OR) RH GRIP PARK BRAKE SW POWER B 307 (YE) RH GRIP PARK BRAKE SW OUTPUT C 832 (OR) RIDE CONTROL VALVE SOLENOID SW POWER D 831 (WH) RIDE CONTROL VALVE SOLENOID SIGNAL

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Electrical systems - Harnesses and connectors

CONNECTOR X-408 - LH HANDLE INTERCONNECT PIN NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14

CONNECTOR WIRE NUMBER 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)

X-408 - LH HANDLE INTERCONNECT CIRCUIT REFERENCE 2ND AUX SW POWER 2ND AUX EXTEND SW 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 SW 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

87382929

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 41 C232 TIER 4B (FINAL) [NFM402195 - ] L228

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-411 - FLASHER MODULE PIN NUMBER 1 2 3

CONNECTOR X-411 - FLASHER MODULE WIRE NUMBER CIRCUIT REFERENCE 156 (RD) FLASHER/BRAKE FUSE POWER 981 (BK) FLASHER GROUND 769 (OR) FLASHER MODULE OUTPUT POWER

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 50 C232 TIER 4B (FINAL) [NFM402195 - ] L228

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-502 - DOOR WIPER MOTOR PIN NUMBER A B C D

CONNECTOR X-502 - DOOR WIPER MOTOR WIRE NUMBER CIRCUIT REFERENCE 227 (WH) DOOR WIPER MOTOR SIGNAL 929 (BK) DOOR WIPER MOTOR GROUND 231 (OR) DOOR WIPER MOTOR PARK 220 (YE) DOOR SW BYPASS

CONNECTOR X-502A - REAR WINDOW WIPER MOTOR PIN NUMBER A B C

CONNECTOR X-502A - REAR WINDOW WIPER MOTOR WIRE NUMBER CIRCUIT REFERENCE 228 (WH) REAR WINDOW WIPER MOTOR SIGNAL 930 (BK) REAR WINDOW WIPER MOTOR GROUND 232 (OR) REAR WINDOW WIPER MOTOR PARK

87693712

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Electrical systems - Harnesses and connectors

CONNECTOR X-503 - WIPER/WASHER SWITCH PIN NUMBER 1 2 3 5 6 7 8

CONNECTOR X-503 - WIPER/WASHER SWITCH WIRE NUMBER CIRCUIT REFERENCE 931 (BK) WIPER/WASHER SW GROUND 225 (WH) MOTOR/IND OUT 229 (OR) WIPER/WASHER SWITCH MOTOR POWER IN 224 (WH) WASHER PUMP SIGNAL 230 (OR) WIPER/WASHER SW PUMP POWER IN 226 (VT) INDICATOR SIGNAL 932 (BK) SW INDICATOR GROUND

87716755

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 90 C232 TIER 4B (FINAL) [NFM402195 - ] L228

WE Electro hydraulic controls WE Electro hydraulic controls

47683911 27/02/2015

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Electrical systems - Harnesses and connectors

CONNECTOR X-902 - FUSE RELAY GROUND PIN NUMBER A B C D E F

CONNECTOR X-902 - FUSE RELAY GROUND WIRE NUMBER CIRCUIT REFERENCE 1095 (BK) OPTION RELAY COIL GROUND 1098 (BK) OPTION RELAY COIL GROUND 1092 (BK) OPTION RELAY COIL GROUND 1097 (BK) OPTION RELAY COIL GROUND 1094 (BK) CAB GROUND B 1096 (BK) OPTION RELAY COIL GROUND

47683911 27/02/2015

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram - Connectors A - Z WE Electro hydraulic controls WE Electro hydraulic controls

C232 TIER 4B (FINAL) [NFM402195 - ] L228

CONNECTOR X-C23 - INSTRUMENT CLUSTER PIN NUMBER 2 3 5 6 7 8 9 10 11 12 13 16 17 19 22 24 25 29 30 32 33 34

CONNECTOR X-C23 - INSTRUMENT CLUSTER WIRE NUMBER CIRCUIT REFERENCE 261 HYDRAULIC OIL FILTER 624 KEY START OUTPUT 505 CAN LO 500 CAN HI INSTRUMENT CLUSTER 301 SWITCHED POWER INSTRUMENT CLUSTER 302 SWITCHED POWER INSTRUMENT CLUSTER 313 UNSWITCHED POWER 132 KEY IGNITION AIR FILTER/ENGINE 267 MALFUNCTION 328 SEAT SW CLUSTER INPUT 205C TELEMATICS CRANK DISABLE 264 HYDRAULIC OIL TEMP SENDER 259 THROTTLE SENSOR SUPPLY 251 DOOR SW SIGNAL 543 THROTTLE SIGNAL 234 FUEL LEVEL SENDER 1070 THROTTLE SENSOR GROUND 137 ACCESSORY RELAY SIGNAL HYDRAULIC LOADER INTERLOCK 303 SIGNAL 622 START SIGNAL FROM CLUSTER 133 MAIN POWER RELAY SIGNAL 1011 INSTRUMENT CLUSTER GROUND

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Electrical systems - Harnesses and connectors

82028495

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Electrical systems - Harnesses and connectors

CONNECTOR CN1A - UCM CN1A PIN NUMBER 1 7 8 9 13 14 16 19

CONNECTOR CN1A - UCM CN1A WIRE NUMBER 1075 1076 202 200 1018 525 124 1022

189

1020

515

240

82016219

RAPH12SSL0240AA

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Electrical systems - Harnesses and connectors

CONNECTOR CN1B - UCM CN1B PIN NUMBER 1 9 13 15 26 27 29 30 31 32

CONNECTOR CN1B - UCM CN1B WIRE NUMBER 1026 1025 560 521 128 126 580 579 166 201

514

87410946

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Electrical systems - Harnesses and connectors

CONNECTOR CN2A - UCM CN2A PIN NUMBER 2 3 4 5 7 8 9 13 14 20 23 25 26

82028493

47683911 27/02/2015

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Electrical systems - Harnesses and connectors

RAPH12SSL0240AA

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Electrical systems - Harnesses and connectors

CONNECTOR CN2B - UCM CN2B PIN NUMBER 1

CONNECTOR CN2B (2) - UCM CN2B WIRE NUMBER 503E

1023

7 8

1019 1099

154

10 13 14

504E 535 562

158

20 21 22

522 523 754

398

532

25 26 27

1021 1028 531

547

31 32 33 34

568 576 575 1029

82028495

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Electrical systems - Harnesses and connectors

RAPH12SSL0240AA

47683911 27/02/2015

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Electrical systems - Harnesses and connectors

CONNECTOR CN3A - UCM CN3A PIN NUMBER 2 3 4 6 7 9 10 11 13 19 20 21 22 23 25 26

84130757

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Electrical systems - Harnesses and connectors

RAPH12SSL0240AA

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Electrical systems - Harnesses and connectors

CONNECTOR CN3B - UCM CN3B PIN NUMBER

CONNECTOR CN3B (3) - UCM CN3B WIRE NUMBER

167

6 8 9

513 142 147

755

570

571

572

17 18

510 895

312

1032

554

526

552

32 33 34

519 516 1033

CNH_84130760AAO

47683911 27/02/2015

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Electrical systems - Harnesses and connectors

RAPH12SSL0240AA

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Electrical systems - Harnesses and connectors

CONNECTOR CN4A - UCM CN4A PIN NUMBER 1 8

CONNECTOR CN4A (4) - UCM CN4A WIRE NUMBER 0060 0061

524

17 18 19 20 24 25 26

561 569 511 1034 549 567 1035

82028493

RAPH12SSL0240AA

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Electrical systems - Harnesses and connectors

CONNECTOR CN4B - UCM CN4B PIN NUMBER 13 15

CONNECTOR CN4B (4) - UCM CN4B WIRE NUMBER 423 541

546

27 34

1036 1037

82028495

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CIRCUIT REFERENCE EHF INTERLOCK 2 SPEED UCM INPUT PROPORTIONAL AUX SWITCH OUTPUT SIGNAL #1 UCM GROUND 4B.27 UCM GROUND 4B.34

Electrical systems - Harnesses and connectors

CONNECTOR X-CO1A - CAB/CHASSIS OPTIONS 1 PIN NUMBER 1 2 5 6 7 10

SL57_87382924

CONNECTOR X-CO2A - CAB/CHASSIS OPTIONS 2 PIN NUMBER 1 2 3 4 5 7 8

84257541

47683911 27/02/2015

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Electrical systems - Harnesses and connectors

84497873

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Electrical systems - Harnesses and connectors

CONNECTOR ECC1A - CHASSIS/CAB INTERFACE -1PIN NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14

CONNECTOR ECC1A - CHASSIS/CAB INTERFACE -1WIRE NUMBER CIRCUIT REFERENCE LIGHT RELAY #1 FRONT WORK 797 LAMP POWER 795 SIDE LAMP POWER SIGNAL 503 CAN HI 504 CAN LO 791 LAMP SW ROAD LAMP SIGNAL LAP BAR/SEAT BELT CLUSTER 314 INPUT 910 CAB/CLUSTER CLEAN GROUNDS 234 FUEL LEVEL SENDER MAIN POWER RELAY IGNITION 357 FUSE 115 BEACON/ACC FUSE OUT 264 HYDRAULIC OIL TEMP SENDER UNSWITCHED BATTERY FUSE 310 POWER 545 FOOT THROTTLE SIGNAL 790 LAMP SW WORK LAMP SIGNAL

87382926

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Electrical systems - Harnesses and connectors

CONNECTOR ECC1B - UCM ECC1B PIN NUMBER

CONNECTOR ECC1B - UCM ECC1B WIRE NUMBER

798

2 3 4 5

795 503A 504A 791

314

7 8

910 234

357

115

264

310

545

790

87382927

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CIRCUIT REFERENCE LIGHT RELAY #1 FRONT WORK LAMP POWER SIDE LAMP POWER SIGNAL CAN HI CAN LO ROAD LAMP SIGNAL LAP BAR / SEAT BELT CLUSTER INPUT CAB/CLUSTER CLEAN GROUNDS FUEL LEVEL SENDER MAIN POWER RELAY IGNITION FUSE TO CAB BEACON/ACC FUSE OUT HYDRAULIC OIL TEMPERATURE SENDER UNSWITCHED BATTERY FUSE POWER FOOT THROTTLE SIGNAL LAMP SWITCH WORK LAMP SIGNAL

Electrical systems - Harnesses and connectors

RAPH12SSL0251AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-ECC2A - CHASSIS/CAB INTERFACE -2CONNECTOR X-ECC2A - CHASSIS/CAB INTERFACE -2PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE 1 134 ACCESSORY FUSE POWER 3 329 SEAT SWITCH UCM INPUT INSTRUMENT CLUSTER 4 309 SWITCHED POWER HYDRAULIC LOADER INTERLOCK 5 303 SIGNAL 6 261 HYDRAULIC OIL FILTER AIR FILTER/ENGINE 7 267 MALFUNCTION FOOT THROTTLE SENSOR 8 1066 GROUND HVAC FUSE TO HVAC BOX 9 843 -VOLTAGE DROP PARALLEL CIRCUIT 10 622 START SIGNAL FROM CLUSTER 11 133 MAIN POWER RELAY SIGNAL 12 175 ACC & OPTION RELAY SIGNALS FOOT THROTTLE SENSOR 13 211 SUPPLY 14 822 HVAC WATER VALVE POWER

87382927

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Electrical systems - Harnesses and connectors

CONNECTOR ECC2B - CHASSIS/CAB INTERFACE -2PIN NUMBER 1 3 4 5 6 7 8 9 10 11 12 13 14

CONNECTOR ECC2B - CHASSIS/CAB INTERFACE -2WIRE NUMBER CIRCUIT REFERENCE 134 ACCESSORY FUSE POWER 329 SEAT SWITCH UCM INPUT 309 CLUSTER SWITCHED POWER HYDRAULIC LOADER INTERLOCK 303 SIGNAL 261 HYDRAULIC OIL FILTER AIR FILTER / ENGINE 267 MALFUNCTION 1066 FOOT THROTTLE GROUND HVAC FUSE - VOLTAGE DROP 843 PARALLEL CIRCUIT 622 START SIGNAL FROM CLUSTER 133A MAIN PWR RLY SIGNAL 175 ACC/OPT SIGNALS FOOT THROTTLE SENSOR 211 SUPPLY 822 HVAC WATER VALVE POWER

87382926

47683911 27/02/2015

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Electrical systems - Harnesses and connectors

RAPH12SSL0251AA

47683911 27/02/2015

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Electrical systems - Harnesses and connectors

CONNECTOR X-ECC3A - CHASSIS/CAB INTERFACE -3CONNECTOR X-ECC3A - CHASSIS/CAB INTERFACE -3PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE 1 404 SELF LEVEL SW OUTPUT POWER 2 248 EGR ECU K-LINE HVAC TEMPERATURE CONTROL 3 824 SIGNAL 4 1090 UJM SENSOR GROUNDS 4A.20 LAMP SW WORK AND SIDE LAMP 5 792 SIGNAL PATTERN INDICATOR ISO LS 6 1023 OUTPUT THERMOSTAT TO BINARY 7 833 PRESSURE SW PATTERN INDICATOR H LS 8 1024 OUTPUT 9 754 PARK BRAKE SW 10 123 LAMP SW POWER

84394888

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Electrical systems - Harnesses and connectors

CONNECTOR ECC3B - CHASSIS/CAB INTERFACE -3PIN NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14

CONNECTOR ECC3B - CHASSIS/CAB INTERFACE -3WIRE NUMBER CIRCUIT REFERENCE SELF LEVEL SWITCH OUTPUT 404 POWER 248 EGR ECU K-LINE HVAC TEMPERATURE CONTROL 824 SIGNAL 1090 UJM SENSOR GROUNDS 4A.20 LAMP SWITCH WORK AND SIDE 792 LAMP SIGNAL PATTERN INDICATOR ISO LS 1023 OUTPUT 833 THERMOSTAT TO PRES SW PATTERN INDICATOR H LS 1024 OUTPUT 754 PARK BRAKE SWITCH 123 LAMP SELECTOR SW POWER 541 2 SPEED UCM INPUT 531 LOADER FLOAT SWITCH INPUT 834 PRESS SW TO COMP RLY HVAC FUSE - VOLTAGE DROP 844 PARALLEL CIRCUIT

84394890

47683911 27/02/2015

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Electrical systems - Harnesses and connectors

RAPH12SSL0251AA

47683911 27/02/2015

55.8 [55.100] / 387

Electrical systems - Harnesses and connectors

CONNECTOR X-ECC4A - CHASSIS/CAB INTERFACE -4CONNECTOR X-ECC4A - CHASSIS/CAB INTERFACE -4PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE FLASHER MODULE OUTPUT 1 769 POWER LH TURN SIGNAL CHASSIS 2 774 POWER LOADER LOCKOUT SW N.O. 3 398 OUTPUT (VALVE OFF) 4 521 CONTROL PATTERN NEUTRAL 5 237 HVAC CONDENSER FAN POWER RH TURN SIGNAL CHASSIS 6 780 POWER A/C COMPRESSOR RELAY PIN 87 7 841 POWER COMPRESSOR/CONDENSER FAN 8 836 FUSE 9 522 CONTROL PATTERN H 10 233 WIPER/WASHER FUSE POWER 11 523 CONTROL PATTERN ISO LOADER LOCK SW N.C. OUTPUT 12 312 (VALVE ON) 13 548 RH UA2 X SENSOR OUTPUT 14 560 RH UA2 Y SENSOR OUTPUT

84394890

CONNECTOR ECC4B - CHASSIS/INTERFACE -4PIN NUMBER 1

CONNECTOR ECC4B - CHASSIS/INTERFACE -4WIRE NUMBER CIRCUIT REFERENCE FLASHER MODULE OUTPUT 769 POWER 47683911 27/02/2015

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Electrical systems - Harnesses and connectors

774

398

4 5

521 237

780

841

836

9 10 11

522 233 523

312

13 14

548 560

84394888

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 COMP RELAY PWR COMPRESSOR / CONDENSER FAN FUSE CONTROL PATTERN H WIPER / WASHER FUSE POWER CONTROL PATTERN ISO LOADER LOCK SWITCH N.C. OUTPUT (VALVE ON) RH UA2 X SENSOR OUTPUT RH UA2 Y SENSOR OUTPUT

RAPH12SSL0251AA

47683911 27/02/2015

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Electrical systems - Harnesses and connectors

CONNECTOR X-ECC5A - CHASSIS/CAB INTERFACE -5CONNECTOR X-ECC5A - CHASSIS/CAB INTERFACE -5PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE 1 129 AUX ELEC ON/OFF FUSE POWER 2 856 AUX ELEC ON/OFF SW SIGNAL 3 549 RH UA1 X SENSOR OUTPUT HIGH FLOW/HYDRAULIC 4 744 COUPLER FUSE POWER 5 752 HYDRAULIC COUPLER SIGNAL HIGH PERFORMANCE HIGH FLOW 755 6 SIGNAL RIDE CONTROL VALVE SOLENOID 7 831 SIGNAL 8 750 STANDARD HIGH FLOW SIGNAL 9 561 RH UA1 Y SENSOR OUTPUT 10 1051 UJM SENSOR GROUNDS 2A.26 11 562 LH UA2 X SENSOR OUTPUT 12 568 LH UA2 Y SENSOR OUTPUT 13 554 2ND AUX EXTEND SW OUTPUT 2ND AUX RETRACT SIGNAL 14 552 POWER

84398821

CONNECTOR ECC5B - CHASSIS/CAB INTERFACE -5- ENHANCED HIGH FLOW CONNECTOR ECC5B - CHASSIS/CAB INTERFACE -5- ENHANCED HIGH FLOW PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE 1 129 AUX ELEC ON/OFF FUSE POWER AUX ELEC ON/OFF SWITCH 2 856 SIGNAL 3 549 RH UA1 X SENSOR OUTPUT

47683911 27/02/2015

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Electrical systems - Harnesses and connectors

744

752

755

831

8 9 10 11 12

750 561 1051 562 568

554

552

84394889

HIGH FLOW / HYDRAULIC COUPLER FUSE 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 LH UA2 X SENSOR OUTPUT LH UA2 Y SENSOR OUTPUT 2ND AUX EXTEND SWITCH OUTPUT 2ND AUX RETRACT SIGNAL POWER

RAPH12SSL0251AA

47683911 27/02/2015

55.8 [55.100] / 391

Electrical systems - Harnesses and connectors

CONNECTOR ECC5B - CHASSIS/ CAB INTERFACE -5PIN NUMBER 1 2 3 4 5 6 7 8 8 9 10 11 12 13 13 14 14

CONNECTOR ECC5B - CHASSIS/ CAB INTERFACE -5WIRE NUMBER CIRCUIT REFERENCE 129 AUX ELEC ON/OFF FUSE POWER AUX ELEC ON/OFF SWITCH 856 SIGNAL 549 RH UA1 X SENSOR OUTPUT HIGH FLOW / HYDRAULIC 744 COUPLER FUSE POWER 752 HYDRAULIC COUPLER SIGNAL HIGH PERFORMANCE HIGH FLOW 755 SIGNAL RIDE CONTROL VALVE SOLENOID 831 SIGNAL 750-1 STANDARD HIGH FLOW SIGNAL 750 STANDARD HIGH FLOW SIGNAL 561 RH UA1 Y SENSOR OUTPUT 1051 UJM SENSOR GROUNDS 562 LH UA2 X SENSOR OUTPUT 568 LH UA2 Y SENSOR OUTPUT 2ND AUX EXTEND SWITCH 554 OUTPUT 2ND AUX EXTEND SWITCH 554-1 OUTPUT 2ND AUX RETRACT SIGNAL 552-1 POWER 2ND AUX RETRACT SIGNAL 552 POWER

SL57_84394889

47683911 27/02/2015

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Electrical systems - Harnesses and connectors

RAPH12SSL0251AA

47683911 27/02/2015

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Electrical systems - Harnesses and connectors

CONNECTOR X-ECC6A - CHASSIS/CAB INTERFACE -6CONNECTOR X-ECC6A - CHASSIS/CAB INTERFACE -6PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE 1 567 LH UA1 X SENSOR OUTPUT 2 569 LH UA1 Y SENSOR OUTPUT HANDLE MULTIFUNCTION #1, #2, 3 354 #3 FUSE POWER RH HANDLE MULTIFUNCTION #1 4 410 UP RH HANDLE MULTIFUNCTION #1 5 411 DOWN 6 416 MULTIFUNCTION #2 UP 7 417 MULTIFUNCTION #2 DOWN LH HANDLE MULTIFUNCTION #3 8 418 UP LH HANDLE MULTIFUNCTION #3 9 419 DOWN 10 892 HORN POWER SIGNAL PROPORTIONAL AUX SW OUTPUT 11 546 SIGNAL #1 12 210 CAB SENSOR SUPPLY 1 13 200 SENSOR SUPPLY 3 PROPORTIONAL AUX SW OUTPUT 14 547 SIGNAL #2

84394889

CONNECTOR ECC6B - CHASSIS/CAB INTERFACE -6PIN NUMBER 1 2

CONNECTOR ECC6B - CHASSIS/CAB INTERFACE -6WIRE NUMBER CIRCUIT REFERENCE 567 LH UA1 X SENSOR OUTPUT 569 LH UA1 Y SENSOR OUTPUT 47683911 27/02/2015

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354

410

411

416

417

418

419

892

546

12 13

210 200

547

84398821

HANDLE MULTIFUNCTION #1, #2, #3 FUSE 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

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RAPH12SSL0251AA

CONNECTOR FUSE1 - MAIN POWER DISTRIBUTION FUSE BLOCK #1 CONNECTOR FUSE1 - MAIN POWER DISTRIBUTION FUSE BLOCK #1 PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE A1 830 HVAC FUSE INPUT LIGHT RELAY #1 PIN 85 COIL A12 946 GROUND A2 820 HVAC RELAY FUSE POWER A3 528B ECU FUSE 1 IN A4 110 ECU FUSE 1 POWER A5 528C ECU FUSE 2 IN A6 155A ECU FUSE 2 POWER LIGHT RLY #2 PIN 87 SIDE LMP A7 707 SW REAR WORK LMP OUT LIGHT RELAY #2 PIN 85 COIL A9 945 GROUND A10 116 LIGHT RELAY #1 PIN 87 B+ STD LAMP CONFIG FRONT WORK A11 710 LAMP CONTROL SIGNAL B1 183 UCM BACKUP ALARM FUSE IN UCM BACKUP ALARM FUSE B2 167 POWER B3 528D ENGINE SENSORS FUSE IN B4 241A ENGINE SENSORS FUSE POWER B7 709 LIGHT RELAY #2 COIL POWER B9 113 LIGHT RELAY #2 B+ LIGHT RELAY #1 PIN 86 WORK B10 325 LAMP SWITCH SIGNAL LIGHT RELAY #1 PIN 30 TO FUSE B12 788 (FRONT WORK LAMP POWER) 135 C1 ACC FUSE IN 47683911 27/02/2015

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134

350

C4 C5

351 835

836

136

947

C10

125

C12

948

160

310

326

300

D5 D6 D7

114 196 144

118

D10 D12

139 117

788

797

792

E4 E5 E6

708 705 706

701

703

700

E10 E11 E12

704 255 256

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ACCESSORY FUSE POWER MAIN PWR RLY TO IGNITION FUSE IN INGITION FUSE POWER COMPRESSOR FUSE INPUT COMPRESSOR / CONDENSER FAN FUSE MAIN PWR RLY OUT MAIN POWER RELAY PIN 85 COIL GROUND ACC RLY OUT ACCESSORY RELAY PIN 85 COIL GROUND UNSWITCHED BATTERY POWER UNSWITCHED BATTERY FUSE POWER MAIN PWR RLY TO CLUSTER FUSE IN INSTRUMENT CLUSER FUSE POWER BEACON/ACC FUSE INPUT B+ ACC/BEACON FUSE POWER MAIN POWER RELAY SIGNAL MAIN POWER RELAY PIN 30 UNSWITCHED BATTERY ACCESSORY RELAY SIGNAL ACCESSORY RELAY PIN 30 B+ LIGHT RELAY #1 PIN 30 TO FUSE (FRONT WORK LAMP POWER) FRONT WORK LAMPS FUSE POWER LAMP SWITCH WORK AND SIDE LAMP SIGNAL SIDE LAMPS FUSE POWER REAR WORK LAMP FUSE IN REAR WORK LAMP FUSE POWER TAIL LAMP SPLICE LH TAIL LAMP FUSE IN LH TAIL LAMP FUSE POWER TAIL LAMP SPLICE RH TAIL LAMP FUSE IN RH TAIL LAMP FUSE POWER CRANK RELAY FUSE INPUT CRANK FUSE POWER

Electrical systems - Harnesses and connectors

84255438

CONNECTOR FUSE2 - MAIN POWER DISTRIBUTION FUSE BLOCK #2 CONNECTOR FUSE2 - MAIN POWER DISTRIBUTION FUSE BLOCK #2 PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE A1 173 UCM BRAKE LAMP FUSE IN A2 172 BRK LMP FUSE PWR A3 184 UCM PARK BRAKE FUSE IN A4 185 DRIVE/INT FUSE PWR A5 187 UCM PUMP REVERSE FUSE IN A6 122 PUMP REV FUSE PWR UCM POWER RELAY PIN 87 A7 190 OUTPUT UCM POWER RELAY COIL A9 1067 GROUND A10 743 OPT RELAY OUT TO FUSE A12 972 OPTION RELAY COIL GROUND B1 174 PROPORTIONAL AUX FUSE IN B2 177 PROP AUX FUSE PWR B3 203 UCM PUMP FORWARD FUSE IN B4 120 PUMP FORWARD FUSE POWER B5 181 UCM LOADER FUSE IN B6 178 UCM BOOM FUSE PWR B7 335 UCM PWR RLY SIGNAL B9 193 UCM POWER RELAY B+ B10 148 OPTION RELAY COIL SIGNAL B12 104 OPTION RELAY PIN 30 B+ 356 C1 MULTIFUNCTION FUSE IN 420 C2 MULTIFUNCTION FUSE POWER UCM PORT/PILOT INTERLOCK 180 C3 FUSE IN 182 C4 UCM INTLK FUSE PWR

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188

189

C10

149

C12

974

355

354

D3 D4

204 176

243

233

D10

146

D12 E1 E2 E3 E4 E5

103 145 129 186 179 714

716

715

719

E9 E10 E11

157 156 743

E12

744

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UCM UNSWITCHED BATTERY FUSE IN UCM UNSWITCHED BATTERY FUSE POWER FE RLY OUT FRONT ELECTRIC RELAY COIL GROUND HANDLE MF #1, #2, #3 FUSE IN HANDLE MULTIFUNCTION #1, #2, #3 FUSE POWER UCM BUCKET FUSE IN BUCKET FUSE PWR WIPER/WASHER SWITCH POWER FROM ACC RELAY WIPER / WASHER FUSE POWER FRONT ELECTRIC RELAY COIL SIGNAL MULTIFUNCTION RELAY PIN 30 B+ AUX ELEC ON/OFF FUSE IN AUX ELEC ON/OFF FUSE POWER UCM 2SPD FUSE IN UCM 2SPD FUSE PWR LH BOOM ROAD LAMPS FUSE IN LH BOOM ROAD LAMPS FUSE POWER RH BOOM ROAD LAMPS FUSE IN RH BOOM ROAD LAMPS FUSE POWER B+ TO FLASHER/BRAKE FUSE IN FLASHER/BRAKE FUSE POWER OPT RELAY OUT TO FUSE HIGH FLOW / HYDRAULIC COUPLER FUSE POWER

Electrical systems - Harnesses and connectors

84255438

CONNECTOR FUSE2 - POWER DISTRIBUTION PIN NUMBER A10 A12 C1 C2 C10 C12 D1 E1 E5 E6 E7 E8 E11

CONNECTOR FUSE2 - POWER DISTRIBUTION WIRE NUMBER CIRCUIT REFERENCE 743 OPT RELAY OUT TO FUSE 972 OPTION RELAY COIL GROUND 356 MULTIFUNCTION FUSE IN 420 MULTIFUNCTION FUSE POWER 149 FE RLY OUT FRONT ELECTRIC RELAY COIL 974 GROUND 355 HANDLE MF #1, #2, #3 FUSE IN 145 AUX ELEC ON/OFF FUSE IN 714 LH BOOM ROAD LAMPS FUSE IN LH BOOM ROAD LAMPS FUSE 716 POWER 715 RH BOOM ROAD LAMPS FUSE IN RH BOOM ROAD LAMPS FUSE 719 POWER 743 OPT RELAY OUT TO FUSE

CONNECTOR X-HVC1 - CAB/HVAC INTERCONNECT PIN NUMBER 1 2 3 4 5

CONNECTOR X-HVC1 - CAB/HVAC INTERCONNECT WIRE NUMBER CIRCUIT REFERENCE 935 HVAC GND COMPRESSOR RELAY PIN 30 838 POWER 828 HVAC FAN LOW 827 HVAC FAN MEDIUM 850 HVAC FAN HIGH

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837

7 8 9

833 834 1012

842

11 12 14

143 841 845

87382926

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A/C SW COMPRESSOR RELAY PIN 86 VIA PRESSURE SW THERMOSTAT TO PRES SW PRES SW TO COMP RLY HVAC THERMOSTAT CLEAN GND HVAC RELAY PIN 87 OUTPUT POWER HVAC KEYED POWER A/C COMP RLY PIN 87 POWER HVAC RELAY FUSE POWER

Electrical systems - Harnesses and connectors

87382914

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Electrical systems - Harnesses and connectors

CONNECTOR TELE - TELEMATICS PIN NUMBER

CONNECTOR TELE - TELEMATICS WIRE NUMBER

336

802

244

E H L M S

308 925 503D 504D 205A

87696550

RAPH12SSL0240AA

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CONNECTOR X-UJML - UJM LH PIN NUMBER 1 2 3 4 7 8 9 10

CONNECTOR X-UJML - UJM LH WIRE NUMBER 215 567 569 1045 218 562 568 1046

SL57_87694583

CONNECTOR X-UJMR - UJM RH PIN NUMBER 1 2 3 4 7 8 9 10

CONNECTOR X-UJMR - UJM RH WIRE NUMBER 219 549 561 1047 217 548 560 1048

SL57_87694583

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Wire connectors - Component diagram - Grounds C232 TIER 4B (FINAL) [NFM402195 - ] L228

WE Electro hydraulic controls WE Electro hydraulic controls

Ground locations Grounds NEG_TERM_A Main chassis ECU

(1) (2) (3)

RAPH12SSL0239AA

Ground location for the ECU, NEG_TERM_A, and the main chassis Grounds X-CAB_GNDA X-CAB_GNDB

(1) (2)

RAPH12SSL0248AA

Ground location for X-CAB_GNDA and X-CAB_GNDB

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Electrical systems - Harnesses and connectors

Grounds CHS_GND_RR OPT_GND_RR

(1) (2)

RAPH12SSL0252AA

Ground location for CHS_GND_RR and OPT_GND_RR Grounds UCM_GND CHS_GND_FRT OPT_GND_FRT

(1) (2) (3)

RAPH12SSL0251AA

Ground location for UCM_GND, CHS_GND_FRT, and OPT_GND_FRT

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Fuse and relay box Relay - Overview C227 C232 L228

WE WE WE

1Z0O2004112131

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

A switch-relay system has two main advantages over a simple switch: • The current that flows through the switch is not the same as all the current requested by the equipment to be operated, but usually by a smaller current: this allows the usage of smaller and less expensive switches; • The distance from the supply, to the equipment, can be made as short as possible to minimize voltage drop.

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50004701

On the relay cover there are 4 or 5 terminal markings: • 3 or 30: input terminal direct from battery positive, normally live. • 2 or 85: winding output terminal, usually to ground. • 1 or 86: winding input terminal. • 4 or 87: output terminal for normally closed contact. • 5 or 87a: output terminal for normally open contact.

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Fuse and relay box Fuse - Overview C227 C232 L228

WE WE WE

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

The rating of the fuse relates to the current, in amperes, that the fuse can carry continuously. If a fuse fails, replace the fuse with same type and amp rating. Once replaced, if it fails again, the cause for the over-current condition must be investigated and corrected. There are a number of methods that can be used to verify the condition of a fuse. The fuse can be removed from the fuse and relay panel socket and visually inspected to determine if the link has been melted. A continuity test can be performed across the fuse terminals, while the fuse is removed from the fuse and relay panel, if it is not visually apparent that the fuse link is blown. If one of the fuse terminals is connected to battery or switched battery power, a voltage test to ground can be performed from one of the exposed terminals (1) and then the other (1), the battery or switched battery voltage should be seen on both tests (terminals). If battery or switched battery power is NOT connected to either fuse terminal or the power has been disconnected and the fuse is NOT part of a continuous electrical circuit then the fuse can be continuity tested in place in the fuse and relay panel, by checking continuity across the fuse on the two exposed terminals (1). NOTICE: If not certain of exact circuit conditions, performing continuity tests on fuses should be done with the fuse removed from the fuse and relay panel. Performing the test with the fuse still installed in its socket in the fuse and relay panel could provide false indications of the actual fuse condition.

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Fuse and relay box - Component localization WE WE WE WE

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

Fuses and relays located in the cab. 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. NOTE: Not all machines have two fuse blocks.

93106923

93107475

The condenser relay is located next to the HVAC assembly.

RAIL15SSL0028BA

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Electrical systems - Harnesses and connectors

Fuse and relay configuration for the fuse block located in the cab area.

RAIL13SSL0618EA

RAIL13SSL0619EA

Fuses and relays located in the engine area. Remove the battery access cover at the rear, lower left of the machine. Remove the battery (1). The relay block (2) for the crank, burner glow plug, and engine control unit (ECU) relays and the ECU fuse are located inside the engine compartment and forward the battery (1). The 60 A glow plug unit (GCU) fuse (4) (not shown) is located under the relay box (2). The flasher relay (3) (if equipped with a flasher system) is located forward the relay block (2). Please see image 6 for details.

RAIL13SSL0095AA

RAPH13SSL0908BA

The 2 A ground fuses (1) are located near the left, rear of the machine, between the engine and the hydraulic tank.

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Electrical systems - Harnesses and connectors

Relay configuration for the relay block located in the engine area. 1. Crank relay 2. ECU relay

RAIL13SSL0094AA

How to open fuse and relay block: Rotate the box up toward the cab and slide the red release tab (1) away from the cover. NOTE: There are two red locking tabs; one on top and one on the bottom of the fuse block cover (2). Once both of the red locking tabs (1) are in the released position, squeeze the clasps on top and bottom to remover cover. To install the cover (2), align the locking tabs and then slide both red locking tabs (1) toward the cover.

63107475

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Electrical systems - Harnesses and connectors

Fuse and relay box - Component localization NOTE: The following information applies to all machines that have the fuse panel underneath the cup holder. Machines with an access panel directly beneath the operator seat on the back of the foot plate see Fuse and relay box - Component localization (55.100).

L221, L228, C227, and C232 with mechanical controls

RAIL13SSL0618EA

L221, L228, C227, and C232 with Electro-Hydraulic (EH) controls

RAIL13SSL0619EA

Fuse and relays in the cab area Remove the thumbscrews (2) on the cup holder panel and remove the cup holder panel to expose the fuses (1). The fuse and relay decal is on the inside of the cup holder panel.

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93106923

93107475

Electrical systems - Harnesses and connectors

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 remove the cover. 3. To install the cover (2), align locking tabs and then slide both red locking tabs (1) toward the cover.

63107475

63109370

Fuses and relays in the engine area 1. Remove the battery access cover on the left-hand lower rear side of the machine to access the relays. 2. Open the rear engine compartment door. NOTE: In some cases you may find it easier to service these fuses or relays with the battery removed.

The large arrow in the image points toward the front of the machine. 1. Battery (1) 2. Relay block (2) 3. Flasher relay (3) (if equipped with a flasher system) 4. 60 A Glow-plug Control Unit (GCU) fuse (4)

RAIL13SSL0095AA

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L221, L228, C227 and C232 relays 1. The relays are the crank relay (1) and Engine Control Unit (ECU) main relay (2).

RAIL13SSL0094AA

RAPH13SSL0908BA

Relay ground fuse The fuse panel’s 2 A ground fuses (1) are on the chassis harness.

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Electrical systems - Harnesses and connectors

Fuse and relay box - Component localization NOTE: The following information applies to all machines with an access panel directly beneath the operator seat on the back of the foot plate. Machines that have the fuse panel underneath the cup holder see Fuse and relay box Component localization (55.100).

L221, L228, C227, and C232 with mechanical controls

47842042A

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Electrical systems - Harnesses and connectors

L221, L228, C227, and C232 with Electro-Hydraulic (EH) controls

47833186A

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Electrical systems - Harnesses and connectors

Fuse and relays in the cab area NOTE: Not applicable to models L221, L228, C227, and C232 with Electro-Hydraulic (EH) controls. 1. Remove all the screws (1) on the fuse panel (2). 2. Remove the fuse panel (2) to expose the cab area fuses and relays (3) 3. The fuse and relay identification decal is on the backside of the fuse panel. 4. Press both locking tabs (4) to release and remove the cover. NOTICE: Only replace fuses or relays with the same type and amperage rating. 5. If necessary remove and replace fuses or relays.

RAIL15SSL0101BA

RAIL15SSL0100BA

RAIL15SSL0105AA

6. Install the fuse cover. Align locking tabs and push down until the cover locks in place. 7. Align and secure the fuse panel cover to the machine.

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Fuse and relays in the cab area NOTE: Only applicable for models L221, L228, C227, and C232 with Electro-Hydraulic (EH) controls. 1. Remove all the screws (1) on the fuse panel (2). 2. Remove the fuse panel (2) to expose the cab area fuses and relays (3) 3. The fuse and relay identification decal is on the backside of the fuse panel. 4. Press both locking tabs (4) to release and remove the cover. NOTICE: Only replace fuses or relays with the same type and amperage rating. 5. If necessary remove and replace fuses or relays.

RAIL14SSL0717AA

RAIL14SSL0715AA

6. Install the fuse cover. Align locking tabs and push down until the cover locks in place. 7. Align and secure the fuse panel cover to the machine.

Engine Control Unit (ECU) and relays in the engine area (all models) Tilt the cab forward. See “Loader arm lock and cab tilt procedure - radial lift machines” Basic instructions - Loader arm lock and cab tilt procedure - radial lift machines () or “Loader arm lock and cab tilt procedure - vertical lift machines” Basic instructions - Loader arm lock and cab tilt procedure - vertical lift machines ().

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L221 and C227 Engine Control Unit (ECU) and relay identification • Engine Control Unit (ECU) relay (1) • Flasher relay (2) (if equipped with a turn signals) • Glow-plug Control Unit (GCU) (3) • Engine Control Unit (ECU) (4)

RAIL15SSL0104BA

L228 and C232 Engine Control Unit (ECU) and relay identification • Engine Control Unit (ECU) (1) • Flasher relay (2) (if equipped with a turn signals) • Engine Control Unit (ECU) relay (3) • Glow-plug Control Unit (GCU) (4)

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RAIL15SSL0103BA

RAIL15SSL0096BA

Index Electrical systems - 55 Harnesses and connectors - 100 Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 03 - Exhaust system and Controller Area Network (CAN) bus (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (*)

Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (*)

Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (*) . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 01 Main Power Distribution (*) . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 02 Accessory Power Distribution (*) . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 03 Ignition Charging System (*) . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 04 System Power and Ground (*) . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 05 Engine Power Distribution and Fuel Pump (*) . .

Wiring harnesses - Electrical schematic sheet 06 Engine F5C T4 (Vehicle) (*) . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 07 Engine F5C T4 (Engine) (*) . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 08 Throttle Sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 09 Control Valve Interlock & 2nd Aux Hydraulics (*)

Wiring harnesses - Electrical schematic sheet 10 Cab to Chassis Interface (*) . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 11 Cab Console Switches (*) . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 12 Left-Hand Control Handle (*) . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 13 Right-Hand Control Handle (*) . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 14 Seat (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 15 Std Aux Hydraulics (*) . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 16 Lamps (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 17 Indicators (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 18 Turn Signal and Work Lights (*) . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 19 Roading Lights (*) . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 20 Wipers and Washers (*) . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 21 Instrument Cluster (*) . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 22 HVAC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 23 Radio (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 24 Multi-Function Loader Arm (*) . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 25 Telematics (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 26 Case Front Lights (*) . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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Wiring harnesses - Electrical schematic sheet 27 Diagnostic Connector (*) . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 28 Fuel Filter Jumper (*) . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 29 NH Front Lights (*) . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 30 Boom Lock Valve (*) . . . . . . . . . . . . . . . . . . . . . . . .

100

Wiring harnesses - Electrical schematic sheet 01 Main Power Distribution (*) . . . . . . . . . . . . . . . . . .

102

Wiring harnesses - Electrical schematic sheet 02 Accessory Power Distribution (*) . . . . . . . . . . . . .

104

Wiring harnesses - Electrical schematic sheet 03 Ignition Charging System (*) . . . . . . . . . . . . . . . . .

106

Wiring harnesses - Electrical schematic sheet 04 System Power and Grounds (*) . . . . . . . . . . . . . .

108

Wiring harnesses - Electrical schematic sheet 05 Engine F5C T4 (Vehicle) (*) . . . . . . . . . . . . . . . . . .

110

Wiring harnesses - Electrical schematic sheet 06 Engine F5C T4 (Engine) (*) . . . . . . . . . . . . . . . . . .

112

Wiring harnesses - Electrical schematic sheet 07 Engine Power Distribution and Fuel Pump (*) . .

114

Wiring harnesses - Electrical schematic sheet 08 Throttle Sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . .

116

Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (*) . . . . . . . . . . . . . . . . . . . .

118

Wiring harnesses - Electrical schematic sheet 10 Hydraulic Interlocks (*) . . . . . . . . . . . . . . . . . . . . . .

120

Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (*) . . . . . . . . . . . . . . . .

122

Wiring harnesses - Electrical schematic sheet 12 Cab to Chassis Interface (*) . . . . . . . . . . . . . . . . .

124

Wiring harnesses - Electrical schematic sheet 13 Cab to Chassis Interface (*) . . . . . . . . . . . . . . . . .

126

Wiring harnesses - Electrical schematic sheet 14 Cab to Chassis Interface (*) . . . . . . . . . . . . . . . . .

128

Wiring harnesses - Electrical schematic sheet 15 Cab Console Switches (*) . . . . . . . . . . . . . . . . . . .

130

Wiring harnesses - Electrical schematic sheet 16 Left-Hand Control Handle (*) . . . . . . . . . . . . . . . . .

132

Wiring harnesses - Electrical schematic sheet 17 Right-Hand Control Handle (*) . . . . . . . . . . . . . . .

134

Wiring harnesses - Electrical schematic sheet 18 Seat Switch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

136

Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (*) . . . . . . . . . . . . . . . . . . . . . .

138

Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (*) . . . . . . . . . . . . . . . . . . . . . .

140

Wiring harnesses - Electrical schematic sheet 21 Lamps (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

142

Wiring harnesses - Electrical schematic sheet 22 Indicators (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

144

Wiring harnesses - Electrical schematic sheet 23 Turn Signal and Work Lights (*) . . . . . . . . . . . . . .

146

Wiring harnesses - Electrical schematic sheet 24 Roading Lights (*) . . . . . . . . . . . . . . . . . . . . . . . . . .

148

Wiring harnesses - Electrical schematic sheet 25 Wipers and Washers (*) . . . . . . . . . . . . . . . . . . . . .

150

Wiring harnesses - Electrical schematic sheet 26 Instrument Cluster (*) . . . . . . . . . . . . . . . . . . . . . . .

152

Wiring harnesses - Electrical schematic sheet 27 HVAC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

154

Wiring harnesses - Electrical schematic sheet 28 Radio (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

156

Wiring harnesses - Electrical schematic sheet 29 Case Front Lights (*) . . . . . . . . . . . . . . . . . . . . . . . .

158

Wiring harnesses - Electrical schematic sheet 30 Multi-Function Loader Arm (*) . . . . . . . . . . . . . . . .

160

Wiring harnesses - Electrical schematic sheet 31 Telematics (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

162

Wiring harnesses - Electrical schematic sheet 32 Enhanced High Flow (*) . . . . . . . . . . . . . . . . . . . . .

164

Wiring harnesses - Electrical schematic sheet 33 Multi-Function ON/OFF (*) . . . . . . . . . . . . . . . . . . .

166

Wiring harnesses - Electrical schematic sheet 34 2nd Aux (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

168

Wiring harnesses - Electrical schematic sheet 35 Diagnostic Connector (*) . . . . . . . . . . . . . . . . . . . .

170

Wiring harnesses - Electrical schematic sheet 36 Fuel Filter Jumper (*) . . . . . . . . . . . . . . . . . . . . . . .

172

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Wiring harnesses - Electrical schematic sheet 37 NH Front Lights (*) . . . . . . . . . . . . . . . . . . . . . . . . .

174

Fuse and relay box - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

410

Fuse and relay box - Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

413

Fuse and relay box - Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

416

Fuse and relay box Fuse - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

409

Fuse and relay box Relay - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

407

Harnesses and connectors - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wire connectors - Component diagram - Connectors A - Z (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

274

Wire connectors - Component diagram - Connectors A - Z (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

363

Wire connectors - Component diagram - Grounds (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

305

Wire connectors - Component diagram - Grounds (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

405

Wire connectors - Component diagram 00 - Connectors X-9000 to X-9009 (*) . . . . . . . . . . . . . . . . . .

177

Wire connectors - Component diagram 00 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

240

Wire connectors - Component diagram 00 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

323

Wire connectors - Component diagram 01 - Connectors X-9010 to X-9019 (*) . . . . . . . . . . . . . . . . . .

182

Wire connectors - Component diagram 01 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

242

Wire connectors - Component diagram 01 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

326

Wire connectors - Component diagram 02 - Connectors X-9020 to X-9029 (*) . . . . . . . . . . . . . . . . . .

185

Wire connectors - Component diagram 02 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

251

Wire connectors - Component diagram 02 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

337

Wire connectors - Component diagram 03 - Connectors X-9030 to X-9039 (*) . . . . . . . . . . . . . . . . . .

188

Wire connectors - Component diagram 03 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

252

Wire connectors - Component diagram 03 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

338

Wire connectors - Component diagram 04 - Connectors X-9040 to X-9049 (*) . . . . . . . . . . . . . . . . . .

196

Wire connectors - Component diagram 05 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

253

Wire connectors - Component diagram 05 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

339

Wire connectors - Component diagram 07 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

254

Wire connectors - Component diagram 09 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

340

Wire connectors - Component diagram 10 - Connectors X-9100 to X-9109 (*) . . . . . . . . . . . . . . . . . .

197

Wire connectors - Component diagram 11 - Connectors X-9110 to X-9119 (*) . . . . . . . . . . . . . . . . . .

199

Wire connectors - Component diagram 11 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

255

Wire connectors - Component diagram 11 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

342

Wire connectors - Component diagram 12 - Connectors X-9120 to X-9129 (*) . . . . . . . . . . . . . . . . . .

202

Wire connectors - Component diagram 13 - Connectors X-9130 to X-9139 (*) . . . . . . . . . . . . . . . . . .

215

Wire connectors - Component diagram 20 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

258

Wire connectors - Component diagram 20 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

343

Wire connectors - Component diagram 23 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

259

Wire connectors - Component diagram 23 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

344

Wire connectors - Component diagram 25 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

260

Wire connectors - Component diagram 25 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

345

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Wire connectors - Component diagram 27 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

261

Wire connectors - Component diagram 27 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

346

Wire connectors - Component diagram 30 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

262

Wire connectors - Component diagram 30 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

347

Wire connectors - Component diagram 31 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

265

Wire connectors - Component diagram 31 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

350

Wire connectors - Component diagram 32 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

266

Wire connectors - Component diagram 32 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

351

Wire connectors - Component diagram 33 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

267

Wire connectors - Component diagram 33 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

352

Wire connectors - Component diagram 36 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

268

Wire connectors - Component diagram 36 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

354

Wire connectors - Component diagram 40 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

269

Wire connectors - Component diagram 40 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

355

Wire connectors - Component diagram 41 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

358

Wire connectors - Component diagram 43 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

270

Wire connectors - Component diagram 50 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

271

Wire connectors - Component diagram 50 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

359

Wire connectors - Component diagram 90 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

273

Wire connectors - Component diagram 90 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

361

Wire connectors - Component localization - Deluxe cab (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

226

Wire connectors - Component localization - Deluxe cab (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

308

Wiring harnesses - Electrical schematic sheet 01 - Power distribution and starting (*) . . . . . . . . . . .

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Electrical systems - 55 Engine starting system - 201

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Electrical systems - 55 Engine starting system - 201

SERVICE Engine starter Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

(*) See content for specific models 47683911 27/02/2015

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Electrical systems - Engine starting system

Engine starter - Remove WE

L221 TIER 4B (FINAL) [NEM479941 - ]

CAUTION Burn hazard! Exhaust surfaces are hot! Always wear protective gloves when cleaning or working on or near the muffler, catalytic converter, or exhaust stack. Failure to comply could result in minor or moderate injury. C0142A

Prior operations 1. Raise the loader arms and tilt the cab forward. See Cab tilting system - Tilt (90.150) for radial lift units. 2. Remove the battery and/or turn the Master Disconnect Switch to the OFF position. See Battery - Disconnect (55.302) or Battery - Remove (55.302) for further details.

Component removal 3. Disconnect the positive (+) battery cable (1) from the starter motor. 4. Disconnect the starter solenoid wire connector (2) from the starter.

RAIL16SSL0167AA

RAIL16SSL0166AA

5. Remove the three mounting bolts securing the starter motor (1) to the flywheel housing. NOTE: To remove the three mounting bolts use a wrench (not shown) and a swivel-head socket (A) with a 203.2 304.8 mm (8.0 - 12.0 in) socket extension (B). 6. Rotate the starter motor (1) to gain clearance within the chassis, and remove the starter from the machine.

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Electrical systems - Engine starting system

Engine starter - Install WE

L221 TIER 4B (FINAL) [NEM479941 - ]

Component installation 1. To gain clearance within the chassis, rotate the starter motor and slide the starter into the flywheel housing. 2. Secure the starter motor (1) to the flywheel housing with the three M10 x 35 mm mounting bolts. Torque the bolts to 40.0 - 47.0 N·m (30.0 - 35.0 lb ft). NOTE: To install the three mounting bolts use a wrench (not shown) and a swivel-head socket (A) with a 203.2 304.8 mm (8.0 - 12.0 in) socket extension (B).

RAIL16SSL0166AA

RAIL16SSL0167AA

3. Connect the starter solenoid wire (1) to the starter. 4. Connect the positive (+) battery cable (2) to the starter motor. Torque the nut to 12.0 - 18.0 N·m (8.9 - 13.3 lb ft).

Post operations 1. Install the battery and/or turn the Master Disconnect Switch to the ON position. See Battery - Connect (55.302) or Battery - Install (55.302) for further details. 2. Lower the loader arms and secure the cab to the chassis. See Cab tilting system - Lower (90.150) for radial units.

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Electrical systems - Engine starting system

Engine starter - Remove WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

Prior operations 1. Raise the loader arms and tilt the cab forward. See Cab tilting system - Tilt (90.150) for vertical lift units. 2. Remove the battery and/or turn the Master Disconnect Switch to the OFF position. See Battery - Disconnect (55.302) or Battery - Remove (55.302) for further details.

Component removal 1. Remove the four nuts securing the Electronic Control Unit (ECU) mounting plate. NOTE: Move the ECU mounting plate just to gain clearance for the starter. 2. Disconnect the positive (+) battery cable (1) from the starter motor. 3. Disconnect the starter solenoid wire connector (2) from the starter.

RAIL16SSL0167AA

RAIL16SSL0166AA

4. Remove the three mounting bolts securing the starter motor (1) to the flywheel housing. NOTE: To remove the three mounting bolts use a wrench (not shown) and a swivel-head socket (A) with a 203.2 304.8 mm (8.0 - 12.0 in) socket extension (B). 5. Rotate the starter motor (1) to gain clearance within the chassis, and remove the starter from the machine.

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Electrical systems - Engine starting system

Engine starter - Install WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

RAIL16SSL0166AA

RAIL16SSL0167AA

3. Connect the starter solenoid wire (1) to the starter. 4. Connect the positive (+) battery cable (2) to the starter motor. Torque the nut to 12.0 - 18.0 N·m (8.9 - 13.3 lb ft).

5. Install the Electronic Control Unit (ECU) mounting plate, and secure with the four nuts.

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Electrical systems - Engine starting system

Engine starter - Remove WE

C227 TIER 4B (FINAL) [NDM471837 - ]

RAIL16SSL0167AA

RAIL16SSL0166AA

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Electrical systems - Engine starting system

Engine starter - Install WE

C227 TIER 4B (FINAL) [NDM471837 - ]

RAIL16SSL0166AA

RAIL16SSL0167AA

3. Connect the starter solenoid wire (1) to the starter. 4. Connect the positive (+) battery cable (2) to the starter motor. Torque the nut to 12.0 - 18.0 N·m (8.9 - 13.3 lb ft).

5. Install the Electronic Control Unit (ECU) mounting plate, and secure with the four nuts.

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Index Electrical systems - 55 Engine starting system - 201 Engine starter - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine starter - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine starter - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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Electrical systems - 55 Cold start aid - 202

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Electrical systems - 55 Cold start aid - 202

FUNCTIONAL DATA Cold start aid Glow plug system Glow plug control module - Overview - Glow plug control module (*) . . . . . . . . . . . . . . 3

(*) See content for specific models 47683911 27/02/2015

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Electrical systems - Cold start aid

Glow plug system Glow plug control module - Overview - Glow plug control module C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

WE WE WE WE

NHIL14ENG0777FA

The Fast Glow Plug Control Unit (FGPCU) powers up to four fast glow plugs (low voltage glow plugs that cannot be permanently driven at battery voltage levels) as controlled by the input signal CTRL (active low). The duty cycle of the CTRL signal sets the power level of the plug outputs so the Engine Control Unit (ECU) can control the overall power of the heating elements. The diagnostic functions are implemented for each glow plug putput independently. The diagnostic output signal transmits the current status of the glow plugs to the ECU. Each glow plug may either operate correctly or present a fault condition (open load, short circuit or thermal shutdown).

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Index Electrical systems - 55 Cold start aid - 202 Glow plug system Glow plug control module - Overview - Glow plug control module (*) . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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Electrical systems - 55 Battery - 302

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Electrical systems - 55 Battery - 302

SERVICE Battery Disconnect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Connect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Electrical systems - Battery

Battery - Disconnect WE WE WE WE

C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

WARNING Hazardous chemicals! Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash hands after handling. Failure to comply could result in death or serious injury. W0006A

WARNING Chemical hazard! When lifting a plastic-cased battery, excessive pressure on the end walls could cause acid to spill through the vent caps. Lift a plastic-cased battery with a battery carrier or with your hands positioned on opposite corners of the battery. Always wash your hands after handling. Failure to comply could result in death or serious injury. W0385A

Disconnect battery 1. Remove battery access cover (2) by removing the mounting bolts (1).

931001637

931001638

2. Turn battery disconnector (1) —if equipped— to the off position (2).

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3. Disconnect negative battery cable connection (1).

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931002054

4. Disconnect positive battery connection (1).

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Electrical systems - Battery

Battery - Remove WE WE WE WE

C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

Battery removal 1. Remove the battery cover hardware (1) and the battery cover (2).

931001637

931001638

2. Turn battery disconnector (1) —if equipped— to the off position (2).

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3. Disconnect the negative cable connection (1).

931001641

931002054

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4. Disconnect the positive cable connection (1).

5. Loosen the nuts (1), and remove the battery hold-down (2).

6. Remove the battery (1) in direction of the arrow.

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Electrical systems - Battery

Battery - Install WE WE WE WE

C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

Battery installation 1. Confirm that the battery quick disconnector (1) is in the off position (2), as shown. NOTE: The battery disconnector is optional.

931001638

931001642

2. Place the battery (1) in the compartment, in the direction of the arrow.

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3. Install the battery hold-down (1), and secure with the nuts (2).

931001640

931001639

931002054

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4. Insure that the hold-down (1) is square to the battery (2).

5. Connect the positive cable connection (1).

6. Connect the negative cable connection (1).

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7. Turn the battery quick disconnector (1) to the on position (2) as shown. NOTE: The battery disconnector is optional.

931001828

931001637

8. Install the battery cover (2) and secure with the hardware (1).

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Battery - Connect WE WE WE WE

C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

Connect battery 1. Turn battery disconnector (1) —if equipped— to the off position (2).

931001638

931002054

2. Connect the positive battery connection (1).

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3. Connect the negative battery connection (1).

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931001828

4. Turn the battery disconnector (1)— if equipped— to the on position (2).

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Index Electrical systems - 55 Battery - 302 Battery - Connect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery - Disconnect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Electrical systems - 55 External lighting - 404

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Electrical systems - 55 External lighting - 404

DIAGNOSTIC Work light Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Work light - Testing Test N°1 Test Point Condition Turn the ignition switch OFF. Check Verify all wiring connections are tight and secure. All connections should be free of corrosion, abrasion and damage. Verify that the chassis ground frame connections are secure and tight and free of oil, paint, dirt, damage and debris. Expected Result Result The connections are secure. The connections are free of corrosion, abrasion and damage. Go to the next step. Other Action Result The connections are not secure or the connections show signs of corrosion, abrasion and damage. Re(Possible pair as required. Cause) Test N°2 Test Point Condition Turn the ignition switch OFF. Check Disconnect the work lamp bulb. Turn the ignition switch ON. Turn the lamp selector switch to the work lamps. Measure the voltage between pin A and chassis ground. The voltage should be between 11.5 V and 14.8 V. Expected Result Result The voltage is between 11.5 V and 14.8 V. Replace the work lamp bulb and retest. Other Action Result The voltage is less than 11.5 V. Go to the next step. (Possible Cause) Test N°3 Test Point Condition Turn the ignition switch OFF. Check Disconnect the work lamp bulb. Measure the resistance between pin B and chassis ground. The resistance should be less than 10 Ω. Expected Result Result The resistance is greater than 10 Ω. There is a problem in the ground circuit to the bulb. Repair as required. Other Action Result The resistance is less than 10 Ω. Go to the next step. (Possible Cause) Test N°4 Test Point Condition Turn the ignition switch OFF. Check Disconnect the lights relay 1. Turn the ignition switch ON. Measure the voltage between Fuse1 B10 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. The voltage should be between 11.5 V and 14.8 V. Expected Result Result The voltage is between 11.5 V and 14.8 V. Go to the next step. Other Action Result The voltage is less than 11.5 V. There is a problem with the relay battery signal. Repair as required. (Possible Cause)

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Test N°5 Test Point Condition Turn the ignition switch OFF. Check Disconnect the lights relay 1. Measure the resistance between Fuse1 A12 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. The resistance should be less than 10 Ω. Expected Result Result The resistance is greater than 10 Ω. There is a problem in the ground circuit to the relay. Repair as required. Other Action Result The resistance is less than 10 Ω. Go to the next step. (Possible Cause) Test N°6 Test Point Condition Turn the ignition switch OFF. Check Disconnect the lights relay 1. Turn the ignition switch ON. Measure the voltage between Fuse1 A11 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. The voltage should be between 11.5 V and 14.8 V. Expected Result Result The voltage is between 11.5 V and 14.8 V. Go to the next step. Other Action Result The voltage is less than 11.5 V. There is a problem with the battery supply from the lamp selector switch. (Possible Repair as required. Cause) Test N°7 Test Point Condition Turn the ignition switch OFF. Check Disconnect the lights relay 1. Turn the ignition switch ON. Measure the voltage between Fuse1 A10 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. The voltage should be between 11.5 V and 14.8 V. Expected Result Result The voltage is between 11.5 V and 14.8 V. Go to the next step. Other Action Result The voltage is less than 11.5 V. There is a problem with the battery supply to the relay. Repair as required. (Possible Cause) Test N°8 Test Point Condition Turn the ignition switch OFF. Check Reconnect the lights relay 1. Turn the ignition switch ON. Use signal reading probes to measure the voltage between Fuse1 B12 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. The voltage should be between 11.5 V and 14.8 V. Expected Result Result The voltage is between 11.5 V and 14.8 V. There is a problem with the battery supply to the work lamps. Check fuse F-014. Repair as required. Other Action Result The voltage is less than 11.5 V. Replace the lights relay 1 and retest. (Possible Cause)

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Index Electrical systems - 55 External lighting - 404 Work light - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Electrical systems - 55 Warning indicators, alarms, and instruments - 408

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Electrical systems - 55 Warning indicators, alarms, and instruments - 408

DIAGNOSTIC Instrument cluster Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Instrument cluster - Troubleshooting L221 TIER 4B (FINAL) [NEM479941 - ]

Problem Possible Cause ATS FAIL is displayed on The Diesel Particulate Filter (DPF) system the instrument cluster. and/or Exhaust Gas Recirculate (EGR) system detected a malfunction. CRKON is displayed on The OPERATE button is being pressed the instrument cluster. while attempting to start the machine. dPF FAIL is displayed on The Engine Control Unit (ECU) concluded the instrument cluster. that the machine is not ready for a regeneration of the Diesel Particulate Filter (DPF).

Correction Scan the control modules for diagnostic trouble codes.

Do not push the OPERATE button while attempting to start the machine. Bring the machine to operating temperatures, place the hand and foot throttle in the idle position, and disable all hydraulics. Wait for IdLE to appear on the instrument cluster. dPF ON is displayed on The Engine Control Unit (ECU) activated a No action needed. The machine is working the instrument cluster. regeneration of the Diesel Particulate Filter as designed. (DPF). dPF OFF is displayed on The Engine Control Unit (ECU) deactivated No action needed. The machine is working the instrument cluster. the regeneration of the Diesel Particulate as designed. Filter (DPF). dPF PARK is displayed on The Engine Control Unit (ECU) is request- Park the machine in a ventilated area, bring the instrument cluster. ing a forced regeneration of the Diesel Par- the machine to operating temperatures, disable all hydraulics, place the hand and ticulate Filter (DPF). foot throttle in idle, and wait for IdLE to appear on the instrument cluster. The Engine Control Unit (ECU) verified all Press the AUX OVERRIDE button on the dPF START PRESS requirements needed to regenerate the instrument cluster. AUXOV is displayed on Diesel Particulate Filter (DPF). the instrument cluster. The instrument cluster is telling the oper- Replace the engine oil, filter, and reset the ENG OIL SERV is ator that the machine needs an engine oil oil life meter on the instrument cluster. displayed on the change. instrument cluster. EOLT is displayed on the The instrument cluster does not have the Program the instrument cluster with the latlatest software. est software, using the Electronic Service instrument cluster. Tool (EST). IdLE is displayed on the The Engine Control Unit (ECU) is verifying No action needed. The machine is working instrument cluster. that the machine is ready for regeneration as designed. of the Diesel Particulate Filter (DPF). JOYNU is displayed on One or both of the control handles are not Return the control handles to the neutral position. the instrument cluster. in the neutral position. One or both of the control handles are not Calibrate both control handles, using the calibrated correctly. Electronic Service Tool (EST). The rubber boots are incorrectly installed or Inspect the rubber boots. worn. The axis signal for one or both of the control Inspect the control handle module that is handles is greater than 1.5 ° or less than faulty. 1.5 ° in any direction. The centering spring on one or both of the Inspect the control handle module that is faulty. control handles is worn. The instrument cluster is asking the oper- No action needed. The machine is workLOCK? is displayed on ator if he/she wants to lock the machine to ing as designed. Do not press the AUX the instrument cluster. OVERRIDE button. This will lock the maprevent unwanted machine operation. chine controls. You will not be able to start the machine without an owner’s code if the AUX OVERRIDE button has been pressed. The lap bar does not detect an operator in Use the Electronic Service Tool (EST) to OPRPR is displayed on the machine. the instrument cluster. monitor the lap bar. Verify that the lap bar is working as designed. The seat switch does not detect an opera- Use the Electronic Service Tool (EST) to tor in the machine. monitor the seat switch. Verify that the seat switch is working as designed.

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Problem REGEN ACTIVE is displayed on the instrument cluster. REGEN ENd is displayed on the instrument cluster.

Possible Cause The Engine Control Unit (ECU) activated a regeneration of the Diesel Particulate Filter (DPF). The Engine Control Unit (ECU) deactivated the regeneration of the Diesel Particulate Filter (DPF). REGEN FAIL is displayed The Engine Control Unit (ECU) concluded on the instrument cluster. that the machine is not ready for a regeneration of the Diesel Particulate Filter (DPF). REGEN OFF is displayed on the instrument cluster. REGEN PARK is displayed on the instrument cluster.

REGEN START PRESS AUXOV is displayed on the instrument cluster. REGEN IdLE is displayed on the instrument cluster. REGEN WAIT is displayed on the instrument cluster. The instrument cluster displays a 30 second countdown resulting in engine shutdown.

Correction No action needed. The machine is working as designed. No action needed. The machine is working as designed.

Bring the machine to operating temperatures, place the hand and foot throttle in the idle position, and disable all hydraulics. Wait for REGEN IdLE to appear on the instrument cluster. The Engine Control Unit (ECU) deactivated No action needed. The machine is working the regeneration of the Diesel Particulate as designed. Filter (DPF). The Engine Control Unit (ECU) is request- Park the machine in a ventilated area, bring ing a forced regeneration of the Diesel Par- the machine to operating temperatures, disable all hydraulics, place the hand and ticulate Filter (DPF). foot throttle in idle, and wait for REGEN IdLE to appear on the instrument cluster. The Engine Control Unit (ECU) verified all Press the AUX OVERRIDE button on the requirements needed to regenerate the instrument cluster. Diesel Particulate Filter (DPF). The Engine Control Unit (ECU) is verifying No action needed. The machine is working that the machine is ready for regeneration as designed. of the Diesel Particulate Filter (DPF). The operator did not press AUX OVER- Restart the forced regeneration process. RIDE when prompted and within ten minutes of being prompted. The instrument cluster detected a critical Scan the control modules for diagnostic machine error which resulted in an engine trouble codes. shutdown.

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Instrument cluster - Troubleshooting Problem Possible Cause ATS FAIL is displayed on The Diesel Particulate Filter (DPF) system the instrument cluster and/or Exhaust Gas Recirculate (EGR) system detected a malfunction. CRKON is displayed on The OPERATE button is being pressed the instrument cluster while attempting to start the machine. dPF FAIL is displayed on The Engine Control Unit (ECU) concluded the instrument cluster that the machine is not ready for a regeneration of the Diesel Particulate Filter (DPF).

Correction Scan the control modules for diagnostic trouble codes.

Do not push the OPERATE button while attempting to start the machine. Bring the machine to operating temperatures, place the hand and foot throttle in the idle position, and disable all hydraulics. Wait for IdLE to appear on the instrument cluster. dPF ON is displayed on The Engine Control Unit (ECU) activated a No action needed. The machine is working the instrument cluster regeneration of the Diesel Particulate Filter as designed. (DPF). dPF OFF is displayed on The Engine Control Unit (ECU) deactivated No action needed. The machine is working the instrument cluster the regeneration of the Diesel Particulate as designed. Filter (DPF). dPF PARK is displayed on The Engine Control Unit (ECU) is request- Park the machine in a ventilated area, bring the instrument cluster ing a forced regeneration of the Diesel Par- the machine to operating temperatures, disable all hydraulics, place the hand and ticulate Filter (DPF). foot throttle in idle, and wait for IdLE to appear on the instrument cluster. The Engine Control Unit (ECU) verified all Press the AUX OVERRIDE button on the dPF START PRESS requirements needed to regenerate the instrument cluster. AUXOV is displayed on Diesel Particulate Filter (DPF). the instrument cluster The instrument cluster is telling the oper- Replace the engine oil, filter, and reset the ENG OIL SERV is ator that the machine needs an engine oil oil life meter on the instrument cluster. displayed on the change. instrument cluster EOLT is displayed on the The instrument cluster does not have the Program the instrument cluster with the latlatest software. est software, using the Electronic Service instrument cluster Tool (EST). IdLE is displayed on the The Engine Control Unit (ECU) concluded Press the AUX OVERRIDE button on the instrument cluster that the machine is ready for regeneration instrument cluster. of the Diesel Particulate Filter (DPF). JOYNU is displayed on One or both of the control handles are not Return the control handles to the neutral position. the instrument cluster in the neutral position. One or both of the control handles are not Calibrate both control handles, using the calibrated correctly. electronic service tool (EST). The rubber boots are incorrectly installed or Inspect the rubber boots. worn. The axis signal for one or both of the control Inspect the control handle module that is handles is greater than 1.5 ° or less than faulty. 1.5 ° in any direction. The centering spring on one or both of the Inspect the control handle module that is faulty. control handles is worn The instrument cluster is asking the oper- No action needed. The machine is workLOCK? is displayed on ator if he/she wants to lock the machine to ing as designed. Do not press the AUX the instrument cluster OVERRIDE button. This will lock the maprevent unwanted machine operation. chine controls. You will not be able to start the machine without an owner’s code if the AUX OVERRIDE button has been pressed. The seat belt switch does not detect an op- Use the Electronic Service Tool (EST) to OPRPR is displayed on erator in the machine. monitor the lap bar. Verify that the seat belt the instrument cluster switch is working as designed. The seat switch does not detect an opera- Use the Electronic Service Tool (EST) to tor in the machine. monitor the seat switch. Verify that the seat switch is working as designed. The Engine Control Unit (ECU) activated a No action needed. The machine is working REGEN ACTIVE is regeneration of the Diesel Particulate Filter as designed. displayed on the (DPF). instrument cluster 47683911 27/02/2015

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Problem Possible Cause REGEN ENd is displayed The Engine Control Unit (ECU) deactivated on the instrument cluster. the regeneration of the Diesel Particulate Filter (DPF). REGEN FAIL is displayed The Engine Control Unit (ECU) concluded on the instrument cluster that the machine is not ready for a regeneration of the Diesel Particulate Filter (DPF). REGEN OFF is displayed on the instrument cluster REGEN PARK is displayed on the instrument cluster

REGEN START PRESS AUXOV is displayed on the instrument cluster REGEN IdLE is displayed on the instrument cluster REGEN WAIT is displayed on the instrument cluster. The instrument cluster displays a 30 second countdown resulting in engine shutdown

Correction No action needed. The machine is working as designed.

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Index Electrical systems - 55 Warning indicators, alarms, and instruments - 408 Instrument cluster - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instrument cluster - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Electrical systems - 55 Cab controls - 512

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Electrical systems - 55 Cab controls - 512

TECHNICAL DATA Instrument cluster Configure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Joystick and Electric Hydraulic (EH) control Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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Electrical systems - Cab controls

Instrument cluster - Configure WE WE WE WE

C227 C232 TIER 4B (FINAL) [NFM402195 - ] L221 L228

Use the four switch buttons to navigate through the instrument cluster Menu by following the setup menu functions. (1) TEXT DISPLAY Displays the menu text. (2) START Navigates selections on every menu level. Certain menus will prompt the user to enter an access code or allow the user to change a numerical value. NOTE: Pushing the Start button will increment the flashing digit 1,2,3 for number entry. (3) OPERATE Increments the flashing digit 7,8,9,0 for number entry. (4) AUX OVERRIDE Exits the sub-menu and moves top level to the next option. Increments the flashing digit 4,5,6 for number entry. (5) POWER For number entry, moves flashing digit to the next place. Saves entry. Enters the sub-menu.

931002267

Top level menu options • EXIT - Exit the setup menu. • EH - Customize the speed of the machine’s Electro hydraulic controls (if equipped). • dSPLY - Alternate method to select between the selected display parameters. • UNITS - Allows the operator to select between Fahrenheit/Imperial units and Celsius/SI units. • JTIME - Job timer. Timer that displays engine operating hours since last reset. Ideal for rentals or job tracking. • dPF or REGEN - Used to Inhibit regeneration of the Diesel Particulate Filter (DPF) for one key cycle. • OIL - Used to reset the oil life monitoring status after an oil change. 47683911 27/02/2015

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• LOCK - Used to create/change owner and user codes NOTE: The Advanced Instrument Cluster (AIC) images are shown in this section for the four switch buttons (2), (3), (4) and (5) used to navigate through the instrument cluster. The top two switch buttons on the Electronic Instrument Cluster (EIC) are function buttons and function the same as the POWER (5) and START (2) switch buttons on the AIC instrument panel for the setup menu functions.

Entering the SETUP mode 1. Place the machine on firm, level ground with the lift arm and bucket down. NOTE: For machines with the Electronic Instrument Cluster (EIC); you will need the key for these procedures. 2. Before sitting in the seat, push and hold the OPERATE button (3) and the AUX OVERRRIDE button (4) for five seconds until the display (1) shows the word SETUP. 3. You may now sit down and navigate through the SETUP menu. Familiarize yourself with the use of the switch buttons in order to help prevent erroneous settings.

931002267

Text display The operator may choose a continuous display of one of the four following parameters or select cycle from the dSPLY top level menu and momentarily display all four of the parameters in a cycle for a few seconds each. • ENHRS - Engine hours. • ENRPM - Engine RPM. • COOLT - Engine coolant temperature. • HOILT - Hydraulic fluid temperature. • CYCLE - Cycle though all four parameters. 47683911 27/02/2015

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Change or select from the dSPLY level menu NOTE: The instrument cluster is programmed to display the last setting selected when you sit in the seat. Once in the SETUP menu, press the START button until dSPLY appears on the screen. 1. Push the POWER button (5) to display the current selection. 2. Push the START button (2) to toggle through the selections. 3. Once the desired selection appears on the text display, push the POWER button (5) to save the selection.

931002267

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Setting controllability for Electro Hydraulic (EH) All changes must be made with the engine in the off position and the electronics asleep. 1. Before sitting in the seat, press and hold the AUX OVERRIDE button (4) and the OPERATE button (3) at the same time for five to seven seconds until SETUP (1) appears in the display. After seeing setup in the display, you may sit in the operator’s seat and make changes. 2. Press the START button (2) to scroll between the different menus until EH (1) appears on the display. 3. Press the POWER button (5) to enter the next menu. 4. Press the START button (2) to scroll to the setting selection you want to adjust (Speed: Drive, Lift, or Tilt) or (CTLR: Drive or L-ARM), then press the POWER button (5) to save the entry. For DFLT, press the POWER button (5) to save the settings back to the factory default settings. The default settings are shown in tables for each model on the following pages. NOTE: Use the AUX OVERRIDE button (4) when you want to go up a level. 5. Press the START button (2) to scroll to the desired speed level (High, Med-2, Med-1, or Low) or (DRV1, DRV2, or DRV3) or (LDR1, LDR2, or LDR3), then press the POWER button (5) to save the entry. 6. After you have saved your selection; the monitor will revert back to step 3 so you can make another adjustment. If no other adjustments are needed, use the AUX OVERRRIDE button (4) to exit the machine function menu. You will now be in the main SETUP menu; use the START button (2) to scroll to EXIT and then push the POWER button (5) again to exit the setup menu. 7. Leave the operator’s seat for ten seconds before trying to start the unit.

931002267

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Setting controllability with Easy-Electro Hydraulic (EZ-EH) The Easy Electro Hydraulic ( EZ-EH) machines have the EZ-EH information sign (A) located at the top of the instrument cluster on the right-hand column. The following instructions are for the shortcut to the Electro Hydraulic (EH) setup. Use these settings to set the speed of the drive , lift and tilt. Also the drive and loader lift arm settings. NOTE: All changes must be made with the hydraulics disabled and the operator in the operator’s seat.

RAIL13SSL0751BA

RAIL13SSL0990EA

EZ-EH guide EZ-EH settings C = custom L = low

M = medium H = high

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1. Press and hold the AUX OVERRIDE button (1) for two seconds to enter the EH shortcut menu. 2. SPEEd will display on the display (2). Press the AUX OVERRRIDE button (1) to select a different menu item ( dRIVE, EXIT, HOUR, HOILT, COOLT, RPM, or CYCLE). 3. Press the OPERATE button (3) to enter the SPEEd menu. The current setting will be displayed. 4. Press the AUX OVERRRIDE button (1) to change the SPEEd setting. 5. Press the OPERATE button (3) to save a new setting. If EXIT is selected, you will exit back to the top menu level. NOTE: If a new setting is saved, SAVEd will be displayed and you will exit to the top level shortcut menu. NOTE: The CTRL menu works the same as the above SPEEd menu.

Customize settings • Custom settings SP-C and CR-C allow you to fully customize the EH settings using the setup menu. • SP-C sets to the SETUP menu SPEEd settings: DRIVE, LIFT, and TILT. CR-C sets to setup menu CRTL settings DRIVE and L-ARM. • If you do not use the SETUP menu to customize settings, SP-C and CR-C will be set by default to: For a new machine from the factory, the custom settings will be set to the factory default settings from before August 2013. Shown in the following table. For a machine updated in the field, the custom settings will be set to the customer’s EH settings at the time of the software upgrade.

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RAIL13SSL0727GA

Menu structure for Electro Hydraulic ( EH) controls Setup Exit EH DSPLY UNITS

JTIME REGEN Oil Lock

Display setup menu. Exit the setup menu. Customize the speed of the machine’s EH controls. Alternate method to select between the selected display parameters. Allows the operator to select between Fahrenheit/Imperial units and Celsius/SI units. Job Timer. Displays engine operating hours since last reset. Inhibit regeneration. Reset oil life monitor.

Lift Tilt L-ARM

Loader arm up and down function. Attachment tilt function. Loader arm.

High

Quick response to control lever movement.

Med-2

Medium/quick response to control lever movement.

Med-1

Medium/slow response to control lever movement. Slow response to control lever movement. Aggressive response to control lever movement. Medium response to control lever movement. Smooth response to control lever movement. Aggressive response to control lever movement. Medium response to control lever movement. Smooth response to control lever movement.

Low DRV1 DRV2

Speed

Used to create/change owner and user codes. Speed of the drive, lift, and tilt functions.

DRV3

CTRL

Controls for drive and loader arm.

LDR1

DFLT

Factory default settings.

LDR2

Drive

Travel forward and reverse function.

LDR3

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Default settings for models L213 and L216 SPEED Tilt Lift Drive

Low Low Low

Med-1 Med-1 Med-1

Drive L-Arm

DRV3 LDR3

DRV2 LDR2

Med-2 Med-2 Med-2

High High High

CTRL DRV1 LDR1

Default settings for models L218 and L220 SPEED Tilt Lift Drive

Low Low Low

Med-1 Med-1 Med-1

Drive L-Arm

DRV3 LDR3

DRV2 LDR2

Med-2 Med-2 Med-2

High High High

CTRL DRV1 LDR1

Default settings for model L221 and L228 SPEED Tilt Lift Drive

Low Low Low

Med-1 Med-1 Med-1

Drive L-Arm

DRV3 LDR3

DRV2 LDR2

Med-2 Med-2 Med-2

High High High

CTRL DRV1 LDR1

Default settings for model C227 and C232 SPEED Tilt Lift Drive

Low Low Low

Med-1 Med-1 Med-1

Drive L-Arm

DRV3 LDR3

DRV2 LDR2

Med-2 Med-2 Med-2 CTRL

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DRV1 LDR1

High High High

Electrical systems - Cab controls

Select Celsius or Fahrenheit temperature scales Once in the SETUP menu, press the START button until UNITS appears on the screen. 1. Push the POWER button (5) to drop down into the sub-menu. Fahrenheit or Celsius will appear in the display. 2. Push the START button (2) to select the temperature scale desired. 3. Once the selected scale appears on the display (1), push the POWER button (5). The display (1) will blink OFF then ON and show the selected temperature scale. 4. To exit, press START button (2) until the display (1) shows the word EXIT. 5. With EXIT in the display (1) press the POWER button (5) to return to normal operation.

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Select a job timer The operator may choose to set a timer that will run independent from the machine hours. To view or reset the timer: Once in the SETUP menu, press the START button until JTIME appears on the screen. 1. Push the POWER button (5) to view the current timer. 2. Push the START button (2) to reset or view the timer. 3. Use the POWER button (5) to save the selection.

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Inhibit Diesel Particulate Filter (DPF) regeneration The regeneration inhibit selection display allows the operator to turn off the auto regeneration procedure during the current key cycle. NOTE: The regeneration inhibit feature returns to the enable setting by default at the next key cycle. NOTE: Operators that continue to disable the regeneration procedure will eventually de-rate the engine’s performance. NOTE: The LCD display reads dPF INHIb or REGEN INHIb for five seconds every five minutes with an audible alarm. Once in the SETUP menu, press the START button until dPF or REGEN appears on the screen. 1. Push the POWER button (5) to view INHIB on the display (1) . 2. Push the START button (2) to toggle between the choices. 3. Push the POWER button (5) to save the current display selection.

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Oil life reset To reset the oil life monitoring feature. Once in the SETUP menu, press the START button until OIL appears on the screen. 1. Push the POWER button (5) to view RESET on the display. 2. Push the START button (2) to reset the oil life. 3. Push the POWER button (5) to save.

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Anti-theft operation Locking the instrument panel If a lock code has been entered; immediately after shutting off the engine the display will show lock? and the AUX OVERRIDE button will flash. Anti-theft is set by pressing the AUX OVERRIDE button. The panel is now locked and LOCKd is displayed. Restarting requires entering the code. If the AUX OVERRIDE button is not pressed, the machine can be started without a code. The panel does not automatically lock. If a lock code has not been entered; when the engine is shut off the display will not show “ lock?” and the engine can be started without a code until a lock code is entered.

Unlocking the instrument panel 1. Sit in the seat to power the instrument panel. The warning lamps will illuminate and there will be an audible beep. 2. Press the flashing POWER button (5). The display (1) will show unloc. 3. Enter code by using multiple presses of the START button (2), AUX OVERRIDE button (4), and OPERATE button (3) . Press the POWER button (5) to save each digit and move to the next. NOTE: For numbers 1, 2, 3 use the START button. For numbers 4, 5, 6 use the AUX OVERRIDE button. For numbers 7, 8, 9, 0 use the OPERATE button. 4. Press the POWER button (5) after the fifth digit to enter the code. The engine preheat lamp will illuminate and the display (1) will begin the thirty second countdown. NOTE: If the incorrect code is entered, ERROR is displayed, followed by 00000 prompting the operator to enter the correct code.

931002267

If no owner code has been created If you decide you do not want to create a code, enter all 0s. You will return to OWNCR.

Creating codes The panel cannot be locked until a code is created. The instrument panel has one owner code and up to ten user codes. The owner code will always unlock the panel. The owner code will be required to create or change user codes and to modify the owner code. 47683911 27/02/2015

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Owner code Once in the SETUP menu, press the START button to move to the LOCK menu. Press the POWER button to enter the LOCK menu.

Create an owner code If no owner code exists, the display will show the word OWNCR (Owner Create), followed by 00000 . Write down the planned 5 digit code or use a code you already know. NOTICE: Once the code is created, the panel cannot be unlocked with out the code. If the panel cannot be unlocked, contact your Dealer. 1. Enter code by using multiple presses of the START button (2), AUX OVERRIDE button (4), and OPERATE button (3). Press the POWER button (5) to save each digit and move to the next. NOTE: For numbers 1, 2, 3 use the START button. For numbers 4, 5, 6 use the AUX OVERRIDE button. For numbers 7, 8, 9, 0 use the OPERATE button. 2. Press the POWER button (5) after the fifth digit to enter the code. The engine preheat lamp will illuminate and the display will begin the thirty second countdown. 3. Press the START button (2) to move to the exit menu, and press the POWER button (5) to exit the SETUP menu. The panel is not locked at this point.

931002267

If an owner code has been created and LOCK function is disabled NOTE: You can turn the lock function ON and OFF by pressing the POWER button. If you cannot remember or enter an incorrect code, you will return to OWNCR.

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Electrical systems - Cab controls

Modify the owner code Once in the LOCK menu, the display will show OWNER. Press the POWER button to enter the OWNER menu. The display will show open followed by 00000. 1. Enter the current owner code by using multiple presses of the START button (2), AUX OVERRIDE button (4), and OPERATE button (3). Press the POWER button (5) to save each digit and move to the next. NOTE: For numbers 1, 2, 3 use the START button. For numbers 4, 5, 6 use the AUX OVERRIDE button. For numbers 7, 8, 9, 0 use the OPERATE button. 2. Press the POWER button (5) after the fifth digit to save the code. The display (1) will show the word OWNCR followed by the saved owner code. 3. Enter a new owner code to overwrite the existing code. The panel will return to the SETUP menu.

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User codes Once in the SETUP menu, press the START button to move to the LOCK menu. Press the POWER button to enter the LOCK menu.

Create or modify a user code NOTE: An owner code must be saved before a user code. Once in the LOCK menu, the display will show the word OWNER. Press the START button to move to the USER menu. 1. Use the START button (2) to move to user0 through user9. Press the POWER button (5) to create or change that user code. The display (1) will show the word USRCR (user create) followed by 00000 . 2. Enter the owner code. 00000 or the existing user code will be displayed. 3. Enter a new user code to enter or overwrite the existing code. The panel will return to the SETUP menu. 4. Press the START button (2) to move to the EXIT menu, and press the POWER button (5) to exit the SETUP menu. The panel is not locked at this point.

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Electrical systems - Cab controls

Joystick and Electric Hydraulic (EH) control - Remove WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

The following procedure has been performed on the left-hand joystick and an enclosed cab. The procedure for an opened cab is very similar to this procedure. Please use this procedure on the right-hand joystick and opened cabs when necessary.

Joystick replacement 1. Remove the fasteners that attach the panel to the cab. 2. Gently pull the panel towards you.

RAIL15SSL0073BA

RAIL15SSL0072BA

RAIL12SSL0543AA

3. Locate and disconnect the joystick from the wiring harness. 4. Remove every wire tie that attaches the joystick harness to the joystick mount.

5. Pull the bottom of the rubber boot (1) up and expose the jam nut (2). 6. Loosen the jam nut (2).

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Electrical systems - Cab controls

7. Detach the cover (1) from the joystick base. 8. Remove every wire tie that attaches the joystick harness to the joystick base. 9. Turn the joystick counterclockwise to remove the joystick.

RAIL12SSL0544AA

RAIL12SSL0558AA

RAIL12SSL0559AA

Joystick base replacement 10. Remove the screws (1) that attach the joystick base to the joystick mount. 11. Remove every wire tie that attaches the joystick harness to the joystick mount.

12. Remove the joystick base from the joystick mount.

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Electrical systems - Cab controls

Joystick and Electric Hydraulic (EH) control - Install WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

Joystick base replacement 1. Attach the joystick base to the joystick mount, using the screws (1).

RAIL12SSL0558AA

RAIL12SSL0545AA

Joystick replacement 2. Measure 22.2 mm (8 3/4 in) from the base of the control handle. 3. Mark the harness at 22.2 mm (8 3/4 in). You will reference this mark later.

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Electrical systems - Cab controls

4. Place the joystick on the shaft. 5. Turn the joystick clockwise to install the joystick.

RAIL12SSL0544AA

RAIL12SSL0567AA

RAIL12SSL0544AA

6. Orientate the joystick handle as show in image 4. NOTE: X equals 15 ° +/- 2 °.

7. Tighten the jam nut (1) to 41 N·m (30 lb ft).

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Electrical systems - Cab controls

8. Wrap the harness around the shaft of the left-hand joystick in a clockwise motion. NOTE: The harness for right-hand joystick wraps around the shaft in a counterclockwise motion. 9. Locate the mark you made in step 3. 10. Attach the marked portion of the harness to the joystick base, using a wire tie.

RAPH15SSL0045BA

RAIL12SSL0542AA

RAIL15SSL0072BA

11. Install the cover (1). 12. Install the boot (2).

13. Connect the joystick to the wiring harness. 14. Attach the wiring harness to the joystick mount.

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Electrical systems - Cab controls

15. Attach the panel to the cab.

RAIL15SSL0073BA

Next operation: Calibrate the joystick by using the Electronic Service Tool (EST)..

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Index Electrical systems - 55 Cab controls - 512 Instrument cluster - Configure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Joystick and Electric Hydraulic (EH) control - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Joystick and Electric Hydraulic (EH) control - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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Electrical systems - 55 Wiper and washer system - 518

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Electrical systems - 55 Wiper and washer system - 518

TECHNICAL DATA Windshield wiper motor Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Windshield wiper motor Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

(*) See content for specific models 47683911 27/02/2015

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Electrical systems - Wiper and washer system

Windshield wiper motor - Torque WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

Component Crown dome nut (1) Wiper nut (2)

Torque Consumable 6 - 7 N·m (53 - None 62 lb in) 9 - 11 N·m (80 - None 97 lb in)

Identification

RAPH15SSL0043BA

Component Bolt (1)

Torque 6 - 7 N·m (53 62 lb in)

Identification

RAPH15SSL0044BA

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Consumable LOCTITE® 221

Electrical systems - Wiper and washer system

Windshield wiper motor - Remove WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

1. Disconnect the washer hose from (1) elbow connector on the outside of the door. 2. Remove the wiper arm by removing the crown nuts (2).

RAPH16SSL0199BA

RAPH16SSL0200BA

RAPH16SSL0203BA

3. Remove the wiper nut (1) securing the wiper motor to the bracket. Remove the bracket (2) retaining the hardware.

4. Disconnect the washer hose (1) and cut the cable tie strap (2) securing the hose to the bracket. 5. Disconnect the electrical connector (3) for the wiper motor.

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6. Remove the wiper motor assembly with the bracket from the inside of the door.

RAPH16SSL0202BA

7. Remove the bracket (1) and the gasket (2) from the motor (4) by removing the two screws (3).

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Electrical systems - Wiper and washer system

Windshield wiper motor - Install WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

1. Install the bracket (1) and the gasket (2) to the motor (4) by securing with two screws (3). Torque the screws (3) to 6.0 - 7.0 N·m (4.0 - 5.0 lb ft). 2. Install the wiper motor assembly with the bracket into the holes in the door.

RAPH16SSL0202BA

RAPH16SSL0203BA

RAPH16SSL0200BA

3. Connect the electrical connector (3) for the wiper motor to the harness. 4. Connect the washer hose (1) to the elbow, and secure the hose to the bracket with cable tie strap (2).

5. Secure the wiper motor to the bracket (2) on the outside of the door with the wiper nut (1). Torque the nut (1) to 9.0 - 11.0 N·m (6.0 - 8.0 lb ft) NOTE: Be sure to install the spacers and washers prior to installing the bracket on the wiper motor actuator.

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Electrical systems - Wiper and washer system

6. Install the wiper arm onto the bracket and the motor, and secure with the crown nuts (2). Torque the crown nuts (2) to 6.0 - 7.0 N·m (4.0 - 5.0 lb ft). 7. Connect the washer hose (1) to the elbow connector on the outside of the door.

RAPH16SSL0199BA

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Index Electrical systems - 55 Wiper and washer system - 518 Windshield wiper motor - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Windshield wiper motor - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Windshield wiper motor - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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Electrical systems - 55 Electronic modules - 640

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Electrical systems - 55 Electronic modules - 640

FUNCTIONAL DATA Electronic modules Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Controller Area Network (CAN) data bus Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

(*) See content for specific models 47683911 27/02/2015

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Electrical systems - Electronic modules

Electronic modules - Component localization C227 TIER 4B (FINAL) [NDM471837 - ] C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

WE WE WE WE

RAIL15SSL0056GA

Mechanical Mechanical Mechanical Mechanical

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Module location Module location table 1. Instrument cluster 2. Engine Control Unit (ECU)

3. Glow plug control unit 4. PWM driver

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Electrical systems - Electronic modules

Electronic modules - Component localization C227 TIER 4B (FINAL) [NDM471837 - ] C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

WE WE WE WE

RAIL15SSL0054GA

Electro Electro Electro Electro

hydraulic hydraulic hydraulic hydraulic

controls controls controls controls

Module location Module location table 1. Instrument cluster 2. Engine Control Unit (ECU)

3. Glow plug control unit 4. Unit control module (UCM)

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Electrical systems - Electronic modules

Controller Area Network (CAN) data bus - Dynamic description C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE WE

Introduction CAN is an acronym for Controller Area Network. The bus connects controllers on a machine, and allows information to be shared between the controllers. CAN was first developed by Bosch and Intel in 1984, and has been in use in the automotive and truck industry since the late 1980‘s. Applications of CAN follow guidelines that are established in SAE J1939.

Glossary of terms Bus CAN CAN HI CAN LO Controller

Terminator

The network, e.g. the wires, connectors, and terminators between the controllers. Controller Area Network. Generally refers to all parts of the system -the controllers, wires, and terminators. A high priority, message carrying wire on the CAN bus. A low priority, message carrying wire on the CAN bus. Components that are connected by the bus and share information. May also be referred to as processors, control modules, units, or modules. An electrical resistor or circuit placed at either end of the bus. They may be passive or active type. They may be a separate component or part of a controller. Terminators prevent a message from rebounding along the bus, clear the bus for the next message, and allow clear messages to travel the bus.

Purpose In the past, if a speed sensor‘s information was needed by a tachometer, an engine controller, and a transmission, the three devices would need to be wired to the speed sensor. The complexity of wiring can be greatly reduced through the use of a CAN bus system. A controller sends the speed sensor data onto the bus, and the other controllers on the bus can read the data. Any controller on the bus that does not care about the data will ignores the message. A CAN bus system also offers improved diagnostics with the use of the Electronic Service Tool (EST). The controllers can detect errors, and fault codes can be displayed to the operator and technician. Onboard diagnostics may provide the ability to test and monitor circuits during operation, aiding in troubleshooting. The advantage of a CAN bus system are: 1. A decrease in the number of wires and overall length of the wiring harness. 2. Information is received by one controller which shares the information with the other controllers on the bus. 3. Less wiring and fewer connectors improve reliability and durability. 4. Improved diagnostics with the EST.

Operation When the CAN bus is initially powered up (keyswitch on), each controller on the bus sends a message announcing its existence and looks for messages from other controllers on the bus. After this initial message, each controller sends data messages as necessary. The frequency of these messages is based on software programming, with important messages broadcast more frequently than low priority messages.

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Electrical systems - Electronic modules

RAIL13TR03931FA

If a controller has not sent any messages within five seconds, it will broadcast a message that announcing its existence. This is done in order to monitor each controller’s status on the bus. If a certain controller has not transmitted any messages for more than five seconds, then the other controllers on the bus will generate an alarm message indicating that a controller is offline. NOTE: This offline status condition may vary from one machine type to another. Some machines may need to be configured to know that a specific controller is on the bus. However, this process of existence messages generally holds true. In a CAN system, controllers are positioned near the majority of their sensors and switches. For example, the Engine Control Unit (ECU) is located in the engine compartment near the engine sensors. This results in less wiring, fewer connections, and a reduction in the number of error sources. The voltage signal from sensors and switches are processed by a controller, which converts the signal to a data message. The data message is sent to the bus by the controller. Every controller that is connected to the bus can read and process the data message as required. Each controller knows which information it needs based on the software that is programmed into it. The terminators absorb the voltage signals at either end of the bus. They are constantly trying to maintain of voltage of 2.5 V on the bus. Terminators prevent a signal from rebounding along the bus, clear the bus for the next signal, and allow clear messages to travel the bus.

Terminators Terminators help eliminate the reflections that can occur when a message reaches the end of the bus. These reflections can cause interference (noise) on a CAN bus, creating communication problems between the controllers. A good way to explain how terminators work is to think about dropping a stone into a pond. After the stone hits the water, the waves travel to the edges of the pond and then rebound to the center. Terminators absorb the waves at the edges and deny the rebound of the waves to the source. Passive terminator or active terminator 1. Passive terminators are usually 120 Ω resistors placed at either end of the bus. Passive terminators are typically used with a two wire CAN system. These resistors are connected between the CAN HI and CAN LO wires. Passive termination is popular because it is a fraction of the cost of active terminators. Passive terminators act as snubbers to kill reflections and work efficiently on systems with lower bus loading (low CAN bus traffic). 2. Active terminators are voltage regulators, and require a external voltage supply to operate. Active terminators are typically used with a four wire CAN system. Active terminators produce 2.5 V on the CAN HI and CAN LO wires to maintain the standard CAN wire voltage. This means they bring the wires to neutral. Active terminators are very efficient, and are typically used on systems with high bus loading (high traffic).

Troubleshooting The CAN system is capable of diagnosing itself and generating an alarm messages to the operator when problems are present. The vehicle may continue to function when an alarm messages appears, but the systems related to that controller may no longer function. When troubleshooting a vehicle with suspected CAN system failure, it is important to determine if the problem is related to one or more controllers or if the bus is at fault. CAN system problems will generally fall into two categories: 47683911 27/02/2015

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1. Problems with individual controllers that affect certain functions, such as transmission or engine operation. 2. Problems with the bus. (The wires between the controllers.) Some questions to answer are: 1. What functions are affected? 2. Are the affected functions related to a specific controller or several different controllers? 3. Are there any error codes or alarm messages active? 4. Are the error codes and/or alarm messages related to a specific controller or are they indicating an fault with the entire system? If only one or two controllers are affected on the vehicle, then those controllers should be tested for faults before suspecting a CAN bus failure. There are two general conditions that may cause an individual controller to go offline. 1. Loss of power or ground to the controller. 2. Controller related faults, such as a CAN controller failure, poor or failed CAN connector, or message errors.

Loss of power or ground The controllers are not powered through the CAN bus wires. Each controller requires a power supply and ground supply. If power or ground is lost, the controller will deactivate and will not be active on the bus. In addition, most controllers require a minimal voltage level to activate, so weak batteries, a faulty charging system, or poor connections may prevent controllers from properly activating.

Controller faults Whenever a controller transmits or receives a fault message, it keeps a record of that error. After its error history fills, the controller assumes that it is faulty, and will stop transmitting on the bus. We describe this situation as a controller that has gone “bus off,” which may cause an alarm message to be displayed. This error history is erased and reset at zero when the controller is deactivated. There are several CAN related faults that may cause a controller to go offline: 1. External problems like bad or open connections to the CAN HI wires and CAN LO wires as a result of damaged wiring. Inspect the wiring for damage, and use a multimeter to check for continuity to the wires. 2. Internal problems like a failure of the controller itself. If the controller is activating but never communicates on the bus, the controller may have failed. If the controller is activating and is initially online but goes offline after a short period of operation, it may be in a bus off state. Faulty messages may result from: 1. Failed terminators (signal reflection occurring) on the CAN bus. Test the terminators for proper operation. 2. Bad connections (e.g. loose pins, corroded terminals, damaged wires) between the controller and the bus. 3. A problem with the controller. If several controllers are offline or the vehicle will not start, there may be a problem with the actual CAN bus. The wires may be shorted to 12 V, shorted to ground, open, or shorted together. Any of these problems can affect the entire CAN bus.

Testing the CAN bus There are several things to consider when testing CAN systems. The primary concern should be to confirm the integrity of the CAN bus circuit, after which you should check for shorts to battery voltage or to chassis ground. You can easily test the CAN bus (CAN HI and CAN LO) for open circuits by conducting a circuit continuity check at the vehicle’s diagnostic connector. However, for vehicles that use active terminators, it is necessary to unplug those terminators, and replace them with jumper wires between the CAN HI wires and CAN LO wires. For our machine, we deactivate all systems and use a multimeter (1) to check the resistance between pins C and D of our vehicle’s diagnostic connector (2). 47683911 27/02/2015

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NOTE: The CAN circuit that is being tested must be connected to the diagnostic connector.

RAIL13TR03932FA

The resistance across the CAN circuit between CAN HI (3) and CAN LO (4) should be approximately 54 - 66 Ω. A reading of 54 - 66 Ω indicates that the passive terminators are good and confirms the integrity of the CAN bus circuit. A reading of 70 - 150 Ω generally indicates that either a passive terminator has failed or there is an open circuit in either the CAN HI wires or CAN LO wires. You must perform additional testing to isolate the source of the fault. A reading of infinite resistance indicate that either both passive terminators have failed or there is an open circuit in both CAN HI wires and CAN LO wires. A reading of 53 Ω or less indicates poor connections in the circuit. A reading of very low resistance indicates that the CAN HI wires and CAN LO wires are shorted together. Additional testing must be completed to determine the location of the short.

Testing the terminators If a passive terminator is suspected as a source of a CAN bus problem, disconnect the passive terminator from the CAN bus and test the resistance of passive terminators with a multimeter. Passive terminators should have a resistance of approximately 120 Ω. NOTE: Some terminators may be an internal part of a controller. Disconnect the controller from the harness before testing.

Testing the CAN bus voltage A CAN circuit can be tested by testing the voltage of the CAN HI wires and CAN LO wires while the system is activated. This test may provide some indication if the CAN circuit is shorted to high voltage or to ground, but is not conclusive of CAN system operation. If a fault is suspected, you must complete additional testing to locate the type and source of the fault. Use a multimeter to check the voltage between either the CAN HI wires or CAN LO wire and chassis ground. 1. The CAN HI circuit should read approximately 2.5 - 3.5 V. 2. The CAN LO circuit should read approximately 1.5 - 2.5 V.

Testing the CAN bus for shorts to battery voltage If there is a short from a 12 V source to CAN HI or CAN LO, the controllers cannot send information on the CAN system. With the keyswitch on, use a multimeter to check the voltage from the circuit to ground. This needs to be carried out for both the CAN HI and CAN LO wires. If data line voltage is at battery voltage, data can no longer be transmitted. If such an error is found on a data line, localize the error by opening the circuit at intermediate connectors and repeating this test.

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Testing the CAN bus for shorts between the wires If there is a short between the CAN HI wires and CAN LO wires, the controllers cannot send information on the CAN bus. Turn the keyswitch off. Disconnect the terminators from the CAN HI wires and CAN LO wires, so the wires are open. Use a multimeter to check for continuity between the CAN HI wires and CAN LO wires. If there is continuity, the two wires are shorted together. If such an error is found, localize the error by opening the circuit at intermediate connectors and repeating this test.

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Index Electrical systems - 55 Electronic modules - 640 Controller Area Network (CAN) data bus - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic modules - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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Electrical systems - 55 FAULT CODES - DTC

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Electrical systems - 55 FAULT CODES - DTC

DIAGNOSTIC 1002-Engine Coolant Temperature Is Above Normal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1004-Hydraulic Filter Restriction Switch - Hydraulic Filter Restricted (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1009-Hydraulic Oil Temperature Is Above Normal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1014-Cluster System Voltage Above Normal (>16.5V) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 1015-Cluster System Voltage Below Normal (<11.5V) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 1025-Foot Throttle Sensor Is Above Range - Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 1026-Hand Throttle Sensor Is Above Range - Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 1030-Foot Throttle Sensor Is Below Range - Open Or Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . 28 1031-Hand Throttle Sensor Is Below Range - Open Or Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . 31 1040-RPM Monitoring Over Speed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 1041-RPM Monitoring Over Speed Max (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 1044-Fuel level sensor below 2.0 ohm for 5 seconds, shorted low (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 1045-Fuel Level Sensor Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 1051-No CAN Communication With Engine Controller (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 1053-Timeout of CAN Message CM1BC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 1054-Timeout of CAN Message ET1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 1056-Timeout of CAN Message DPFC1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 1058-Timeout of CAN Message EDC2BC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 1059-Timeout of CAN Message DM1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 1201-Hydraulic oil filter switch open circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 1205-Hydraulic Enable (EH Machines) - Hydraulic Enable Output, Short to Power (*) . . . . . . . . . . . . . . 57 1206-CAN Connection: Configuration Response Timeout (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 1207-Memory Parameters - Invalid Configuration Between IC and UCM (*) . . . . . . . . . . . . . . . . . . . . . . . 61 1208-Seat Switch Plausibility Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 1211-Calibration Functions - Joystick Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 1212-Calibration Functions - Ground Drive Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 66 1213-Calibration Functions - Loader Valve Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 67 1215-Saturation Function not complete - Forward Pumps (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 1216-Saturation Function not complete - Reverse Pumps (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 1221-VCM Temperature / Current Draw Over Limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

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1222-VCM Sustained Over Temperature Limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 1223-VCM Sustained Over Current Limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 1224-VCM Internal Memory or Core Monitoring Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 1225-VCM EEPROM Memory Checksum Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 1350-Hyd Enable Switch - Implausible State (Hardwire vs CAN) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 1532-Backup Alarm - Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 1533-Backup Alarm - Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 1900-VCM Ground Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 1901-VCM - VCM Supply Voltage High (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 1902-VCM - VCM Supply Voltage Low (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 1903-VCM - VCM Supply Voltage Below Operational Limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 1904-VCM - Rail 12VB - 5V Regulators Supply Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 1905-VCM - 5Vref1 Sensor Supply Voltage Out Of Range (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 1906-VCM - 5Vref3 Sensor Supply Voltage Out Of Range (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 1907-VCM - Rail 12VF1 - Aux Retract Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 1908-VCM - Rail 12VF2 - Bucket Extend Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 1909-VCM - Rail 12VF3 - Boom Raise/Lower Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 1910-VCM - Rail 12VH - Loader Pilot Interlock And Port Lock Input Power Off (*) . . . . . . . . . . . . . . . . . 102 1911-VCM - Rail 12VH1 - Left And Right Pump Reverse Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . 104 1912-VCM - Rail 12VM - Left And Right Brake Lights And Aux Extend Input Power Off (*) . . . . . . . . . 106 1913-VCM - Rail 12VS1 - Bucket Curl Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 1914-VCM - Rail 12VS2 - Backup Alarm Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 1915-VCM - Rail 12VT1 - Two Speed Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 1916-VCM - Rail 12VU1 - Right And Left Pumps Forward Input Power Off (*) . . . . . . . . . . . . . . . . . . . . 114 1917-UCM - Rail 12VU2: Park Brake Solenoid Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 3007-Engine coolant temperature sensor voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . . . . 118 3008-Engine coolant temperature sensor voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . . 120 3010-Intake manifold temperature sensor voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . . . 122 3011-Intake manifold temperature sensor voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . 125 3015-Fuel temperature sensor voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 3016-Fuel temperature sensor voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 3019-Intake manifold pressure sensor voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . . . . . . 132 3024-ECU internal failure - Ambient pressure sensor voltage is higher than expected (*) . . . . . . . . . . . 135 3025-ECU internal failure - Ambient pressure sensor voltage is lower than expected (*) . . . . . . . . . . . 136 3027-Oil pressure switch active with engine off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 3037-Intake manifold pressure sensor voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . 139 3051-Battery voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 3052-Battery voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 3059-Main relay stuck error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 3061-Cylinder1 - Short circuit Low/High (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 3063-Short circuit error of injector in cylinder 1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

(*) See content for specific models 47683911 27/02/2015

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3069-Cylinder3 - Short circuit Low/High (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 3071-Short circuit error of injector in cylinder 3 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 3077-Cylinder2 - Short circuit Low/High (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 3079-Short circuit error of injector in cylinder 2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 3081-Cylinder4 - Short circuit Low/High (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 3083-Short circuit error of injector in cylinder 4 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 3088-Crankshaft speed sensor values are not plausible (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 3089-Crankshaft speed sensor pattern is not plausible (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 3090-Camshaft speed sensor values are not plausible (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 3091-Camshaft speed sensor pattern is not plausible (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 3093-Compared camshaft and crankshaft speed sensor values are not plausible (*) . . . . . . . . . . . . . . 177 3096-CAN A Bus off failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 3102-Fuel rail pressure sensor voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 3104-Fuel pressure relief valve is open (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 3105-Fuel pressure relief valve is forced to open, perform pressure increase (*) . . . . . . . . . . . . . . . . . . 184 3106-Fuel pressure relief valve reached maximum allowed opening count (*) . . . . . . . . . . . . . . . . . . . . 185 3107-Fuel metering unit is shorted to battery voltage at the low side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 186 3108-Fuel metering unit is shorted to ground at the low side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 3110-Rail pressure sensor value is above maximum offset (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 3111-Rail pressure sensor value is below minimum offset (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 3112-Fuel rail pressure sensor voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 3137-Fuel metering unit has an open load error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 3141-Fuel pump pressure has exceeded desired pressure limits (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 3146-Water in fuel detected or water in fuel circuit failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 3157-ECM Not Detected On CAN Bus - The Engine Dataset Registration Information Was Not Available From The Engine Within The Time Required. (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 3158-The Engine Dataset Installed Does Not Match The Dataset Registered For This Machine. Register The New Dataset If The Dataset Has Just Been Updated (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 3166-Fuel filter heater actuator is shorted to battery voltage (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 3167-Fuel filter heater actuator is shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 3168-Fuel filter heater actuator has an open load error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 3169-Fuel filter heater ECU driver has an over temperature error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 3176-High pressure pump fuel delivery quantity in over run exceeds a maximum threshold (*) . . . . . . 210 3177-Engine over speed condition detected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211 3179-CAN communication failure between vehicle controller and ECU - BC2ECU2 message (*) . . . . 212 3180-CAN communication error between vehicle controller to ECU (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 214 3188-Open load error of injector in cylinder 1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 3192-Open load error of injector in cylinder 2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 3196-Open load error of injector in cylinder 3 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 3200-Open load error of injector in cylinder 4 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 3210-Injection bank 1 short circuit failure (all injectors of the same bank can be affected) (*) . . . . . . . 224 3218-Injection bank 2 short circuit failure (all injectors of the same bank can be affected) (*) . . . . . . . 226 (*) See content for specific models 47683911 27/02/2015

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3230-ECU internal failure - Injector CY33x component (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 3235-Exceeded the number of injections for a given engine speed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 3236-Number of injections is limited by system (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 3237-Number of desired injections exceeds threshold (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 3238-ECU internal failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 3239-ECU internal failure - EEPROM read error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 3240-ECU internal failure - EEPROM write error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 3241-ECU internal failure - EEPROM write/read error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 3242-ECU internal failure - Software resets in DSM 0 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 3243-ECU internal failure - Software resets in DSM 1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 3244-ECU internal failure - Software resets in DSM 2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 3245-ECU internal failure - Query/response communication errors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 3252-ECU internal failure - SPI communication error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 3253-ECU internal failure - Voltage ratio in ADC monitoring (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242 3255-ECU internal failure - ADC test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 3256-ECU internal failure - NTP error in ADC monitoring (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 3258-Starter relay high side driver circuit shorted to battery (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 3259-Starter relay high side driver circuit shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247 3260-Starter relay low side driver circuit open failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 3261-Starter relay low side driver circuit shorted to battery (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251 3262-Starter relay low side driver circuit shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 3265-Fuel injection requested during overrun (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 3266-ECU internal failure - Calculated engine speed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256 3283-ECU 5 volt sensor supply 2 out of range (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257 3285-ECU 5 volt sensor supply 3 out of range (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 3293-Fuel rail pressure has exceeded maximum positive deviation limits (*) . . . . . . . . . . . . . . . . . . . . . 261 3301-Fuel rail pressure has exceeded maximum negative deviation limits (*) . . . . . . . . . . . . . . . . . . . . . 262 3305-Fuel rail pressure has dropped below the minimum limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 3309-Fuel rail pressure has exceeded maximum limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264 3334-CAN communication failure between vehicle controller and ECU controller - TSC1_PE message (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265 3335-CAN-Receive-Frame Torque / Speed control from ABS / ASR to ECU through TSC1_PR Message active (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 3338-CAN communication failure between vehicle controller and ECU controller - TSC1_VE message (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269 3339-CAN communication failure between vehicle controller and ECU controller - TSC1_VE message (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 3350-Engine cranked for too long or key switch failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 3358-CAN transmit error - EEC1 message (Electronic Engine Control 1 message - Torque, accelerator pedal, engine speed, and other signals) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 3361-ECU internal failure - EEPROM erase error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 3362-ECU internal failure - Fuel calibration (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 3368-Torque limitation caused by performance limiter (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 (*) See content for specific models 47683911 27/02/2015

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3369-Torque limitation caused by smoke limitation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 3370-Strong torque limitation from engine protection active (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281 3371-Strong torque limitation from injection system active (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 3374-Injection quantity adjustment failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283 3390-Air Filter Restriction Switch Short To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284 3402-Maximum rail pressure exceeded (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286 3403-Starter relay low side ECU driver circuit over temperature (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287 3405-Wastegate pressure modulator control circuit open (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 3406-Wastegate pressure modulator control circuit over temperature (*) . . . . . . . . . . . . . . . . . . . . . . . . . 291 3409-Low oil pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293 3410-Throttle valve actuator will not open to commanded position (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 296 3411-Throttle valve actuator will not close to commanded position (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 297 3414-Glow plug 1 control circuit shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298 3415-Glow plug 3 control circuit shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 3416-Glow plug 4 control circuit shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302 3417-Glow plug 2 control circuit shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 3418-Wastegate pressure modulator control circuit shorted to battery (*) . . . . . . . . . . . . . . . . . . . . . . . . 306 3419-Wastegate pressure modulator control circuit shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . 308 3425-Turbocharger boost pressure is higher than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 3430-EGR Failure - Moderate Inducement (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311 3431-EGR Failure - Severe Inducement (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 3432-EGR Failure - Mild Inducement (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313 3433-DPF - Moderate Inducement (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314 3434-DPF - Severe Inducement (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 3435-DPF - Mild Inducement (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316 3436-Inducement system is locked due to 3 detections in 40 hours. The system must be reset using the dealer service tool screen "Engine Restart Counter Reset" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 3517-Ambient temperature sensor voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 3518-Ambient temperature sensor voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 3616-Torque limitation caused by turbo charger protection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322 3650-Battery voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323 3651-Battery voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324 3652-CAN A Bus off passive failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326 3655-Torque limitation active (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328 3656-Torque limitation caused by particulate filter (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329 3657-CAN Bus Received frames : Timeout Error of CAN-Receive-Frame CM1BC (*) . . . . . . . . . . . . . 330 3665-EGR valve will not open to commanded position (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332 3666-EGR valve will not close to commanded position (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333 3667-EGR valve control circuit open (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334 3668-EGR valve control circuit over current (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336 3669-EGR valve control circuit high side shorted to battery (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338

(*) See content for specific models 47683911 27/02/2015

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3670-EGR valve control circuit low side shorted to battery (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340 3671-EGR valve control circuit high side shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342 3672-EGR valve control circuit low side shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344 3673-EGR valve control circuit over load (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346 3674-EGR valve control circuit supply voltage too low (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 3675-EGR valve is blocked in closed position (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 3676-EGR valve position sensor voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351 3677-EGR valve position sensor voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353 3680-Engine speed limitation via fuel injection cut off is active (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355 3684-Exhaust manifold temperature too high (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356 3688-Water in fuel sensor or sensor circuit failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357 3689-Glow Control Unit (GCU) data error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359 3691-Glow plug control circuits open (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361 3692-Glow plug control circuits shorted (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363 3693-Glow plug control circuits shorted to battery (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365 3694-Glow plug control circuits shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367 3699-ECU internal failure - EEPROM memory failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369 3703-The minimum rail pressure value necessary to allow fuel injection has not been reached (*) . . . 370 3704-Missing adjustment value programming for injector in cylinder 2 (*) . . . . . . . . . . . . . . . . . . . . . . . . 371 3705-Missing adjustment value programming for injector in cylinder 3 (*) . . . . . . . . . . . . . . . . . . . . . . . . 372 3706-Missing adjustment value programming for injector in cylinder 4 (*) . . . . . . . . . . . . . . . . . . . . . . . . 373 3707-Lambda sensor nernst cell open circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374 3708-Lambda sensor pump current open circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376 3709-Lambda sensor virtual ground open circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378 3711-Lambda sensor heater power stage short circuit to battery (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380 3712-Lambda sensor heater power stage short circuit to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382 3713-Lambda sensor heater power stage open circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384 3714-Lambda sensor O2 calibrator too high error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386 3715-Lambda sensor O2 calibrator too low error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387 3716-Lambda sensor O2 value above maximum threshold (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388 3720-Lambda sensor heater battery voltage too low (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390 3721-ECU internal failure - SPI chip error configuration (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391 3722-Lambda sensor estimated temperature higher than threshold (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 392 3723-Lambda sensor estimated temperature lower than threshold (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 394 3724-Lambda sensor cell circuits short circuit to battery (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396 3725-Lambda sensor cell circuits short circuit to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398 3727-Low oil viscosity (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 3728-Too low oil viscosity (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401 3735-Fuel metering unit has an over-temperature error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402 3738-ECU internal failure - ROM error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404 3739-ECU internal failure - Loss of synchronization to MM from CPU (*) . . . . . . . . . . . . . . . . . . . . . . . . . 405

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3740-ECU internal failure - ECU shutdown test failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406 3741-ECU internal failure - Wrong set response time (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407 3742-ECU internal failure - SPI errors during MoCSOP execution (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408 3743-ECU internal failure - Undervoltage monitoring error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409 3744-ECU internal failure - Overvoltage monitoring error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410 3745-ECU internal failure - WDA is not working correctly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411 3746-ECU internal failure - Alarm task period error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412 3747-ECU internal failure - Positive test failed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413 3748-ECU internal failure - Timeout in the shut off path test error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414 3750-ECU internal failure - Fuel injection energizing time not plausible (*) . . . . . . . . . . . . . . . . . . . . . . . 415 3751-ECU internal failure - Fuel injection energizing phase is not plausible (*) . . . . . . . . . . . . . . . . . . . . 416 3752-Fuel injection correction has exceeded a minimum limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417 3753-ECU internal failure - Injection quality correction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418 3754-ECU internal failure - SPI errors during MoCSOP execution (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419 3755-ECU internal failure - Torque request comparison (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420 3756-ECU internal failure - Post injection quality (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421 3757-ECU internal failure - Post injection shut-off failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422 3758-ECU internal failure - Post injection efficiency failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423 3759-ECU internal failure - Torque request due to fuel pressure exceeds maximum torque limit (*) . . 424 3760-ECU internal failure - Torque request due to air control exceeds maximum torque limit (*) . . . . . 425 3761-ECU internal failure - Torque request exceeds maximum torque limit (*) . . . . . . . . . . . . . . . . . . . . 426 3762-ECU 5 volt supply voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427 3763-ECU 5 volt supply voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428 3764-ECU after run power interruption (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429 3766-Diesel particulate filter pressure sensor: Fault check for the pressure sensor plausibility (*) . . . 432 3767-ECU internal failure - 'WDA active' reported due to errors in query/response communication (*) 433 3768-ECU internal failure - 'ABE active' reported due to undervoltage detection (*) . . . . . . . . . . . . . . . . 434 3769-ECU internal failure - 'ABE active' report due to overvoltage detection (*) . . . . . . . . . . . . . . . . . . . 435 3770-ECU internal failure - 'WDA/ABE active' reported (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436 3773-Turbocharger boost pressure is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437 3786-Diesel particulate filter signal range check is high (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438 3787-Diesel particulate filter signal range check flow resistance of the particulate filter - very high (*) 439 3789-Regeneration duration check exceeds maximum allowed duration (*) . . . . . . . . . . . . . . . . . . . . . . 440 3794-Intake manifold pressure sensor drifted high (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441 3795-Intake manifold pressure sensor drifted low (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442 3796-Diesel particulate filter pressure sensor hose line error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443 3797-DPF differential pressure sensor is higher than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444 3798-DPF differential pressure sensor is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446 3799-Fuel pressure relief valve is forced open, perform pressure shock (*) . . . . . . . . . . . . . . . . . . . . . . . 448 3800-Quantity balance check if a successful PRV opening is ensured (*) . . . . . . . . . . . . . . . . . . . . . . . . 449 3801-Exhaust gas pressure sensor voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 450

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3802-Exhaust gas pressure sensor voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 452 3803-ECU internal failure - Error on R2S2 module (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454 3808-High pressure pump fuel delivery quantity at low idle is too high (*) . . . . . . . . . . . . . . . . . . . . . . . . 455 3810-Rail pressure raw value is intermittent (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456 3811-ECU 5 volt sensor supply 1 out of range (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458 3812-Physical range check high for ECU temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464 3813-Physical range check low for ECU temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465 3814-Engine Controller Internal Temperature Out Of Range (SPI Error - LM71) (*) . . . . . . . . . . . . . . . . 466 3818-Throttle valve actuator control circuit open (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467 3819-Throttle valve actuator control circuit over current (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469 3820-Throttle valve actuator control circuit over temperature (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471 3821-Throttle valve actuator control circuit high side shorted to battery (*) . . . . . . . . . . . . . . . . . . . . . . . 473 3823-Throttle valve actuator control circuit high side shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . . . 475 3824-Throttle valve actuator control circuit low side shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . 477 3825-Throttle valve actuator control circuit over load (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479 3827-Throttle valve actuator control circuit supply voltage too low (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481 3834-Throttle valve actuator position sensor voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . 482 3835-Throttle valve actuator position sensor voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . 484 3838-DOC inlet temperature sensor voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . 486 3839-DOC inlet temperature sensor voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 488 3840-PMCat inlet temperature sensor voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . 490 3841-PMCat inlet temperature sensor voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . 492 3842-Exhaust manifold temperature sensor voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . . 494 3843-Exhaust manifold temperature sensor voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . 497 3844-Error in comparing energizing time to maximum value for injector in cylinder 1 (*) . . . . . . . . . . . . 499 3845-Error in comparing energizing time to maximum value for injector in cylinder 2 (*) . . . . . . . . . . . . 500 3846-Error in comparing energizing time to maximum value for injector in cylinder 3 (*) . . . . . . . . . . . . 501 3847-Error in comparing energizing time to maximum value for injector in cylinder 4 (*) . . . . . . . . . . . . 502 3848-Error in comparing energizing time to minimum value for injector in cylinder 1 (*) . . . . . . . . . . . . 503 3849-Error in comparing energizing time to minimum value for injector in cylinder 2 (*) . . . . . . . . . . . . 504 3850-Error in comparing energizing time to minimum value for injector in cylinder 3 (*) . . . . . . . . . . . . 505 3851-Error in comparing energizing time to minimum value for injector in cylinder 4 (*) . . . . . . . . . . . . 506 3899-Engine coolant temperature has exceeded the pre-warning threshold (*) . . . . . . . . . . . . . . . . . . . 507 3900-Engine coolant temperature has exceeded the warning threshold (*) . . . . . . . . . . . . . . . . . . . . . . . 508 3906-Number of injections is limited by quantity balance of high pressure pump (*) . . . . . . . . . . . . . . . 509 3910-Fuel metering unit intermittent electrical connection failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510 3915-Averaged rail pressure is outside the expected tolerance range (*) . . . . . . . . . . . . . . . . . . . . . . . . . 512 3916-Fuel pressure relief valve has reached maximum allowed open time (*) . . . . . . . . . . . . . . . . . . . . 513 3978-PM Catalyst load high (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514 3979-PM Catalyst load very high (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515 3993-EGR valve will not close during after run (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516

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3995-Cold start bypass valve has an over-temperature error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517 3996-Cold start bypass valve is shorted to battery voltage (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519 3997-Cold start bypass valve is shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521 4043-Hydraulic Oil Temperature Sensor Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523 4044-Hydraulic Oil Temperature Sensor Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525 4055-Park Brake Valve (On/Off) - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527 4056-Park Brake Valve (On/Off) - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 529 4057-Park Brake Valve (On/Off) - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 531 4061-Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit (*) . . . . . . 533 4062-Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground (*) . . . 535 4071-Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit (*) . . . . . . . 537 4072-Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground (*) . . . . 539 4081-Forward Pump Control Valves (Directional) - Common Solenoid Return Short to Power (*) . . . . 541 4082-Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground (*) . . 543 4083-Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit (*) . . . . . . 545 4309-Park Brake Button - Park Brake Button Timeout (30 sec) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547 4361-Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit (*) . . . . . . 549 4362-Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground (*) . . . 551 4371-Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit (*) . . . . . . . 553 4372-Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground (*) . . . . 555 4381-Reverse Pump Control Valves (Directional) - Common Solenoid Return Short to Power (*) . . . . 557 4382-Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground (*) . . 559 4383-Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit (*) . . . . . . 561 4401-Park Brake (Mechanical Machines) Solenoid Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 563 4402-Park Brake (Mechanical Machines) Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565 4431-Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) (*) . . . 567 4731-Right Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . 570 4732-Right Swash Plate Angle Sensor - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573 4734-Right Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . 575 4735-Right Swash Plate Angle Sensor - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578 4737-Right Swash Plate Angle Sensor - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580 4741-Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . 583 4742-Left Swash Plate Angle Sensor - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586 4744-Left Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . 588 4745-Left Swash Plate Angle Sensor - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591 4747-Left Swash Plate Angle Sensor - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593 4752-Left Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596 4754-Right Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598 4781-Solenoid Valve - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 4782-Solenoid Valve - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602 (*) See content for specific models 47683911 27/02/2015

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4783-Solenoid Valve - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604 4951-Hydraulic Interlock Solenoid Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606 4952-Hydraulic Interlock Solenoid Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608 5051-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . 610 5052-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . . 612 5053-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . . 614 5061-Port Lock Valve (On/Off) - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616 5062-Port Lock Valve (On/Off) - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618 5063-Port Lock Valve (On/Off) - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620 5121-Right Joystick F-B Axis - Pin A Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . . . 622 5122-Right Joystick F-B Axis - Pin B Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . . . 626 5124-Right Joystick F-B Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630 5131-Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . 635 5132-Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . 639 5134-Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . 643 5135-Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . 647 5137-Right Joystick R-L Axis (ISO/H Pattern) - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651 5141-Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 656 5142-Aux Thumbwheel Axis - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 658 5144-Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 660 5145-Aux Thumbwheel Axis - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 662 5147-Aux Thumbwheel Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 664 5201-Left Joystick L-R Axis - Pin A Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . 667 5202-Left Joystick L-R Axis - Pin B Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . 671 5204-Left Joystick L-R Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675 5211-Left Joystick F-B Axis - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 680 5212-Left Joystick F-B Axis - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 684 5214-Left Joystick F-B Axis - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 688 5215-Left Joystick F-B Axis - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 692 5217-Left Joystick F-B Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 696 5221-Loader Arm Valve (Directional) Solenoid Raise (A) Supply Open Circuit (*) . . . . . . . . . . . . . . . . . 701 5222-Loader Arm Valve (Directional) Solenoid Raise (A) Supply Shorted To Ground (*) . . . . . . . . . . . . 703 5231-Loader Arm Valve (Directional) Solenoid Lower (B) Supply Open Circuit (*) . . . . . . . . . . . . . . . . . 705 5232-Loader Arm Valve (Directional) Solenoid Lower (B) Supply Shorted To Ground (*) . . . . . . . . . . . 707 5241-Loader Arm Valve (Directional) Loader Arm Solenoid(s) Shorted To Power (*) . . . . . . . . . . . . . . . 709 5242-Loader Arm Valve (Directional) Loader Arm Solenoid(s) Shorted To Ground (*) . . . . . . . . . . . . . . 711 5243-Loader Arm Valve (Directional) Solenoids Return Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . 713 5251-Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Open Circuit (*) . . . . . . . . . . . . 715 5252-Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Shorted To Ground (*) . . . . . . . 717 5261-Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Open Circuit (*) . . . . . . . . . . . . . . . 719 5262-Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Shorted To Ground (*) . . . . . . . . . 721

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5271-Loader Bucket Valve (Directional) Loader Bucket Solenoid(s) Shorted To Power (*) . . . . . . . . . . 723 5272-Loader Bucket Valve (Directional) Loader Bucket Solenoid(s) Shorted To Ground (*) . . . . . . . . . 725 5273-Loader Bucket Valve (Directional) Solenoids Return Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . 727 5281-Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Open Circuit (*) . . . . . . . . . . . 729 5282-Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Shorted To Ground (*) . . . . . . 731 5291-Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Open Circuit (*) . . . . . . . . . . . 733 5292-Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Shorted To Ground (*) . . . . . 735 5309-Float Button - Float Button Timeout (30 sec) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 737 5313-EHF Enable Switch STP (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 739 5323-EHF Fwd/Rev Switch STP (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 741 5371-EHF Forward Solenoid (A) Supply STG (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 744 5372-EHF Forward Solenoid (A) Supply OC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746 5381-EHF Reverse Solenoid (B) Supply STG (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 748 5382-EHF Reverse Solenoid (B) Supply OC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 5391-EHF Solenoids Return OC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 752 5392-EHF Pump Solenoid(s) STG (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 754 5393-EHF Pump Solenoid(s) STP (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 756 5409-Aux Override Disabled Due To Aux Override Button Timeout (30 Seconds) (*) . . . . . . . . . . . . . . . 758 5501-Loader Arm Spool Sensor Open or Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 759 5502-Loader Arm Spool Sensor Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 761 5503-Electro-Hydraulic Aux Output Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 763 5504-Bucket Valve Spool Sensor Open Or Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 765 5505-Bucket Valve Spool Sensor Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 767 5507-Auxiliary Valve Spool Sensor Open Or Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 769 5508-Auxiliary Valve Spool Sensor Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 771 5511-Implausible Loader Arm Sensor State Vs Loader Arm Command - Stuck Spool Or PRV (*) . . . . 773 5512-Implausible Bucket Sensor State Vs Loader Bucket Command - Stuck Spool Or PRV (*) . . . . . 775 5513-Implausible Auxiliary Sensor State Vs Auxiliary Command - Stuck Spool Or PRV (*) . . . . . . . . . 777 5601-Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Power (*) . . . . . . . 779 5602-Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Ground (*) . . . . . . 781 5603-Loader Auxiliary Valve (Directional) Solenoids Return Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . 783 5701-Pattern Switch Open Or Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 785 5703-Pattern Switch Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 788 5811-Loader Port Lock Switch Is In An Implausible State (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 791 9004-Memory Error - Triple Redundant - Hour Meter Location 1 Corrupt (*) . . . . . . . . . . . . . . . . . . . . . . 794 9005-Memory Error - Triple Redundant - Hour Meter Location 2 Corrupt (*) . . . . . . . . . . . . . . . . . . . . . . 795 9006-Memory Error - Triple Redundant - Hour Meter Location 3 Corrupt (*) . . . . . . . . . . . . . . . . . . . . . . 796 9151-Bus-Warn at CAN-Bus No.1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 797 9152-Bus-Warn at CAN-Bus No.1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 799 9153-Timeout of CAN Message EEC1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801 9154-Timeout of CAN Message TSC1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803

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9156-Hydraulic Enable Button Error From AIC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805 9158-H Pattern Indicator Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806 9159-ISO Pattern Indicator Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808 9160-H Pattern Indicator Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 810 9161-ISO Pattern Indicator Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 812 9401-Memory Error - Double Redundant Memory - Corruption Detected And Repaired (*) . . . . . . . . . 814 9403-Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable (*) 815 9404-Memory Error - Triple Redundant - Hour Meter Failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 816 9405-Loss Of DM1 Message From VCM (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 817 9406-No CAN Communication From VCM (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 818 9407-Memory Error - Unrecoverable Hardware ID (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 819 9408-Memory Error - Unrecoverable Panel ID (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 820 9410-Loss Of EGR Inducement Status Message From EDC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 821 17105-Turbo protection cold start detection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 822 17513-PMCat inlet temperature sensor physical range check high (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 823 17514-Timeout Error of CAN-Receive-Frame CM1BC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 824

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Electrical systems - FAULT CODES

1002-Engine Coolant Temperature Is Above Normal C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The instrument cluster has received a message from the ECU that the coolant temperature is above 111 °C (232 °F) for a period greater than 5 s. Cause: The coolant temperature is above normal. The instrument cluster has received a message from the ECU that the coolant temperature above 111 °C (232 °F) for a period greater than 5 s. Possible failure modes: 1. The engine has a low coolant level. 2. Faulty wiring or connections. 3. A faulty coolant temperature sensor. 4. A faulty ECU. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault is not recorded again. OK to return the machine to service. B. Fault code 1002 - Engine Coolant Temperature Is Above Normal is recorded again. Refer to procedure 3007-Engine coolant temperature sensor voltage is higher than expected (55.640). Wiring harnesses - Electrical schematic sheet 07 Engine F5C T4 (Engine) (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 06 Engine F5C T4 (Engine) (55.100.DP-C.20.E.06)

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Electrical systems - FAULT CODES

1004-Hydraulic Filter Restriction Switch - Hydraulic Filter Restricted WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The instrument cluster measures a short circuit to ground on the hydraulic oil filter restriction input. A connection to ground indicated that the hydraulic filter is clogged or restricted. Cause: The instrument cluster measures a short circuit to ground on the hydraulic oil filter input, X-C23 pin 15. Possible failure modes: 1. Clogged hydraulic filter. 2. Signal wire has an short circuit to chassis ground. 3. Faulty reading from the switch. 4. Faulty instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 1004 is not recorded again. OK to return the machine to service. B. Fault code 1004 is recorded again. Go to step 2. 2. Inspect the hydraulic oil filter. Inspect the hydraulic filter. Replace the filter if needed. A. The filter is in good condition and does not need to be replaced. Go to step 3. B. The filter is in poor condition or is clogged. Replace the filter. Return to step 3 to confirm elimination of the fault. 3. Verify the harness and connectors are not damaged. Inspect the instrument cluster and hydraulic filter restriction switch connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the instrument cluster to the hydraulic filter restriction switch. Verify that the harness is free of damage, corrosion, abrasion or incorrect attachment. A. The wiring is free of corrosion, damage, abrasion, and incorrect attachment. Go to step 3. B. The wiring is not free of corrosion, damage, abrasion, or incorrect attachment. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the resistance through the filter restriction switch. Disconnect the oil filter switch from the harness. Measure the resistance between the oil filter switch pin and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. The resistance should be greater than 20,000 Ω. A. The resistance is greater than 20,000 Ω. Go to step 5. B. The resistance is less than 10 Ω. Replace hydraulic filter restriction switch and retest. Return to step 1 to confirm elimination of fault. 47683911 27/02/2015

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Electrical systems - FAULT CODES

5. Measure the resistance of the signal wire to chassis ground. Disconnect instrument cluster connector X-C23. Disconnect the hydraulic oil filter restriction switch from the harness. Measure the resistance between the hydraulic oil filter restriction switch connector pin 1 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 10 Ω. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 Instrument Cluster (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 10 Cab to Chassis Interface (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 26 Instrument Cluster (55.100.DP-C.20.E.26) Wiring harnesses - Electrical schematic sheet 12 Cab to Chassis Interface (55.100.DP-C.20.E.12)

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Electrical systems - FAULT CODES

1009-Hydraulic Oil Temperature Is Above Normal WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The instrument cluster monitored a hydraulic oil temperature that is greater than 110 °C (230 °F) for a period greater than 3 s. Cause: The hydraulic oil temperature is above 110 °C (230 °F) for a period greater than 3 s. Possible failure modes: 1. Low hydraulic oil level. 2. Faulty fan operation. 3. Clogged cooling core. 4. Faulty reading from sensor. 5. Faulty instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1009 is recorded again. Go to step 2. 2. Verify hydraulic oil level. Check the hydraulic oil level, add oil as required. Refer to the Operator's Manual for more details. A. The oil level is correct and the fault is not recorded again. Return the machine to service. B. The oil level is correct, but the fault is recorded again. Go to step 3. 3. Check fan operations. Operate the engine at 1500 RPM. Check the fan operation. Check the cooling core for clogs. A. The cooling system is operating properly. Go to step 4. B. The cooling system is not operating properly or the cooling core is clogged. Repair the fan or clear the clogs from the cooling core. Repair as required. Return to step 1 to confirm elimination of fault. 4. Check the temperature sender. Disconnect the terminal connector from the hydraulic oil temperature sender. Measure the resistance between the hydraulic oil temperature sender ground connection and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance across the temperature sender terminals.

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Electrical systems - FAULT CODES

Hydraulic Oil Temperature Sensor Open Circuit Resistance Measurements Temperature Resistance in ohms (± 10%) 110 °C (230 °F) 130 Ω 105 °C (221 °F) 151 Ω 100 °C (212 °F) 175 Ω 95 °C (203 °F) 202 Ω 92 °C (198 °F) 223 Ω 88 °C (190 °F) 258 Ω 85 °C (185 °F) 280 Ω 81 °C (178 °F) 323 Ω 78 °C (172 °F) 358 Ω 74 °C (165 °F) 412 Ω 68 °C (154 °F) 511 Ω 16 °C (61 °F) 4250 Ω A. The resistance measurements compare to the values in the table. Go to step 5. B. The resistance measurements are not acceptable. The measured resistance is less than 100 Ω and greater than 5,000 Ω. Replace the hydraulic oil temperature sender. Return to step 1 to confirm elimination of fault. 5. Check the wiring to the instrument cluster. Disconnect the instrument cluster connector X-C23. Disconnect the hydraulic oil temperature sensor. Measure the resistance between the hydraulic oil temperature sender connector pin 1 (signal wire) and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is greater than 20,000 Ω. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground in the wire. Repair or replace the wire as required. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 Instrument Cluster (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 10 Cab to Chassis Interface (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 26 Instrument Cluster (55.100.DP-C.20.E.26) Wiring harnesses - Electrical schematic sheet 12 Cab to Chassis Interface (55.100.DP-C.20.E.12)

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Electrical systems - FAULT CODES

1014-Cluster System Voltage Above Normal (>16.5V) WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The instrument cluster measured an alternator voltage greater than 16 V for a period greater than 5 s. The fault will reset once the alternator voltage drops below 16 V for a period greater than 5 s. Cause: The voltage on the instrument cluster input, X-C23 pin 9 is greater than 16 V. Possible failure modes: 1. A faulty alternator. The alternator output is greater than 16 V. 2. A faulty instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 1014 is not recorded again. OK to return the machine to service. B. Fault code 1014 is recorded again. Go to step 2. 2. Measure the alternator output. Start the engine. Set the engine speed to low idle and measure the voltage at the alternator. The voltage should be approximately 14.5 V. A. The voltage is approximately 14.5 V. Go to step 3. B. The voltage is greater than 16 V. Replace the alternator. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at instrument cluster. Disconnect the instrument cluster connector X-C23. Turn the ignition switch ON. Start the engine. Measure the voltage between pin X-C23 pin 9 and chassis ground. The chassis ground connection should be clean and free of paint, oil, and dirt. The voltage should be approximately 14.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 14.5 V. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault code. B. The voltage is greater than 16 V. Replace the alternator. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 Instrument Cluster (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 03 Ignition Charging System (55.100.DP-C.20.E.03) Wiring harnesses - Electrical schematic sheet 10 Cab to Chassis Interface (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 01 Main Power Distribution (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 26 Instrument Cluster (55.100.DP-C.20.E.26) Wiring harnesses - Electrical schematic sheet 03 Ignition Charging System (55.100.DP-C.20.E.03) Wiring harnesses - Electrical schematic sheet 12 Cab to Chassis Interface (55.100.DP-C.20.E.12) Wiring harnesses - Electrical schematic sheet 01 Main Power Distribution (55.100.DP-C.20.E.01)

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Electrical systems - FAULT CODES

1015-Cluster System Voltage Below Normal (<11.5V) WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The instrument cluster has measured an alternator voltage less than 11.5 V for a period greater than 5 s. The fault will reset once the alternator voltage is greater than 12 V for a period greater than 5 s. Cause: The voltage on the instrument cluster input, X-C23 pin 9 is less than 11.5 V. Possible failure modes: 1. A problem in the wiring. 2. A faulty alternator. The alternator output is less than 11.5 V. 3. A faulty instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 1015 is not recorded again. OK to return the machine to service. B. Fault code 1015 is recorded again. Go to step 2. 2. Measure the alternator output. Start the engine. Set the engine speed to low idle. Measure the voltage at the alternator. The voltage should be approximately 14.5 V. A. The voltage is approximately 14.5 V. Go to step 3. B. The voltage is less than 11.5 V. Replace the alternator. Return to test step 1 to confirm elimination of fault. 3. Measure the voltage at the instrument cluster. Disconnect the instrument cluster X-C23. Turn the ignition switch ON. Start the engine. Measure the voltage between pin X-C23 pin 9 and chassis ground. The chassis ground connection should be clean and free of paint, oil, and dirt. The voltage should be approximately 14.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 14.5 V. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault code. B. The voltage is less than 11.5 V. There is a problem in the wiring between the alternator and the instrument cluster. Repair as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 Instrument Cluster (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 03 Ignition Charging System (55.100.DP-C.20.E.03) Wiring harnesses - Electrical schematic sheet 10 Cab to Chassis Interface (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 01 Main Power Distribution (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 26 Instrument Cluster (55.100.DP-C.20.E.26) Wiring harnesses - Electrical schematic sheet 03 Ignition Charging System (55.100.DP-C.20.E.03) 47683911 27/02/2015

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Wiring harnesses - Electrical schematic sheet 12 Cab to Chassis Interface (55.100.DP-C.20.E.12) Wiring harnesses - Electrical schematic sheet 01 Main Power Distribution (55.100.DP-C.20.E.01)

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Electrical systems - FAULT CODES

1025-Foot Throttle Sensor Is Above Range - Shorted To Power WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The instrument cluster has detected an problem with the foot throttle signal to the instrument cluster. Diagnostic Trouble Code 1025 has an error priority of White. Engine speed is based on the signal from the hand throttle while Diagnostic Trouble Code 1025 is active. Cause: The instrument cluster has sensed a higher than normal voltage on throttle signal pin, X-C23 pin 23. The fault is active while the ignition switch is on and throttle voltage is greater than 5.6 V. Possible failure modes: 1. A short circuit in the foot throttle wiring to another voltage source. 2. A failure of the throttle position sensor. 3. The instrument cluster has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1025 is recorded again. Go to step 2. 2. Verify the harness is not damaged Turn the ignition switch OFF. Verify the connections from the instrument cluster to the foot throttle position sensor are tight and secure. Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment from the instrument cluster to the foot throttle position sensor. A. The foot throttle position sensor harness is not damaged and all of the connections are secure. Go to step 3. B. The throttle position sensor harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the supply voltage to the throttle sensor. Turn the ignition switch OFF. Disconnect the foot throttle sensor connector X-20. Turn the ignition switch ON. Measure the voltage between pin C and pin B. The voltage should be between 4.8 V and 5.2 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is between 4.8 V and 5.2 V. Go to step 4. B. The voltage is greater than 5.2 V or less than 4.8 V. Go to step 7. 4. Measure the voltage on the sensor signal line. Turn the ignition switch OFF. 47683911 27/02/2015

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Electrical systems - FAULT CODES

Disconnect the foot throttle position sensor from the harness. Disconnect the instrument cluster connector X-C23. Turn the ignition switch ON. Measure the voltage between X-20 pin A and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 5. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the wire as required. Return to step 1 to confirm elimination of the fault. 5. Check the signal voltage from the sensor.

RCPH10TLB053FAM

(1) (2)

Throttle Signal Legend Throttle Signal Voltage Throttle movement in degrees of travel. 0 ° equals low idle. 20 ° equals WOT (Wide Open Throttle).

This step is used to monitor the throttle signal. The sensor must be connected and active in order to continue. The dealer must build a breakout harness as shown below. Connect the breakout harness between the foot throttle sensor and the instrument cluster. Measure the voltage between pin A and pin B (or slide back probes into pin A and pin B). Turn the ignition switch ON, engine OFF. Measure the voltage between pin A and pin B. Move the throttle from low idle to WOT (wide open throttle). The voltage should change from approximately 0.55 V at low idle to 4.2 V at WOT. A. The voltage changed from approximately 0.55 V to 4.2 V. Go to step 6. B. The voltage did not change from 0.55 V to 4.2 V as the throttle moved from low idle to WOT or the voltage was less than 0.55 V. Temporarily replace the sensor and retest. Return to step 1 to confirm elimination of fault. 6. Measure the throttle signal from the sensor to the instrument cluster. 47683911 27/02/2015

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Turn the ignition switch OFF. Remove the breakout harness. Reconnect the sensor to the instrument cluster harness. Remove pin 23 from connector X-C23. Turn the ignition switch ON, engine OFF. Measure the voltage between the removed wire, pin 23 and chassis ground. Move the throttle from low idle to WOT (wide open throttle). The voltage should change from approximately 0.55 V at low idle to 4.2 V at WOT. A. The voltage changed from approximately 0.55 V to 4.2 V. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. B. The voltage did not change from 0.55 V to 4.2 V as the throttle moved from low idle to WOT or the voltage was less than 0.55 V at low idle. There is a problem in the throttle signal wire from the sensor to the instrument cluster. Repair or replace the wire as required. Return to step 1 to confirm elimination of fault. 7. Measure the voltage at the instrument cluster Turn the ignition switch OFF. Remove the wires from instrument cluster connector X-C23 pin 17 and X-C23 25. Fabricate two jumper wires that will connect into X-C23 pin 25 and X-C23 pin 17. Connect the jumper wires into X-C23 pin 25 and X-C23 pin 17. Turn the ignition switch ON. Use the jumper wires to measure the voltage between X-C23 pin 25 and X-C23 pin 17. A. The voltage is correct. There is a problem in the wiring harness from the instrument cluster to the throttle position sensor. Repair or replace the harness as required. Return to step 1. B. The voltage is greater than 5.2 V or less than 4.8 V. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 Instrument Cluster (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 08 Throttle Sensor (55.100.DP-C.20.E.08) Wiring harnesses - Electrical schematic sheet 10 Cab to Chassis Interface (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 26 Instrument Cluster (55.100.DP-C.20.E.26) Wiring harnesses - Electrical schematic sheet 08 Throttle Sensors (55.100.DP-C.20.E.08) Wiring harnesses - Electrical schematic sheet 12 Cab to Chassis Interface (55.100.DP-C.20.E.12)

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Electrical systems - FAULT CODES

1026-Hand Throttle Sensor Is Above Range - Shorted To Power WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The instrument cluster has detected an problem with the hand throttle signal to the instrument cluster. Diagnostic Trouble Code 1026 has an error priority of White. The engine speed is based on the signal from the hand throttle while Diagnostic Trouble Code 1026 is active. Cause: The instrument cluster has sensed a higher than normal voltage on throttle signal pin, X-C23 pin 22. The fault is active while the ignition switch is on and throttle voltage is greater than 5.6 V. Possible failure modes: 1. A short circuit in the throttle wiring to another voltage source. 2. A failure of the hand throttle position sensor. 3. The instrument cluster has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1026 is recorded again. Go to step 2. 2. Verify the harness is not damaged Turn the ignition switch OFF. Verify the connections from the instrument cluster to the hand throttle position sensor are tight and secure. Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment from the instrument cluster to the hand throttle position sensor. A. The hand throttle position sensor harness is not damaged and all of the connections are secure. Go to step 3. B. The throttle position sensor harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the supply voltage to the throttle sensor. Turn the ignition switch OFF. Disconnect the hand throttle sensor connector X-20A. Turn the ignition switch ON. Measure the voltage between pin C and pin B. The voltage should be between 4.8 V and 5.2 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is between 4.8 V and 5.2 V. Go to step 4. B. The voltage is greater than 5.2 V or less than 4.8 V. Go to step 7. 4. Measure the voltage on the sensor signal line. Turn the ignition switch OFF. 47683911 27/02/2015

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Electrical systems - FAULT CODES

Disconnect the hand throttle position sensor from the harness. Disconnect the instrument cluster connector X-C23. Turn the ignition switch ON. Measure the voltage between X-20A pin A and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 5. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the wire as required. Return to step 1 to confirm elimination of the fault. 5. Check the signal voltage from the sensor.

RCPH10TLB053FAM

(1) (2)

Throttle Signal Legend Throttle Signal Voltage Throttle movement in degrees of travel. 0 ° equals low idle. 20 ° equals WOT (Wide Open Throttle).

This step is used to monitor the throttle signal. The sensor must be connected and active in order to continue. The dealer must build a breakout harness as shown below. Connect the breakout harness between the hand throttle sensor and the instrument cluster. Measure the voltage between pin A and pin B (or slide back probes into pin A and pin B). Turn the ignition switch ON, engine OFF. Measure the voltage between pin A and pin B. Move the throttle from low idle to WOT (wide open throttle). The voltage should change from approximately 0.55 V at low idle to 4.2 V at WOT. A. The voltage changed from approximately 0.55 V to 4.2 V. Go to step 6. B. The voltage did not change from 0.55 V to 4.2 V as the throttle moved from low idle to WOT or the voltage was less than 0.55 V. Temporarily replace the sensor and retest. Return to step 1 to confirm elimination of fault. 6. Measure the throttle signal from the sensor to the instrument cluster. 47683911 27/02/2015

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Electrical systems - FAULT CODES

Turn the ignition switch OFF. Remove the breakout harness. Reconnect the sensor to the instrument cluster harness. Remove pin 22 from connector X-C23. Turn the ignition switch ON, engine OFF. Measure the voltage between the removed wire, pin 22 and chassis ground. Move the throttle from low idle to WOT (wide open throttle). The voltage should change from approximately 0.55 V at low idle to 4.2 V at WOT. A. The voltage changed from approximately 0.55 V to 4.2 V. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. B. The voltage did not change from 0.55 V to 4.2 V as the throttle moved from low idle to WOT or the voltage was less than 0.55 V at low idle. There is a problem in the throttle signal wire from the sensor to the instrument cluster. Repair or replace the wire as required. Return to step 1 to confirm elimination of fault. 7. Measure the voltage at the instrument cluster Turn the ignition switch OFF. Remove the wires from instrument cluster connector X-C23 pin 17 and X-C23 25. Fabricate two jumper wires that will connect into X-C23 pin 25 and X-C23 pin 17. Connect the jumper wires into X-C23 pin 25 and X-C23 pin 17. Turn the ignition switch ON. Use the jumper wires to measure the voltage between X-C23 pin 25 and X-C23 pin 17. A. The voltage is correct. There is a problem in the wiring harness from the instrument cluster to the throttle position sensor. Repair or replace the harness as required. Return to step 1. B. The voltage is greater than 5.2 V or less than 4.8 V. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 Instrument Cluster (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 08 Throttle Sensor (55.100.DP-C.20.E.08) Wiring harnesses - Electrical schematic sheet 10 Cab to Chassis Interface (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 26 Instrument Cluster (55.100.DP-C.20.E.26) Wiring harnesses - Electrical schematic sheet 08 Throttle Sensors (55.100.DP-C.20.E.08) Wiring harnesses - Electrical schematic sheet 12 Cab to Chassis Interface (55.100.DP-C.20.E.12)

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Electrical systems - FAULT CODES

1030-Foot Throttle Sensor Is Below Range - Open Or Shorted To Ground WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The instrument cluster has detected an problem with the foot throttle signal to the instrument cluster. Diagnostic Trouble Code 1030 has an error priority of White. The engine speed is based on the hand throttle sensor while Diagnostic Trouble Code 1030 is active. Cause: The instrument cluster has sensed that the foot throttle signal has failed. The fault is active while the engine is on and the foot throttle input voltage, X-C23 pin 22 falls below 0.2 V. Possible failure modes: 1. A short circuit in the wiring. 2. An open circuit in the wiring. 3. A failure of the foot throttle position sensor. 4. A failure of the instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1030 is recorded again. Go to step 2. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Verify the connections from the instrument cluster to the foot throttle position sensor are tight and secure. Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment from the instrument cluster to the foot throttle position sensor. A. The foot throttle position sensor harness is not damaged and all connections are secure. Go to step 3. B. The foot throttle position sensor harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the supply voltage to the foot throttle sensor. Turn the ignition switch OFF. Disconnect the foot throttle connector. Turn the ignition switch to the ON position. Measure the voltage between pin C and pin B. The voltage should be approximately between 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is between 4.8 V and 5.2 V. Go to step 4. B. The voltage is greater than 5.2 V or less than 4.8 V. Go to step 6. 47683911 27/02/2015

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4. Measure the foot throttle signal from the sensor.

RCPH10TLB053FAM

(1) (2)

Foot Throttle Signal Legend Foot Throttle Signal Voltage Foot throttle movement in degrees of travel. 0 ° equals low idle. 20 ° equals WOT (Wide Open foot throttle).

This step is used to monitor the foot throttle signal. The sensor must be connected and active in order to continue. The dealer must build a breakout harness as shown below. Connect the breakout harness between the foot throttle connector X-20 and the instrument cluster harness. Measure the voltage between pin A and pin B (or slide back probes into pin A and pin B). Turn the ignition switch ON, engine OFF. Measure the voltage between pin A and pin B. Move the foot throttle from low idle to WOT (wide open foot throttle). The voltage should change from approximately 0.55 V at low idle to 4.2 V at WOT. A. The voltage changed from approximately 0.55 V to 4.2 V. Go to step 5. B. The voltage did not change between 0.55 V and 4.2 V as the foot throttle moved from low idle to WOT or the voltage was less than 0.5 V at low idle. Temporarily replace the sensor and retest. Return to step 1 to confirm elimination of fault. 5. Measure the foot throttle signal from the sensor to the instrument cluster. Turn the ignition switch OFF. Remove the breakout harness. Reconnect the sensor to the instrument cluster harness. Remove pin 22 from connector X-C23. Turn the ignition switch ON, engine OFF.

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Electrical systems - FAULT CODES

Measure the voltage between removed wire, pin 22 and chassis ground. Move the foot throttle from low idle to WOT (wide open foot throttle). The voltage should change from approximately 0.55 V volts at low idle to 4.2 V at WOT. A. The voltage changed from approximately 0.55 V to 4.2 V. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. B. The voltage did not change between 0.55 V and 4.2 V as the foot throttle moved from low idle to WOT or the voltage was less than 0.55 V at low idle. There is a problem in the foot throttle signal wire from the sensor to the instrument cluster. Repair or replace the wire as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage at the instrument cluster Turn the ignition switch OFF. Remove the pin 17 and pin 25 from connector X-C23. Fabricate two jumper wires and insert them into X-C23 pin 25 and X-C23 pin 17. Turn the ignition switch ON. Use the jumper wires to measure the voltage between X-C23 pin 25 and X-C23 pin 17. A. The voltage is correct. There is a problem in the wiring harness from the instrument cluster to the foot throttle position sensor. Repair or replace the harness as required. Return to step 1. B. The voltage is greater than 5.2 V or less than 4.8 V. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 Instrument Cluster (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 08 Throttle Sensor (55.100.DP-C.20.E.08) Wiring harnesses - Electrical schematic sheet 10 Cab to Chassis Interface (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 26 Instrument Cluster (55.100.DP-C.20.E.26) Wiring harnesses - Electrical schematic sheet 08 Throttle Sensors (55.100.DP-C.20.E.08) Wiring harnesses - Electrical schematic sheet 12 Cab to Chassis Interface (55.100.DP-C.20.E.12)

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Electrical systems - FAULT CODES

1031-Hand Throttle Sensor Is Below Range - Open Or Shorted To Ground WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The instrument cluster has detected an problem with the hand throttle signal to the instrument cluster. Diagnostic Trouble Code 1031 has an error priority of White. The engine speed is based on the foot throttle sensor while Diagnostic Trouble Code 1031 is active. Cause: The instrument cluster has sensed that the hand throttle signal has failed. The fault is active while the engine is on and the hand throttle input voltage, X-C23 pin 23 falls below 0.2 V. Possible failure modes: 1. A short circuit in the wiring. 2. An open circuit in the wiring. 3. A failure of the hand throttle position sensor. 4. A failure of the instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1031 is recorded again. Go to step 2. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Verify the connections from the instrument cluster to the hand throttle position sensor are tight and secure. Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment from the instrument cluster to the hand throttle position sensor. A. The hand throttle position sensor harness is not damaged and all connections are secure. Go to step 3. B. The hand throttle position sensor harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the supply voltage to the hand throttle sensor. Turn the ignition switch OFF. Disconnect the hand throttle connector. Turn the ignition switch to the ON position. Measure the voltage between pin C and pin B. The voltage should be approximately between 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is between 4.8 V and 5.2 V. Go to step 4. B. The voltage is greater than 5.2 V or less than 4.8 V. Go to step 6. 47683911 27/02/2015

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4. Measure the hand throttle signal from the sensor.

RCPH10TLB053FAM

(1) (2)

Hand Throttle Signal Legend Hand Throttle Signal Voltage Hand throttle movement in degrees of travel. 0 ° equals low idle. 20 ° equals WOT (Wide Open hand throttle).

This step is used to monitor the hand throttle signal. The sensor must be connected and active in order to continue. The dealer must build a breakout harness as shown below. Connect the breakout harness between the hand throttle connector X-20A and the instrument cluster harness. Measure the voltage between pin A and pin B (or slide back probes into pin A and pin B). Turn the ignition switch ON, engine OFF. Measure the voltage between pin A and pin B. Move the hand throttle from low idle to WOT (wide open hand throttle). The voltage should change from approximately 0.55 V at low idle to 4.2 V at WOT. A. The voltage changed from approximately 0.55 V to 4.2 V. Go to step 5. B. The voltage did not change between 0.55 V and 4.2 V as the hand throttle moved from low idle to WOT or the voltage was less than 0.5 V at low idle. Temporarily replace the sensor and retest. Return to step 1 to confirm elimination of fault. 5. Measure the hand throttle signal from the sensor to the instrument cluster. Turn the ignition switch OFF. Remove the breakout harness. Reconnect the sensor to the instrument cluster harness. Remove pin 23 from connector X-C23. Turn the ignition switch ON, engine OFF.

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Electrical systems - FAULT CODES

Measure the voltage between removed wire, pin 23 and chassis ground. Move the hand throttle from low idle to WOT (wide open hand throttle). The voltage should change from approximately 0.55 V volts at low idle to 4.2 V at WOT. A. The voltage changed from approximately 0.55 V to 4.2 V. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. B. The voltage did not change between 0.55 V and 4.2 V as the hand throttle moved from low idle to WOT or the voltage was less than 0.55 V at low idle. There is a problem in the hand throttle signal wire from the sensor to the instrument cluster. Repair or replace the wire as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage at the instrument cluster Turn the ignition switch OFF. Remove the pin 17 and pin 25 from connector X-C23. Fabricate two jumper wires and insert them into X-C23 pin 25 and X-C23 pin 17. Turn the ignition switch ON. Use the jumper wires to measure the voltage between X-C23 pin 25 and X-C23 pin 17. A. The voltage is correct. There is a problem in the wiring harness from the instrument cluster to the hand throttle position sensor. Repair or replace the harness as required. Return to step 1. B. The voltage is greater than 5.2 V or less than 4.8 V. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 Instrument Cluster (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 08 Throttle Sensor (55.100.DP-C.20.E.08) Wiring harnesses - Electrical schematic sheet 10 Cab to Chassis Interface (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 26 Instrument Cluster (55.100.DP-C.20.E.26) Wiring harnesses - Electrical schematic sheet 08 Throttle Sensors (55.100.DP-C.20.E.08) Wiring harnesses - Electrical schematic sheet 12 Cab to Chassis Interface (55.100.DP-C.20.E.12)

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Electrical systems - FAULT CODES

1040-RPM Monitoring Over Speed C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Cause: The instrument cluster has detected an engine speed greater than 2750 RPM for a period greater than 5 s. The warning lamp will illuminate Amber. The fault will stay active until engine speed drops below 2700 RPM. Solution: 1. Fault code 1040 - RPM Monitoring Over Speed is a CAN data link message from the ECU to the instrument cluster. The fault code is displayed on the instrument cluster to warn the operator that the engine speed has exceeded 2750 RPM for a period greater than 5 s.

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Electrical systems - FAULT CODES

1041-RPM Monitoring Over Speed Max C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Cause: The instrument cluster has received a message from the ECU that the engine speed is greater than 3000 RPM for a period greater than 5 s. Solution: 1. Stop the engine. Fault code 1041 - RPM Monitoring Over Speed Max is a CAN data link message from the ECU to the instrument cluster. This fault code is displayed on the instrument cluster to alert the operator that the engine speed has exceeded 3000 RPM.

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Electrical systems - FAULT CODES

1044-Fuel level sensor below 2.0 ohm for 5 seconds, shorted low WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The instrument cluster has detected the fuel sender resistance is below 2 Ω for a period greater than 30 s. Cause: The instrument cluster has detected the fuel sender resistance is below 2 Ω for a period greater than 30 s. Possible failure modes: 1. Wiring or circuits shorted to minus battery or chassis ground. 2. A faulty fuel level sensor. 3. A faulty instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault is not recorded again. OK to return the machine to service. B. Fault code 1044 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the instrument cluster and the fuel level sender connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the instrument cluster to the fuel level sender. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance at the fuel level sensor. Tilt the cab. Remove the fuel level sender from the tank. Disconnect the sender from the harness. Move the fuel level float from the low position to the high position while measuring the resistance of the sender. The resistance should change linearly from approximately 4.5 Ω at the full tank position to approximately 340 Ω at the empty tank position. The resistance should change linearly without any fluctuations to a higher or lower resistance. A. The resistance measurements from the sensor are within specifications. Go to step 4. B. The resistance readings from the sensor are not steady or the values are not accurate. Temporarily replace sensor and retest. Return to step 1 to confirm elimination of fault. 4. Check the fuel level sensor wiring. Measure the resistance between X-14 pin A and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. 47683911 27/02/2015

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Fabricate a jumper wire that will connect between connector X-C23 pin 24 and chassis ground. Connect the jumper wire between connector X-C23 pin 24 and chassis ground. Measure the resistance between X-14 pin B and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 Ω. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. B. One or both resistance measurements are greater than 10 Ω. There is a problem in the wiring harness. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 Instrument Cluster (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 10 Cab to Chassis Interface (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 04 System Power and Ground (55.100.DP-C.20.E.04) Wiring harnesses - Electrical schematic sheet 26 Instrument Cluster (55.100.DP-C.20.E.26) Wiring harnesses - Electrical schematic sheet 12 Cab to Chassis Interface (55.100.DP-C.20.E.12) Wiring harnesses - Electrical schematic sheet 04 System Power and Grounds (55.100.DP-C.20.E.04)

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1045-Fuel Level Sensor Open Circuit WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The instrument cluster has detected an open circuit in the fuel sender signal. Cause: The instrument cluster has determined that the fuel level sensor resistance has failed high. The resistance of the fuel level sensor is greater than 5,000 Ω. Possible failure modes: 1. An open circuit in the wiring. 2. A faulty fuel level sensor. 3. The instrument cluster has internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1045 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the instrument cluster and the fuel level sender connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the instrument cluster to the fuel level sender. Verify that the harness is free of damage, corrosion, abrasion or incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance at the fuel level sensor. Tilt the cab. Remove the fuel level sender from the tank. Disconnect the sender from the harness. Move the fuel level float from the low position to the high position while measuring the resistance across the sender. The resistance should change linearly from approximately 4.5 Ω at the full tank position to approximately 340 Ω at the empty tank position. The resistance should change linearly without any fluctuations to a higher or lower resistance. A. The resistance measurements from the sensor were within specifications. Go to step 4. B. The resistance readings from the sensor were not steady or the values were not accurate. Temporarily replace the sensor and retest. Return to step 1 to confirm elimination of fault. 4. Check fuel level wiring.

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Measure the resistance between X-14 pin A and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance from X-14 pin B to instrument cluster connector X-C23, pin 24. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-14 pin B and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurements are within specifications. Temporarily replace the instrument cluster and retest. Go to step 1 to confirm elimination of the fault. B. The resistance readings are not with the limits defined in the step. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 Instrument Cluster (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 10 Cab to Chassis Interface (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 04 System Power and Ground (55.100.DP-C.20.E.04) Wiring harnesses - Electrical schematic sheet 26 Instrument Cluster (55.100.DP-C.20.E.26) Wiring harnesses - Electrical schematic sheet 12 Cab to Chassis Interface (55.100.DP-C.20.E.12) Wiring harnesses - Electrical schematic sheet 04 System Power and Grounds (55.100.DP-C.20.E.04)

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1051-No CAN Communication With Engine Controller C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: CAN bus communications between the instrument cluster and the ECU may have been interrupted. The instrument cluster did not receive the EEC1 message from the ECU. This fault code may be displayed with other CAN bus fault messages. The instrument cluster will illuminate the stop lamp and will continually sound the audible alarm while this fault is active. Cause: The instrument cluster did not receive a CAN message from the ECU. CAN bus communications between the instrument cluster and the ECU may have been interrupted. Possible failure modes: 1. A failed main relay. 2. Blown ECU fuse 1 or fuse 2. 3. An open circuit in the CAN bus wiring. 4. A short circuit in the CAN bus wiring. 5. A faulty instrument cluster. 6. A faulty ECU. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 1051 - No CAN Communication With Engine Controller is not recorded again. Go to step 2. B. Fault code 1051 - No CAN Communication With Engine Controller is recorded again. There may be one or two other CAN bus fault codes associated with 1051 - No CAN Communication With Engine Controller. Go to step 2. C. Fault code 1051 - No CAN Communication With Engine Controller is recorded along with other CAN data link faults such as 1053 - Timeout of CAN Message CM1BC - 1059 - Timeout of CAN Message DM1, and/or 3096 - CAN A Bus off failure, 3179 - CAN communication failure between vehicle controller and ECU BC2ECU2 message and 3180 - CAN communication error between vehicle controller to ECU. Go to step 5. 2. Check the ECU fuses in the fuse panel. Check the ECU fuse 1 and fuse 2. Verify that they are not blown and have 12 V when the ignition switch is ON. A. The fuses are OK. There is 12 V when the ignition switch is ON. Go to step 3. B. The fuses are blown. Replace the fuses and retest. Locate the cause of the blown fuse. Check the main relay for water intrusion. Return to step 1 to confirm elimination of the fault. C. There is no power to the fuses. Check the 2 A ground fuses located along the left side of the engine. The ground fuses are in the Black/Blue fuse holders hanging from the engine harness along the front edge of the hydraulic tank. Repair as required. Return to step 1 to confirm elimination of the fault. 3. Check the main relay. Remove the main relay from the panel. The ECU relay is located in the engine relay panel by the battery box, left-side engine compartment. 47683911 27/02/2015

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Check the main relay for water intrusion. A. There are no signs of water intrusion in the main relay. Go to step 4. B. The main relay shows signs of water intrusion such as corrosion or water inside the relay. Replace the relay and retest. Return to step 1 to confirm elimination of the fault. 4. Verify that the CAN bus circuit is functioning properly. Connect the Electronic Service Tool to the service tool connector. Turn the ignition switch ON. Verify the connections to the ECU, instrument cluster, diagnostic connector, and the optional Telematics unit are tight and secure. Check for CAN bus fault codes while wiggling the harness. Turn the ignition switch OFF. Disconnect the instrument cluster connector X-C23. Measure the resistance between X-C23 pin 6 and X-C23 pin 5 on the instrument cluster. The resistance should be between 108 Ω and 132 Ω. Disconnect ECU connector X-012. Measure the resistance between X-012 pin 24 and X-012 pin 25 on the ECU. The resistance should be between 108 Ω and 132 Ω. A. All connections are secure. Both resistance measurements are within range. OK to return the machine to service. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. C. One or both resistance measurements are less than 108 Ω or greater than 132 Ω. Replace the control that has the bad resistance value. Return to step 1 to confirm elimination of fault.

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5. Verify the harness is not damaged. Turn the ignition switch OFF. Verify the connections to the ECU, instrument cluster, diagnostic connector, the UCM, and the optional Telematics unit are tight and secure. Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment from the ECU to the instrument cluster. Verify all data link drops are free of damage, abrasion, corrosion and incorrect attachment. A. The CAN bus harness is not damaged and all connections are secure. Go to step 6. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 6. Measure the resistance through the CAN data link harness. Turn the ignition switch OFF. Measure the resistance between the diagnostic port connector, pins X-DIAG pin C and X-DIAG pin D. The resistance should be approximately 60 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 54 Ω. Go to step 8. B. The resistance is between 54 Ω and 66 Ω. Go to step 7. C. The resistance is greater than 66 Ω. Go to step 9. 7. Measure the harness resistance between chassis ground and positive battery. Turn the ignition switch OFF. Disconnect the instrument cluster connector, X-C23. Disconnect all other devices connected to the CAN bus. Measure the resistance between X-C23 pin 6 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-C23 pin 6 and positive battery (X-C23 pin 9). The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-C23 pin 5 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-C23 pin 5 and positive battery (X-C23 pin 9). The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Circuit description Positive battery Minus battery CAN high CAN low

Instrument cluster connection X-C23 pin 9 X-C23 pin 34 X-C23 pin 6 X-C23 pin 5

Alternate diagnostic port connection X-DIAG pin B X-DIAG pin A X-DIAG pin C X-DIAG pin D

A. All resistance measurements are greater than 20,000 Ω. Verify the ECU is powered and operational. Verify that all minus battery and chassis ground connections to the CAN bus modules are clean and secure. Repair as required. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 20,000 Ω. There is a short circuit in the CAN bus. Temporarily replace the CAN bus wires and retest. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault code. 8. Measure the resistance between the CAN high and CAN low wires. Turn the ignition switch OFF.

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Disconnect all modules on the CAN bus. Measure the resistance between CAN high (diagnostic connector pin C) and CAN low (diagnostic connector pin D). A. The resistance is greater than 20,000 Ω. Connect each component to the CAN bus one at a time. The resistance should be greater than 54 Ω. Replace the module that drops the CAN bus resistance below 54 Ω. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 54 Ω there is a short circuit between the CAN high and CAN low wires. Repair or replace the harness as required. Return to test step 1 to confirm elimination of the fault. 9. Measure the resistance through the CAN bus circuit. Turn the ignition switch OFF. Disconnect all components connected to the CAN bus. Fabricate a jumper 20 cm (8 in) that will connect between ECU connector X-012 pin 24 and X-012 pin 25. Connect the jumper between X-012 pin 24 and X-012 pin 25. Measure the resistance between the diagnostic port connector X-DIAG pin C and X-DIAG pin D. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.

RAIL12FRK1168FA

(1)

Digital volt meter set to measure resistance.

(4)

(2)

Diagnostic port X-DIAG

(5)

(3)

The jumper wire is installed between the (6) CAN high pin and the CAN low pin

CAN Bus to Instrument Cluster CAN high X-C23 pin 6 CAN low X-C23 pin 5 CAN Bus to ECU CAN high X-012 pin 24 CAN low X-012 pin 25 CAN Bus to UCM CAN high X-CN2B pin 1 CAN low X-CN2B pin 10 CAN Bus to Telematics (optional) CAN high X-TELE pin 3 CAN low X-TELE pin 4

Measure the resistance between Telematics connector pin 3 and pin 4. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.

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Measure the resistance between the UCM connector pin 1 and pin 10. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between instrument cluster connector pin 6 and pin 5. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.

RAIL12FRK1167FA

(1)

Digital volt meter set to measure resistance.

(4)

(2)

Diagnostic port X-001

(5)

(3)

Jumper wire installed between the CAN high and CAN low pins

(6)

A. All resistance measurements are less than 10 Ω. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. B. One or more resistance measurements are greater than 20,000 Ω. There is an open circuit in the CAN bus wires. Repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 06 Engine F5C T4 (Vehicle) (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 Cab to Chassis Interface (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 25 Telematics (55.100.DP-C.20.E.25) Wiring harnesses - Electrical schematic sheet 27 Diagnostic Connector (55.100.DP-C.20.E.27) Wiring harnesses - Electrical schematic sheet 21 Instrument Cluster (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 05 Engine F5C T4 (Vehicle) (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 12 Cab to Chassis Interface (55.100.DP-C.20.E.12) Wiring harnesses - Electrical schematic sheet 31 Telematics (55.100.DP-C.20.E.31) Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 35 Diagnostic Connector (55.100.DP-C.20.E.35) Wiring harnesses - Electrical schematic sheet 26 Instrument Cluster (55.100.DP-C.20.E.26)

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1053-Timeout of CAN Message CM1BC WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: CAN bus communications between the instrument cluster and the ECU may have been interrupted. The instrument cluster did not receive the CM1BC message from the ECU. This fault code may be displayed with other CAN bus fault messages. Cause: The instrument cluster did not receive a CAN message from the ECU. CAN bus communications between the instrument cluster and the ECU may have been interrupted. Possible failure modes: 1. An open circuit in the CAN data link wiring. 2. A short circuit in the CAN data link wiring. 3. A faulty device on the CAN data link. 4. A faulty instrument cluster. 5. A faulty ECU. Solution: 1. Use the EST to verify the controller status. Connect the EST to the service tool connector. Turn the ignition switch ON. Verify that the all of the controllers are ONLINE. A. The ECU status is OFFLINE and fault codes 9153 and 1051 are active. Check the 2 A relay ground fuses. Replace the fuses as required. Verify that the fault codes are no longer active. If the fault code is still active, refer to 1051-No CAN Communication With Engine Controller (55.408) B. The ECU status is ONLINE. Go to step 2. 2. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 1053 - Timeout of CAN Message CM1BC is not recorded again. Go to step 3. B. Fault code 1053 - Timeout of CAN Message CM1BC is recorded again. There are one or two other CAN bus fault codes associated with 1053 - Timeout of CAN Message CM1BC. Go to step 3. C. Fault code 1053 - Timeout of CAN Message CM1BC is recorded along with multiple CAN data link faults such as 1051-1063, and/or 3096, 3179 and 3180. Go to 1051-No CAN Communication With Engine Controller (55.408) step 3. 3. Verify that the CAN bus circuit is functioning properly. Connect the Electronic Service Tool to the service tool connector. Turn the ignition switch ON. Verify the connections to the ECU, the instrument cluster, the diagnostic connector, the UCM (if installed), and the optional Telematics unit are tight and secure. Check for CAN bus fault codes while wiggling the harness.

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Turn the ignition switch OFF. Disconnect the instrument cluster connector X-C23. Measure the resistance between X-C23 pin 5 and X-C23 pin 6 on the instrument cluster. The resistance should be between 108 Ω and 132 Ω. Disconnect the ECU connector X-012. Measure the resistance between X-012 pin 24 and X-012 pin 25 on the ECU. The resistance should be between 108 Ω and 132 Ω. A. All connections are secure. Both resistance measurements are within the specified range. OK to return the machine to service. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 2 to confirm elimination of the fault. C. One or both resistance measurements are less than 108 Ω or greater than 132 Ω. Replace the control module that has the bad resistance value. Return to step 2 to confirm elimination of fault.

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1054-Timeout of CAN Message ET1 WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: CAN bus communications between the instrument cluster and the ECU may have been interrupted. The instrument cluster did not receive the ET1 message from the ECU. This fault code may be displayed with other CAN bus fault messages. Cause: The instrument cluster did not receive a CAN message from the ECU. CAN bus communications between the instrument cluster and the ECU may have been interrupted. Possible failure modes: 1. An open circuit in the CAN data link wiring. 2. A short circuit in the CAN data link wiring. 3. A faulty device on the CAN data link. 4. A faulty instrument cluster. 5. A faulty ECU. Solution: 1. Use the EST to verify the controller status. Connect the EST to the service tool connector. Turn the ignition switch ON. Verify that the all of the controllers are ONLINE. A. The ECU status is OFFLINE and fault codes 9153 and 1051 are active. Check the 2 A relay ground fuses. Replace the fuses as required. Verify that the fault codes are no longer active. If the fault code is still active, refer to 1051-No CAN Communication With Engine Controller (55.408) B. The ECU status is ONLINE. Go to step 2. 2. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 1054 - Timeout of CAN Message ET1 is not recorded again. Go to step 3. B. Fault code 1054 - Timeout of CAN Message ET1 is recorded again. There are one or two other CAN bus fault codes associated with 1054 - Timeout of CAN Message ET1. Go to step 3. C. Fault code 1054 - Timeout of CAN Message ET1 is recorded along with multiple CAN data link faults such as 1051-1063, and/or 3096, 3179 and 3180. Go to 1051-No CAN Communication With Engine Controller (55.408) step 3. 3. Verify that the CAN bus circuit is functioning properly. Connect the Electronic Service Tool to the service tool connector. Turn the ignition switch ON. Verify the connections to the ECU, the instrument cluster, the diagnostic connector, the UCM (if installed), and the optional Telematics unit are tight and secure. Check for CAN bus fault codes while wiggling the harness.

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1056-Timeout of CAN Message DPFC1 WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: CAN bus communications between the instrument cluster and the ECU may have been interrupted. The instrument cluster did not receive the DPFC1 message from the ECU. This fault code may be displayed with other CAN bus fault messages. Cause: The instrument cluster did not receive a CAN message from the ECU. CAN bus communications between the instrument cluster and the ECU may have been interrupted. Possible failure modes: 1. An open circuit in the CAN data link wiring. 2. A short circuit in the CAN data link wiring. 3. A faulty device on the CAN data link. 4. A faulty instrument cluster. 5. A faulty ECU. Solution: 1. Use the EST to verify the controller status. Connect the EST to the service tool connector. Turn the ignition switch ON. Verify that the all of the controllers are ONLINE. A. The ECU status is OFFLINE and fault codes 9153 and 1051 are active. Check the 2 A relay ground fuses. Replace the fuses as required. Verify that the fault codes are no longer active. If the fault code is still active, refer to 1051-No CAN Communication With Engine Controller (55.408) B. The ECU status is ONLINE. Go to step 2. 2. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 1056 - Timeout of CAN Message DPFC1 is not recorded again. Go to step 3. B. Fault code 1056 - Timeout of CAN Message DPFC1 is recorded again. There are one or two other CAN bus fault codes associated with 1056 - Timeout of CAN Message DPFC1. Go to step 3. C. Fault code 1056 - Timeout of CAN Message DPFC1 is recorded along with multiple CAN data link faults such as 1051-1063, and/or 3096, 3179 and 3180. Go to 1051-No CAN Communication With Engine Controller (55.408) step 3. 3. Verify that the CAN bus circuit is functioning properly. Connect the Electronic Service Tool to the service tool connector. Turn the ignition switch ON. Verify the connections to the ECU, the instrument cluster, the diagnostic connector, the UCM (if installed), and the optional Telematics unit are tight and secure. Check for CAN bus fault codes while wiggling the harness.

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1058-Timeout of CAN Message EDC2BC WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: CAN bus communications between the instrument cluster and the ECU may have been interrupted. The instrument cluster did not receive the EDC2BC message from the ECU. This fault code may be displayed with other CAN bus fault messages. Cause: The instrument cluster did not receive a CAN message from the ECU. CAN bus communications between the instrument cluster and the ECU may have been interrupted. Possible failure modes: 1. An open circuit in the CAN data link wiring. 2. A short circuit in the CAN data link wiring. 3. A faulty device on the CAN data link. 4. A faulty instrument cluster. 5. A faulty ECU. Solution: 1. Use the EST to verify the controller status. Connect the EST to the service tool connector. Turn the ignition switch ON. Verify that the all of the controllers are ONLINE. A. The ECU status is OFFLINE and fault codes 9153 and 1051 are active. Check the 2 A relay ground fuses. Replace the fuses as required. Verify that the fault codes are no longer active. If the fault code is still active, refer to 1051-No CAN Communication With Engine Controller (55.408) B. The ECU status is ONLINE. Go to step 2. 2. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 1058 - Timeout of CAN Message EDC2BC is not recorded again. Go to step 3. B. Fault code 1058 - Timeout of CAN Message EDC2BC is recorded again. There are one or two other CAN bus fault codes associated with 1058 - Timeout of CAN Message EDC2BC. Go to step 3. C. Fault code 1058 - Timeout of CAN Message EDC2BC is recorded along with multiple CAN data link faults such as 1051-1063, and/or 3096, 3179 and 3180. Go to 1051-No CAN Communication With Engine Controller (55.408) step 3. 3. Verify that the CAN bus circuit is functioning properly. Connect the Electronic Service Tool to the service tool connector. Turn the ignition switch ON. Verify the connections to the ECU, the instrument cluster, the diagnostic connector, the UCM (if installed), and the optional Telematics unit are tight and secure. Check for CAN bus fault codes while wiggling the harness.

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1059-Timeout of CAN Message DM1 WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: CAN bus communications between the instrument cluster and the ECU may have been interrupted. The instrument cluster did not receive the DM1 message from the ECU. This fault code may be displayed with other CAN bus fault messages. Cause: The instrument cluster did not receive a CAN message from the ECU. CAN bus communications between the instrument cluster and the ECU may have been interrupted. Possible failure modes: 1. An open circuit in the CAN data link wiring. 2. A short circuit in the CAN data link wiring. 3. A faulty device on the CAN data link. 4. A faulty instrument cluster. 5. A faulty ECU. Solution: 1. Use the EST to verify the controller status. Connect the EST to the service tool connector. Turn the ignition switch ON. Verify that the all of the controllers are ONLINE. A. The ECU status is OFFLINE and fault codes 9153 and 1051 are active. Check the 2 A relay ground fuses. Replace the fuses as required. Verify that the fault codes are no longer active. If the fault code is still active, refer to 1051-No CAN Communication With Engine Controller (55.408) B. The ECU status is ONLINE. Go to step 2. 2. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 1059 - Timeout of CAN Message DM1 is not recorded again. Go to step 3. B. Fault code 1059 - Timeout of CAN Message DM1 is recorded again. There are one or two other CAN bus fault codes associated with 1059 - Timeout of CAN Message DM1. Go to step 3. C. Fault code 1059 - Timeout of CAN Message DM1 is recorded along with multiple CAN data link faults such as 1051-1063, and/or 3096, 3179 and 3180. Go to 1051-No CAN Communication With Engine Controller (55.408) step 3. 3. Verify that the CAN bus circuit is functioning properly. Connect the Electronic Service Tool to the service tool connector. Turn the ignition switch ON. Verify the connections to the ECU, the instrument cluster, the diagnostic connector, the UCM (if installed), and the optional Telematics unit are tight and secure. Check for CAN bus fault codes while wiggling the harness.

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1201-Hydraulic oil filter switch open circuit WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The instrument cluster has sensed that there is an open circuit in the hydraulic filter restriction circuit. Diagnostic trouble code 1201 has an error priority of white. There are no restrictions while Diagnostic Trouble Code 1201 is active. Cause: The instrument cluster has sensed that there is an open circuit in the hydraulic filter restriction circuit. The fault is active when the ignition switch is ON and the start input is low and there is an open circuit in the hydraulic filter circuit. Possible failure modes: 1. An open circuit in the wiring. 2. A failure of the hydraulic filter restriction switch. 3. A failure in the instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1201 is recorded again. Go to step 2. 2. Check the hydraulic oil filter. Verify that the hydraulic oil filter is clean. Replace the oil filter as required. A. The oil filter is dirty. Replace the oil filter and retest. Return the step 1 to confirm elimination of fault. B. The filter is not dirty and does not need to be replaced. Go to step 3. 3. Verify that the wiring and connectors are free of damage. Inspect the instrument cluster and the hydraulic oil filter switch connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the instrument cluster to the hydraulic oil filter switch . Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 4. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. Turn the ignition switch OFF. Disconnect the hydraulic oil filter switch connector. Fabricate a jumper wire that will connect between connector X-OILFTL pin 1 and chassis ground. Connect the jumper wire between connector X-OILFTL pin 1 and chassis ground. Turn the ignition switch on and access the fault code screen. Fault code 1201 should no longer be active. 47683911 27/02/2015

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A. Fault code 1201 is not active. Replace the hydraulic filter restriction switch and retest. Return to step 1 to confirm elimination of fault. B. Fault code 1201 is still active. Go to step 5. 5. Measure the resistance through the signal wire. Turn the ignition switch OFF. Leave the hydraulic oil filter switch disconnected. Leave the jumper wire connected to connector X-OILFLT. Disconnect instrument cluster connector X-C23. Measure the resistance between instrument cluster connector X-C23 pin 2 and chassis ground. The resistance should be less than 10 Ω. A. The resistance is less than 10 Ω. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 10 Ω. There is an open circuit in the wiring. Replace the wiring harness as required. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 Instrument Cluster (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 10 Cab to Chassis Interface (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 26 Instrument Cluster (55.100.DP-C.20.E.26) Wiring harnesses - Electrical schematic sheet 12 Cab to Chassis Interface (55.100.DP-C.20.E.12)

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1205-Hydraulic Enable (EH Machines) - Hydraulic Enable Output, Short to Power WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: Fault code 1205 has an error priority of Amber. There are no restrictions with Fault code 1205. Cause: The Instrument Cluster has determined that the Hydraulic Enable output from the Instrument Cluster does not match the request from the Instrument Cluster. (The fault is only activated when Ignition is on and Hydraulic Enable Commanded State is Low and Hydraulic Enable Solenoid is energized.) Possible failure modes: 1. Shorted or open wire in circuit. 2. Failure of UCM. 3. Instrument Cluster has internal failure. Solution: 1.

Use the machine to recreate conditions for error. Use the EST to verify 1205 - Hydraulic Enable (EH Machines) - Hydraulic Enable Output, Short to Power is active. A. If the fault is active, continue with step 2. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 10.

Check for short to high. Disconnect connector X-CN3A from the UCM. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for voltage between connector X-CN3A pin 23, or connector X-C23 pin 30 and ground. A. If there is no voltage, continue with step 4. B. If there is voltage, there is a short to high source on wire 303 (White) between connector X-CN3A pin 23 and connector X-C23 pin 30. Continue with step 3.

Locate the short to high. Disconnect connector X-ECC2A from connector X-ECC2B. Using a multi-meter, check for voltage between connector X-CN3A pin 23, or connector X-ECC2B pin 5 and ground. A. If there is no voltage, there is a short to high source on wire 303 (White) between connector X-ECC2A pin 5 and connector X-C23 pin 30. Repair or replace the wire. B. If there is voltage, there is a short to high source on wire 303 (White) between connector X-CN3A pin 23 and connector X-ECC2B pin 5. Repair or replace the wire.

Check for open circuit. Disconnect connector X-CN3A from the UCM. Disconnect connector X-C23 from the UCM. Using a multi-meter, check continuity between connector X-CN3A pin 23 and connector X-C23 pin 30. A. If there is continuity, continue with step 7. B. If there is no continuity, there is an open wire condition on wire 303 (White) between connector X-CN3A pin 23 and connector X-C23 pin 30. Continue with step 5.

Locate the open circuit. Disconnect connector X-ECC2A from connector X-ECC2B. Using a multi-meter, check continuity between connector X-ECC2A pin 5 and connector X-C23 pin 30. A. If there is no continuity, there is an open wire condition on wire 303 (White) between connector X-ECC2A pin 5 and connector X-C23 pin 30. Repair or replace the wire. B. If there is continuity, continue with step 6 47683911 27/02/2015

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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 30 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 303 (White) between connector X-CN3A pin 23 and connector X-C23 pin 30. 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 30 and ground. A. If there is no continuity, there is a short to ground on wire 303 (White) between connector X-CN3A pin 23 and X-ECC2B pin 5. Repair or replace the shorted wire. B. If there is continuity, there is a short to ground condition on wire 303 (White) between connector X-ECC2A pin 5 and connector X-C23 pin 30. Repair or replace the shorted wire.

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 10. 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.

10. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify 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 harnesses - Electrical schematic sheet 26 Instrument Cluster (55.100.DP-C.20.E.26) Wiring harnesses - Electrical schematic sheet 12 Cab to Chassis Interface (55.100.DP-C.20.E.12) Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20)

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1206-CAN Connection: Configuration Response Timeout WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: CAN bus communications between the instrument cluster and the ECU may have been interrupted. The instrument cluster did not receive the EEC3 message from the ECU. This fault code may be displayed with other CAN bus fault messages. The instrument cluster will illuminate the stop lamp and will continually sound the audible alarm while this fault is active. Cause: The instrument cluster did not receive a CAN message from the ECU. CAN bus communications between the instrument cluster and the ECU may have been interrupted. Possible failure modes: 1. An open circuit in the CAN bus wiring. 2. A short circuit in the CAN bus wiring. 3. A faulty instrument cluster. 4. A faulty ECU. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 1206 - CAN Connection: Configuration Response Timeout is not recorded again. Go to step 2. B. Fault code 1206 - CAN Connection: Configuration Response Timeout is recorded again. There are one or two other CAN bus fault codes associated with 1206 - CAN Connection: Configuration Response Timeout. Go to step 2. C. Fault code 1206 - CAN Connection: Configuration Response Timeout is recorded along with other CAN data link faults such as 1051-1059, and/or 3096, 3179 and 3180. Go to 1051-No CAN Communication With Engine Controller (55.640) step 3. 2. Verify that the CAN bus circuit is functioning properly. Connect the Electronic Service Tool to the service tool connector. Turn the ignition switch ON. Verify the connections to the ECU, the instrument cluster, the UCM, the diagnostic connector, and the optional Telematics unit are tight and secure. Check for CAN bus fault codes while wiggling the harness. Turn the ignition switch OFF. Disconnect the instrument cluster connector X-C23-EH. Measure the resistance between X-C23-EH pin 6 and X-C23-EH pin 5 on the instrument cluster. The resistance should be between 108 Ω and 132 Ω. Disconnect the ECU connector X-012. Measure the resistance between X-012 pin 24 and X-012 pin 25 on the ECU. The resistance should be between 108 Ω and 132 Ω. A. All connections are secure. Both resistance measurements are within the specified range. OK to return the machine to service. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of the fault. 47683911 27/02/2015

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C. One or both resistance measurements are less than 108 Ω or greater than 132 Ω. Replace the control module that has the bad resistance value. Return to step 1 to confirm elimination of fault.

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1207-Memory Parameters - Invalid Configuration Between IC and UCM WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: On EH controled machines, error code 9403 - Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable and/or 1207 - Memory Parameters - Invalid Configuration Between IC and UCM displays after updating the earlier instrument cluster software to version 1.3.0.0 Diagnostic Trouble Code 1207 - Memory Parameters - Invalid Configuration Between IC and UCM has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 1207 - Memory Parameters - Invalid Configuration Between IC and UCM. Cause: The Instrument Cluster expects the Enhanced High Flow (EHF) option is on the machine and displays the error codes when the machine model configuration does not match the expectation of the Instrument Cluster. Solution: 1. Use EST to reset the machine model configurations and clear the fault code(s). (1) Connect the EST to the machine diagnostics connector per the Cable and Adapter Help icon. (2) Sit in the seat to power the controllers. (3) Click on the Controller Status icon. Verify that the Instrument Cluster (IC) and the Vehicle Control Module (VCM) are both online. (4) Click on the configuration icon. (5) Double click on the Machine Configurations selection. (6) Click on Set up Controller for Configuring. . (7) Change the drop down box selections to match the machine. a) In Panel identifier, Select Electro-hydraulic. b) Select Door Status. c) Select Model d) Select Region e) If the machine is EHF, Select available and if the machine is not EHF, select not available. (8) Click on Send Modified Values to Controller. (9) Wait 5 seconds and then Power Cycle the machine by exiting the seat. (10) Verify error code 9403 - Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable and/or 1207 - Memory Parameters - Invalid Configuration Between IC and UCM is no longer displayed. A. Error code 9403 - Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable and/or 1207 - Memory Parameters - Invalid Configuration Between IC and UCM is no longer displayed. OK to return the machine to service. B. Error code 9403 - Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable and/or 1207 - Memory Parameters - Invalid Configuration Between IC and UCM are active, For non-EHF machines continue with step 2 C. Error code 9403 - Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable and/or 1207 - Memory Parameters - Invalid Configuration Between IC and UCM are active, For EHF machines continue with step 3 47683911 27/02/2015

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2. Configure the machine to a model that offers EHF as an option and reconfigure to the original model. Example: The SR150 or L215 are models that do not offer the EHF option and is displaying fault code 9403 Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable after configuring correctly and performing the power cycle. (1) Change the drop down box selections to match the machine. a) In Panel identifier, Select Electro-hydraulic. b) Select Door Status. c) Select a known EHF model such as SV300 or L230. d) Select Region e) Select available. (2) Click on Send Modified Values to Controller. (3) Wait 5 seconds and then Power Cycle the machine by exiting the seat. (4) Verify error code 9403 - Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable and/or 1207 - Memory Parameters - Invalid Configuration Between IC and UCM is no longer displayed. (5) Configure the machine to the correct settings of SR150 or L215 and EHF Not Available. 3. Ensure Enhanced High Flow is available and select a different model that offers EHF option. Example: SV300 and L230 are models that offer EHF option and display 9403 - Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable after configuring correctly. (1) Change the drop down box selections to match the machine. a) In Panel identifier, Select Electro-hydraulic. b) Select Door Status. c) Select a different known model that is not the same model as the actual machine. d) Select Region e) If the machine is EHF, Select available and if the machine is not EHF, select not available. (2) Click on Send Modified Values to Controller. (3) Wait 5 seconds and then Power Cycle the machine by exiting the seat. (4) Verify error code 9403 - Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable and/or 1207 - Memory Parameters - Invalid Configuration Between IC and UCM is no longer displayed. (5) When fault code 9403 - Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable and/or 1207 - Memory Parameters - Invalid Configuration Between IC and UCM are no longer displayed, follow steps 1 - 4 again to reconfigure the machine back to the correct model.

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Electrical systems - FAULT CODES

1208-Seat Switch Plausibility Fault WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The instrument cluster and the UCM do not agree on the presence of an operator. Diagnostic Trouble Code 1208 Seat Switch Plausibility Fault has an error priority of Amber. There are no restrictions while Diagnostic Trouble Code 1208 - Seat Switch Plausibility Fault is active. Cause: The instrument cluster X-C23 pin 12 and UCM connector X-CN3B pin 30 do not agree on the presence of an operator. Possible failure modes: 1. Faulty wiring. 2. Failure of the instrument cluster. 3. Failure of the UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1208 - Seat Switch Plausibility Fault is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the instrument cluster, and the seat switch connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM and the instrument cluster to the seat switch. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Use EST to test the circuit. Turn the ignition switch ON. Sit in the operator’s seat. Use the EST to access the status of the seat switch. The switch status should be ON. EST seat switch parameters Reference

Data Description Seat switch status

Source UCM

A. The UCM seat switch status is OFF. Go to step 4. B. The UCM seat switch status is ON. Go to step 5. 4. Test the UCM input. Turn the ignition switch OFF. 47683911 27/02/2015

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Fabricate a jumper wire that will connect between the positive battery terminal and UCM connector X-CN3B pin 30. Connect the jumper wire between the positive battery terminal and UCM connector X-CN3B pin 30. Turn the ignition switch ON. Sit in the operator’s seat. Use the EST to access the status of the seat switch. The switch status should be ON. A. The UCM seat switch status is OFF. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The UCM seat switch status is ON. There is a problem in the wiring between the seat switch and UCM connector X-CN3B. Check splice SP-101. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 5. Test the instrument cluster input. Turn the ignition switch OFF. Fabricate a jumper wire that can connect between the positive battery terminal and instrument cluster connector X-C23 pin 12. Connect the jumper wire between the positive battery terminal and instrument cluster connector X-C23 pin 12. Turn the ignition switch ON. Sit in the operator’s seat. Use the EST to access the active fault codes. Fault code 1208 - Seat Switch Plausibility Fault should no longer be active. A. Fault code 1208 - Seat Switch Plausibility Fault is no longer active. There is a problem in the wiring between the seat switch and instrument cluster connector X-C23. Check splice SP-086. Return to step 1 to confirm elimination of the fault. B. Fault code 1208 - Seat Switch Plausibility Fault is still active. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 18 Seat Switch (55.100.DP-C.20.E.18) Wiring harnesses - Electrical schematic sheet 12 Cab to Chassis Interface (55.100.DP-C.20.E.12) Wiring harnesses - Electrical schematic sheet 26 Instrument Cluster (55.100.DP-C.20.E.26) Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20)

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Electrical systems - FAULT CODES

1211-Calibration Functions - Joystick Calibration Not Complete WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: Diagnostic Trouble Code 1211 - Calibration Functions - Joystick Calibration Not Complete has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 1211 - Calibration Functions - Joystick Calibration Not Complete. Cause: UCM has sensed that the Joystick Calibration is not complete. Possible failure modes: 1. The joystick calibration is not complete. 2. A faulty UCM. Solution: 1. Use the machine to recreate conditions for error. Use the EST to verify fault code 1211 - Calibration Functions - Joystick Calibration Not Complete is active. A. If the fault is active, continue with step 2. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 3. 2. Use the EST to perform calibration on the Joystick. Electrical system - H1 - Calibration procedures - Joystick (55.000) A. If the fault code clears, continue normal operation. B. If the fault code does not clear, replace the joystick and perform the joystick calibration. If the code persists, replace the UCM. 3. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and the display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

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Electrical systems - FAULT CODES

1212-Calibration Functions - Ground Drive Calibration Not Complete WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: Diagnostic Trouble Code 1212 - Calibration Functions - Ground Drive Calibration Not Complete has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 1212 - Calibration Functions - Ground Drive Calibration Not Complete. Cause: UCM has sensed that the Ground Drive Calibration is not complete. Possible failure modes: 1. The ground drive calibration not complete. 2. A faulty UCM. Solution: 1. Use the machine to recreate conditions for error. Use the EST to verify fault code 1212 - Calibration Functions - Ground Drive Calibration Not Complete is active. A. If the fault is active, continue with step 2. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 3. 2. Use the EST to perform calibration on the Ground Drive. Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures - Ground Drive (55.000) A. If the fault code clears, continue normal operation. B. If the fault code does not clear, and calibration will not complete, submit an Asist concern for the machine model and a brief explanation of the error message that was received and record the step the calibration failed on. 3. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and the display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

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Electrical systems - FAULT CODES

1213-Calibration Functions - Loader Valve Calibration Not Complete WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: Diagnostic Trouble Code 1213 - Calibration Functions - Loader Valve Calibration Not Complete has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 1213 - Calibration Functions - Loader Valve Calibration Not Complete. Cause: UCM has sensed that the Loader Valve Calibration is not complete. Possible failure modes: 1. The loader valve calibration is not complete. 2. A faulty UCM. Solution: 1. Use the machine to recreate conditions for error. Use the EST to verify fault code 1213 - Calibration Functions - Loader Valve Calibration Not Complete is active. A. If the fault is active, continue with step 2. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 3. 2. Use the EST to perform calibration on the loader valve. A. If the fault code clears, continue normal operation. B. If the fault code does not clear, replace the loader valve and perform the loader valve calibration. If the code persists, submit an Asist concern for the machine model and a brief explanation of the error message that was received and record the step the calibration failed on. 3. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and the display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

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Electrical systems - FAULT CODES

1215-Saturation Function not complete - Forward Pumps WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: 1215 - Saturation Function not complete - Forward Pumps is triggered each time a ground drive calibration is performed with the service tool. This fault code is a reminder to complete the full-stroke calibration procedure. Solution: 1. Use the EST to perform calibration on the Ground Drive. Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures - Ground Drive (55.000) A. If the fault code clears, continue normal operation. B. If the fault code does not clear, and calibration will not complete, submit an Asist concern for the machine model and a brief explanation of the error message that was received and record the step the calibration failed on.

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Electrical systems - FAULT CODES

1216-Saturation Function not complete - Reverse Pumps WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: 1216 - Saturation Function not complete - Reverse Pumps is triggered each time a ground drive calibration is performed with the service tool. This fault code is a reminder to complete the full-stroke calibration procedure. Solution: 1. Use the EST to perform calibration on the Ground Drive. Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures - Ground Drive (55.000) A. If the fault code clears, continue normal operation. B. If the fault code does not clear, and calibration will not complete, submit an Asist concern for the machine model and a brief explanation of the error message that was received and record the step the calibration failed on.

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Electrical systems - FAULT CODES

1221-VCM Temperature / Current Draw Over Limit C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE Electro hydraulic controls WE WE Electro hydraulic controls

Context: Diagnostic Trouble Code 1221 - VCM Temperature / Current Draw Over Limit has an error priority of Amber. Limp Home Hydraulics are enabled while Diagnostic Trouble Code 1221 - VCM Temperature / Current Draw Over Limit is active. Cause: The UCM has sensed a high current or a high temperature within the UCM. Possible failure modes: 1. A failure of the UCM. Solution: 1. Turn off the machine. Restart the machine and recreate conditions for error. Use the EST to verify fault code 1221 - VCM Temperature / Current Draw Over Limit is active. A. If the fault is active, the UMC has failed. Replace the UCM. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 2. 2. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and the display. Investigate the nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

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Electrical systems - FAULT CODES

1222-VCM Sustained Over Temperature Limit C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE Electro hydraulic controls WE WE Electro hydraulic controls

Context: Diagnostic Trouble Code 1222 - Health Monitor Functions - UCM - UCM Sustained Over Temperature Limit has an error priority of Red. The hydraulics are disabled while this fault code is active. Cause: The UCM has sensed a high temperature within the UCM. Possible failure modes: 1. A failure of the UCM. Solution: 1. Turn off the machine. Restart the machine and recreate conditions for error. Use the EST to verify that fault code 1222 - VCM Sustained Over Temperature Limit is active. A. If the fault is active, the UCM has failed. Replace the UCM. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 2. 2. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and the display. Investigate the nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

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1223-VCM Sustained Over Current Limit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: Diagnostic Trouble Code 1223 - Health Monitor Functions - UCM - UCM Sustained Over Current Limit has an error priority of Red. The hydraulics are disabled while the fault is active. Cause: The UCM has sensed a high current within the UCM. Possible failure modes: 1. A failure of the UCM. Solution: 1. Turn off the machine. Restart the machine and recreate conditions for error. Use the EST to verify fault code 1223 - VCM Sustained Over Current Limit is active. A. If the fault is active, the UCM has failed. Replace the UCM. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 2. 2. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and the display. Investigate the nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

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1224-VCM Internal Memory or Core Monitoring Fault WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: Diagnostic Trouble Code 1224 - Health Monitor Functions - UCM - Internal Memory or Core Monitoring Fault has an error priority of Red. The hydraulics are disabled while the fault is active. Cause: The UCM has sensed an internal fault within the UCM. Possible failure modes: 1. A failure of the UCM. Solution: 1. Turn off the machine. Restart the machine and recreate conditions for error. Use the EST to verify fault code 1224 - VCM Internal Memory or Core Monitoring Fault is active. A. If the fault is active, the UCM has failed. Replace the UCM. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 2. 2. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and the display. Investigate the nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

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1225-VCM EEPROM Memory Checksum Fault C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE Electro hydraulic controls WE WE Electro hydraulic controls

Context: Diagnostic Trouble Code 1225 - Health Monitor Functions - UCM - EEPROM Memory Checksum Fault has an error priority of Red. The hydraulics are disabled while the fault is active. Cause: The UCM has sensed a checksum failure within the UCM memory. Possible failure modes: 1. A failure of the UCM. Solution: 1. Turn off the machine. Restart the machine and recreate conditions for error. Use the EST to verify fault code 1225 - VCM EEPROM Memory Checksum Fault is active. A. If the fault persists for three machine restarts, the UCM has failed. Replace the UCM. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 2. 2. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and the display. Investigate the nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

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1350-Hyd Enable Switch - Implausible State (Hardwire vs CAN) WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: Diagnostic Trouble Code 1350 - Hyd Enable Switch - Implausible State (Hardwire vs CAN) has an error priority of amber. The loader functions and the ground drive functions will operate in limp home mode while this fault is active. Cause: The UCM is receiving conflicting information about the hydraulic enable switch. The fault is active when the ignition is on and the hydraulic enable pin voltage is opposite of value transmitted from instrument cluster.

Possible failure modes: 1. A faulty instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault code: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1350 - Hyd Enable Switch - Implausible State (Hardwire vs CAN) is recorded again. Fault code 9156 - Hyd Enable Switch - Hyd Enable Button Error from AIC may also be active. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault.

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1532-Backup Alarm - Short to Ground WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed an improper current from the backup alarm. Diagnostic Trouble Code 1532 - Backup Alarm Short to Ground has an error priority of White. The backup alarm is disabled while Diagnostic Trouble Code 1532 - Backup Alarm - Short to Ground is active. Cause: The UCM has sensed an improper current from the backup alarm. The fault is active only when both pumps are in reverse and the backup alarm solenoid output current is high. Possible failure modes: 1. A short circuit in the wiring. 2. A faulty backup alarm. 3. The UCM has an internal failure. Solution: 1. Use the machine to recreate conditions for error. Use the EST to verify fault code 1532 - Backup Alarm - Short to Ground is active. A. If the fault is active, continue with step 2. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 4. 2. Check for a short circuit to ground. Disconnect connector X-BKUP-PWR from the backup alarm. Disconnect UCM connector CN3B. Measure the resistance between CN3B pin 18 and chassis ground. The resistance should be greater than 20,000 Ω. A. The resistance is greater than 20,000 Ω. Go to step 3. B. The resistance is less than 20,000 Ω. There is a short circuit in the wiring. Repair as required. Return to step 1 to confirm elimination of the fault. 3. Measure the resistance through the backup alarm. Disconnect connector X-BKUP-GND from the backup alarm. Use a multi-meter to measure the resistance between the pins on the backup alarm. A. If resistance is normal, replace the UCM. B. If resistance is infinite, the backup alarm has developed an open. Replace the backup alarm . C. If resistance is 0 Ω, the backup alarm has shorted internally. Replace the backup alarm. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and the display. Investigate the nearby wiring. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. 47683911 27/02/2015

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B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 04 System Power and Grounds (55.100.DP-C.20.E.04)

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1533-Backup Alarm - Short to Power WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the backup alarm output does not agree with the desired backup alarm status. Diagnostic Trouble Code 1533 - Backup Alarm - Short to Power has an error priority of White. The backup alarm is disabled while Diagnostic Trouble Code 1533 - Backup Alarm - Short to Power is active. Cause: The UCM has sensed that the backup alarm output does not agree with the desired backup alarm status. The fault is activate while the pumps are not in reverse and the backup alarm solenoid output voltage is greater than 8 V. Possible failure modes: 1. A short circuit in the wiring. 2. A faulty backup alarm. 3. The UCM has an internal failure. Solution: 1. Use the machine to recreate conditions for error. Use the EST to verify fault code 1533 - Backup Alarm - Short to Power is active. A. If the fault is active, continue with step 2. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 4. 2. Check for short circuit to another voltage. Disconnect connector X-BKUP-PWR from the backup alarm. Disconnect UCM connector CN3B. Use a multi-meter to measure the voltage between UCM connector CN3B pin 18 and chassis ground. A. If there is no voltage, continue with step 3. B. If there is voltage, there is a short to another voltage source on the between the UCM connector and the backup alarm. Repair or replace the wire as required. 3. Check for proper operation of the UCM. Reconnect the UCM connector CN3B. Use a multi-meter to measure the voltage between connector X-BKUP-PWR pin 1 and chassis ground. A. If voltage is greater than 8 V, the UCM has failed. Replace the UCM. B. If voltage is less than 8 V, continue with step 4. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and the display. Investigate the nearby wiring. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. 47683911 27/02/2015

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Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 04 System Power and Grounds (55.100.DP-C.20.E.04)

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1900-VCM Ground Fault WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed low current in the UCM ground line. Diagnostic Trouble Code 1900 - VCM Ground Fault has an error priority of Red. All hydraulics are disabled while Diagnostic Trouble Code 1900 - VCM Ground Fault is active. Cause: The UCM has sensed low current in the UCM ground line. The fault is active while the ignition is on and there is a high resistance in the UCM ground line. Possible failure modes: 1. Faulty chassis ground connections. 2. An open circuit in the UCM ground circuit. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault code: Start and operate machine. A. The fault code is not recorded again. Verify that the chassis ground connection is clean and secure to the frame. Verify that the frame connection is free of paint, grease, oil, dirt, and debris. OK to return the machine to service. B. Fault code 1900 - VCM Ground Fault is recorded again. Go to step 2. C. If fault code 1900 - VCM Ground Fault is recorded along with other UCM fault codes, verify that the chassis ground connection is clean and secure to the frame. Verify that the frame connection is free of paint, grease, oil, dirt, and debris. Return to step 1 to confirm elimination of the fault. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Verify the connections from the UCM to the chassis ground are tight and secure. Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment from the UCM to the chassis ground connection. Verify that the chassis ground connections are clean and secure to the frame. Verify that the connection is free of paint, grease, oil, dirt, and debris. A. The harness is not damaged and all connections are secure. Go to step 3. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the UCM ground connection. Turn the ignition switch OFF. Disconnect the UCM connector CN1A. Measure the resistance between CN1A pin 7 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. 47683911 27/02/2015

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Measure the resistance between CN1A pin 1 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 Ω. The UCM ground connection is free of grease, oil, paint, dirt and debris. Temporarily replace the UCM and retest. Return to 1 to confirm elimination of the fault. B. One or both resistance measurements are greater than 10 Ω. There is a high resistance or an open circuit in the UCM chassis ground connection. Verify that the UCM ground connection is free of paint, oil, grease, dirt, and debris. Repair or replace the UCM ground wire as required. Return to 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 04 System Power and Grounds (55.100.DP-C.20.E.04) Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20)

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1901-VCM - VCM Supply Voltage High WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the voltage on CN1A pin 20 is greater than 16 V. There are no restrictions while Diagnostic Trouble Code 1901 - VCM - VCM Supply Voltage High is active. Cause: The UCM has sensed that the voltage on CN1A pin 20 is greater than 16 V. The fault is active while the ignition is ON and the input voltage is greater than 16 V. Possible failure modes: 1. A faulty ground connection on the rear right-hand ground lug. 2. A problem with the battery or the battery charging system. 3. A faulty UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1901 - VCM - VCM Supply Voltage High is recorded again. Go to step 2. C. If fault code 1901 - VCM - VCM Supply Voltage High is recorded along with other diagnostic codes such 1014 - Cluster Battery Monitor: Over Voltage > 16.5 volts and 3051 - Battery voltage is higher than expected, there is a problem in the electrical charging system on the machine. Troubleshoot the alternator charging system. 2. Verify the harness is not damaged Turn the ignition switch OFF. Verify the connections to the UCM and to the alternator are tight and secure. Verify the chassis ground connections to the UCM are tight and secure. The chassis ground connections must be free of paint, rust, oil, dirt, and debris. Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment. A. The wiring harness is not damaged and all connections are secure. Go to step 3. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Check the ground connection on the rear right-hand ground lugs. Verify that the grounding boss is free of paint, oil, dirt, and debris. Verify that the ground connection is tight and secure. A. The grounding boss is clean and free of paint. The grounding connection is secure. Go to step 4. B. The grounding boss is dirty or cover with paint. Remove the dirt. Remove the paint. Repair as required. Return to step 1 to confirm elimination of fault. 4. Measure the alternator output voltage. 47683911 27/02/2015

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Start the engine. Set engine speed to low idle. Measure the voltage at the alternator. The voltage should be approximately 14.8 V. A. The voltage is approximately 14.8 V. Go to step 5. B. The voltage is greater than 16 V. There is a problem with the alternator. Replace the alternator and retest. Return to step 1 to confirm elimination of fault. 5. Measure the voltage at the UCM. Turn the ignition switch ON. Disconnect UCM connector CN1A. Start the engine. Measure the voltage between UCM connector CN1A pin 20 and chassis ground. The voltage should be between 11 V and 14.8 V. A. The voltage is approximately 14.8 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is greater than 16 V. Replace the alternator. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 02 Accessory Power Distribution (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 01 Main Power Distribution (55.100.DP-C.20.E.01)

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1902-VCM - VCM Supply Voltage Low WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the voltage on CN1A pin 20 is less than 11.5 V. There are no restrictions while Diagnostic Trouble Code 1902 - VCM - VCM Supply Voltage Low is active. Cause: The UCM has sensed that the voltage on CN1A pin 20 is less than 11.5 V, but greater than 9 V. The fault has been active for a period greater than 30 s. Possible failure modes: 1. A problem with the battery or the battery charging system. 2. A short circuit in the wiring. 3. A faulty UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1902 - VCM - VCM Supply Voltage Low is recorded again. Go to step 2. C. If fault code 1902 - VCM - VCM Supply Voltage Low is recorded along with other diagnostic codes such 1015 - Cluster Battery Monitor: Under Voltage < 11.5 volts and 3052 - Battery voltage is lower than expected, then there is a problem in the electrical charging system on the machine. Troubleshoot the alternator charging system. 2. Verify the harness is not damaged Turn the ignition switch OFF. Verify the connections to the UCM and the alternator are tight and secure. Verify the chassis ground connections to the UCM are tight and secure. The chassis ground connections should be free of paint, rust, oil, dirt, and debris. Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment. A. The wiring harness is not damaged and all connections are secure. Go to step 3. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the alternator output. Start the engine. Set engine speed to low idle. Measure the voltage at the alternator. The voltage should be approximately 14.8 V. A. The voltage is approximately 14.8 V. Go to step 4.

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B. The voltage is less than 11.5 V. There is a problem with the alternator. Replace the alternator. Return to step 1 to confirm elimination of fault. 4. Measure the voltage at the UCM. Turn the ignition switch ON. Disconnect UCM connector CN1A. Start the engine. Measure the voltage between UCM connector CN1A pin 20 and chassis ground. The voltage should be between 11 V and 14.8 V. A. The voltage is approximately 14.8 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is less than 11.5 V. There is a problem with the alternator. Replace the alternator. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 02 Accessory Power Distribution (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 01 Main Power Distribution (55.100.DP-C.20.E.01)

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1903-VCM - VCM Supply Voltage Below Operational Limit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the voltage on CN1A pin 20 is less than 9 V. Diagnostic Trouble Code 1903 - VCM - VCM Supply Voltage Below Operational Limit has an error priority of Red. All hydraulics are disabled while Diagnostic Trouble Code 1903 - VCM - VCM Supply Voltage Below Operational Limit is active. Cause: The UCM has sensed that the voltage on CN1A pin 20 is less than 9 V. The fault is active for a period greater than 30 s. Possible failure modes: 1. A problem with the battery or the battery charging system. 2. A short circuit in the wiring. 3. A faulty UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1903 - VCM - VCM Supply Voltage Below Operational Limit is recorded again. Go to step 2. C. If fault code 1903 - VCM - VCM Supply Voltage Below Operational Limit is recorded along with other diagnostic codes such 1015 - Cluster Battery Monitor: Under Voltage < 11.5 volts and 3052 - Battery voltage is lower than expected, there is a problem in the electrical charging system on the machine. Troubleshoot the alternator charging system. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Verify the connections to the UCM and the alternator are tight and secure. Verify the chassis ground connections to the UCM are tight and secure. The chassis ground connections should be free of paint, rust, oil, dirt, and debris. Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment. A. The wiring harness is not damaged and all connections are secure. Go to step 3. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 3. Measure the alternator output. Start the engine. Set engine speed to low idle. Measure the voltage at the alternator. The voltage should be approximately 14.8 V. A. The voltage is approximately 14.8 V. Go to step 4. 47683911 27/02/2015

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B. The voltage is less than 9 V. Replace the alternator. Return to step 1 to confirm elimination of fault. 4. Measure the voltage at the UCM. Turn the ignition switch ON. Disconnect UCM connector CN1A. Start the engine. Measure the voltage between UCM connector CN1A pin 20 and chassis ground. The voltage should be between 11 V and 14.8 V. A. The voltage is approximately 14.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is less than 9 V. Replace the alternator and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 02 Accessory Power Distribution (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 01 Main Power Distribution (55.100.DP-C.20.E.01)

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1904-VCM - Rail 12VB - 5V Regulators Supply Input Power Off WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the voltage on CN1A pin 26 is less than 9 V. Diagnostic Trouble Code 1904 - VCM - Rail 12VB - 5V Regulators Supply Input Power Off has an error priority of Red. All hydraulics are disabled while Diagnostic Trouble Code 1904 - VCM - Rail 12VB - 5V Regulators Supply Input Power Off is active. Cause: The UCM has sensed that voltage on CN1A pin 26 is less than 9 V. The fault is active while the ignition is ON, the engine is not cranking, and Diagnostic Code 1904 - VCM - Rail 12VB - 5V Regulators Supply Input Power Off is not active. Possible failure modes: 1. A problem with the battery or the battery charging system. 2. An open circuit in the wiring. 3. A short circuit in the wiring. 4. A faulty UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault code: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1904 - VCM - Rail 12VB - 5V Regulators Supply Input Power Off is recorded again. Go to step 2. C. Fault code 1904 - VCM - Rail 12VB - 5V Regulators Supply Input Power Off is recorded along with other diagnostic codes such as 1907 - VCM - Rail 12VF1 - Aux Retract Input Power Off and/or 1917 - VCM - Rail 12VU1 - Right And Left Pumps Forward Input Power Off. Test the fuses and relays. Repair as required. Return to step 1 to confirm elimination of the fault. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Verify the connections to the UCM connector are tight and secure. Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment. A. The wiring harness is not damaged and all connections are secure. Go to step 3. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Test the UCM connection Turn the ignition switch OFF. Fabricate a jumper wire that will connect from the positive battery post to UCM connector CN1A pin 26. Connect the jumper from the positive battery post to UCM connector CN1A pin 26.

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Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be active. A. The fault code is not longer active. There is a problem in the wiring from between splice SP-119 and the UCM connector. Repair as required. Return to step 1 to confirm elimination of the fault. B. The fault code is still active. There is a problem with UCM. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 03 Ignition Charging System (55.100.DP-C.20.E.03) Wiring harnesses - Electrical schematic sheet 02 Accessory Power Distribution (55.100.DP-C.20.E.02)

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Electrical systems - FAULT CODES

1905-VCM - 5Vref1 Sensor Supply Voltage Out Of Range WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the sensor supply voltage CN1A pin 8 is out of range. Diagnostic Trouble Code 1905 VCM - 5Vref1 Sensor Supply Voltage Out Of Range has an error priority of Red. All hydraulics are disabled while Diagnostic Trouble Code 1905 - VCM - 5Vref1 Sensor Supply Voltage Out Of Range is active. Cause: The UCM has sensed that the sensor supply voltage CN1A pin 8 is out of range. The fault is active while the ignition switch is ON and the voltage on CN1A pin 8 is less than 4.4 V or greater than 5.6 V. Possible failure modes: 1. An open circuit in the wiring. 2. A short circuit in the wiring. 3. A faulty sensor. 4. A faulty UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1905 - VCM - 5Vref1 Sensor Supply Voltage Out Of Range is active and recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the right hand control handle, the chassis loader interface, and the universal joystick module. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the UCM, the right hand control handle, the chassis loader interface, and the universal joystick module. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the UCM Turn the ignition switch ON. Measure the voltage between UCM connector CN1A pin 8 and chassis ground. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 4.4 V. Go to step 4. B. The voltage is greater than 5.6 V. Go to step 6. C. The voltage is greater than 4.4 V but less than 5.6 V. There does not seem to be a problem at this time. Reprogram the UCM with the latest software. If the fault code persists, temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 47683911 27/02/2015

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4. Check for a short circuit to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector CN1A. Disconnect the right hand control handle, the chassis loader interface, and the universal joystick module. Use a digital voltmeter to measure the resistance between CN1A pin 8 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Go to step 5. B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 5. Reconnect the components to the harness while monitoring the resistance. Use a digital voltmeter to measure the resistance between CN1A pin 8 and chassis ground. Reconnect the components one at a time (the right hand control handle, the chassis loader interface, and the universal joystick module), while monitoring the resistance reading. The resistance should be greater than 20,000 Ω while the components are reconnected into the circuit. A. The resistance is greater than 20,000 Ω but dropped below 20,000 Ω when a component was reconnected into the circuit. Temporarily replace the component that dropped the resistance and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 20,000 Ω while each component was reconnected into the circuit. Temporarily replace the UCM and retest. Return to step 1 to confirm the elimination of the fault. 6. Check for an open circuit in the wiring. Turn the ignition switch OFF. Disconnect the UCM connector CN1A. Fabricate a jumper wire that will connect CN1A pin 8 and chassis ground. Connect the jumper wire between CN1A pin 8 and chassis ground. The chassis ground connection must be clean and free of paint, dirt, and oil. Disconnect the right hand control handle, the chassis loader interface, and the universal joystick module. Measure the resistance between the chassis/loader interface connector X-10 pin 14 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between the right control module connector X-403 pin 1 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between the universal joystick module connector X-UJML pin 7 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between the universal joystick module connector X-UJMR pin 7 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are less than 10 Ω. Go to step 7. B. One of more resistance readings are greater than 10 Ω. There is an open circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm the elimination of the fault. 7. Check for a short circuit to battery. Turn the ignition switch OFF. Disconnect the UCM connector CN1A.

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Disconnect the right hand control handle, the chassis loader interface, and the universal joystick module. Turn the ignition switch ON. Measure the voltage between CN1A pin 8 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal and intermittent condition. A. The voltage is less than 0.5 V. Go to step 8. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm the elimination of the fault. 8. Reconnect the components to the harness while monitoring the voltage. Use a digital voltmeter to measure the voltage between CN1A pin 8 and chassis ground. Reconnect the components one at a time (the right hand control handle, the chassis loader interface, and the universal joystick module), while monitoring the voltage reading. The voltage should be less than 0.5 V while the components are reconnected into the circuit. A. The voltage is less than 0.5 V but changed to a voltage greater than 1 V when a component was reconnected into the circuit. Temporarily replace the component that changed the voltage. Return to step 1 to confirm elimination of the fault. B. The voltage is less than 0.5 V while each component was reconnected into the circuit. Temporarily replace the UCM and retest. Return to step 1 to confirm the elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 14 Cab to Chassis Interface (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 17 Right-Hand Control Handle (55.100.DP-C.20.E.17) Wiring harnesses - Electrical schematic sheet 16 Left-Hand Control Handle (55.100.DP-C.20.E.16) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

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1906-VCM - 5Vref3 Sensor Supply Voltage Out Of Range WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the sensor supply voltage CN1A pin 9 is out of range. Diagnostic Trouble Code 1906 VCM - 5Vref3 Sensor Supply Voltage Out Of Range has an error priority of Red. All hydraulics are disabled while Diagnostic Trouble Code 1906 - VCM - 5Vref3 Sensor Supply Voltage Out Of Range is active. Cause: The UCM has sensed that the sensor supply voltage CN1A pin 9 is out of range. The fault is active while the ignition switch is ON and the voltage at CN1A pin 9 is less than 4.4 V or greater than 5.6 V. Possible failure modes: 1. An open circuit in the wiring. 2. A short circuit in the wiring. 3. A faulty sensor. 4. A faulty UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1906 - VCM - 5Vref3 Sensor Supply Voltage Out Of Range is active and recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the right hand control handle, and the universal joystick module. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the UCM, the right hand control handle, and the universal joystick module. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the UCM Turn the ignition switch ON. Measure the voltage between UCM connector CN1A pin 9 and chassis ground. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 4.4 V. Go to step 4. B. The voltage is greater than 5.6 V. Go to step 6. C. The voltage is greater than 4.4 V but less than 5.6 V. There does not seem to be a problem at this time. Reprogram the UCM with the latest software. If the fault code persists, temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 47683911 27/02/2015

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4. Check for a short circuit to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector CN1A. Disconnect the right hand control handle, and the universal joystick module. Use a digital voltmeter to measure the resistance between CN1A pin 9 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Go to step 5. B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 5. Reconnect the components to the harness while monitoring the resistance. Use a digital voltmeter to measure the resistance between CN1A pin 9 and chassis ground. Reconnect the components one at a time (the right hand control handle, and the universal joystick module), while monitoring the resistance reading. The resistance should be greater than 20,000 Ω while the components are reconnected into the circuit. A. The resistance is greater than 20,000 Ω but dropped below 20,000 Ω when a component was reconnected into the circuit. Temporarily replace the component that dropped the resistance and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 20,000 Ω while each component was reconnected into the circuit. Temporarily replace the UCM and retest. Return to step 1 to confirm the elimination of the fault. 6. Check for an open circuit in the wiring. Turn the ignition switch OFF. Disconnect the UCM connector CN1A. Fabricate a jumper wire that will connect CN1A pin 9 and chassis ground. Connect the jumper wire between CN1A pin 9 and chassis ground. The chassis ground connection must be clean and free of paint, dirt, and oil. Disconnect the right hand control handle, and the universal joystick module. Measure the resistance between the right control module connector X-403 pin 10 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between the universal joystick module connector X-UJML pin 1 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between the universal joystick module connector X-UJMR pin 1 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are less than 10 Ω. Go to step 7. B. One of more resistance readings are greater than 10 Ω. There is an open circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm the elimination of the fault. 7. Check for a short circuit to battery. Turn the ignition switch OFF. Disconnect the UCM connector CN1A. Disconnect the right hand control handle, and the universal joystick module. Turn the ignition switch ON. 47683911 27/02/2015

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Measure the voltage between CN1A pin 9 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal and intermittent condition. A. The voltage is less than 0.5 V. Go to step 8. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm the elimination of the fault. 8. Reconnect the components to the harness while monitoring the voltage. Use a digital voltmeter to measure the voltage between CN1A pin 9 and chassis ground. Reconnect the components one at a time (the right hand control handle, and the universal joystick module), while monitoring the voltage reading. The voltage should be less than 0.5 V while the components are reconnected into the circuit. A. The voltage is less than 0.5 V, but changed to a voltage greater than 1 V when a component was reconnected into the circuit. Temporarily replace the component that changed the voltage. Return to step 1 to confirm elimination of the fault. B. The voltage is less than 0.5 V while each component was reconnected into the circuit. Temporarily replace the UCM and retest. Return to step 1 to confirm the elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 14 Cab to Chassis Interface (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 17 Right-Hand Control Handle (55.100.DP-C.20.E.17) Wiring harnesses - Electrical schematic sheet 16 Left-Hand Control Handle (55.100.DP-C.20.E.16)

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1907-VCM - Rail 12VF1 - Aux Retract Input Power Off WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the voltage on CN1B pin 26 and CN1B pin 27 is less than 9 V. Diagnostic Trouble Code 1907 - VCM - Rail 12VF1 - Aux Retract Input Power Off has an error priority of Amber. The auxiliary functions are disabled while Diagnostic Trouble Code 1907 - VCM - Rail 12VF1 - Aux Retract Input Power Off is active. Cause: The UCM has sensed that the voltage on CN1B pin 26 and CN1B pin 27 is less than 9 V. The fault is active while the ignition is ON, the engine is not cranking, and Diagnostic Code 1903 - VCM - VCM Supply Voltage Below Operational Limit is not active. Possible failure modes: 1. Fuse F-018 is blown or missing. 2. An open circuit in the wiring. 3. A failure of the UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1907 - VCM - Rail 12VF1 - Aux Retract Input Power Off is recorded again. Go to step 2. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Inspect the UCM connections and the accessory power distribution fuse block #1 connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM connector CN1B to the accessory power distribution fuse block #1. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The wiring harness is not damaged and all connections are secure. Go to step 3. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block FUSE2-EH pin B2 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Go to step 4. B. The voltage is less than 9 V. Go to step 5. 4. Test the UCM connection. Turn the ignition switch OFF. 47683911 27/02/2015

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Fabricate a jumper wire that will connect from the positive battery post to UCM connector CN1B pin 26 and CN1B pin 27. Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be active. A. The fault code is not longer active. There is a problem in the wiring from between fuse F-018 and the UCM connector. Repair as required. Return to step 1 to confirm elimination of the fault. B. The fault code is still active. There is a problem with UCM. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block FUSE2-EH pin B1 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Replace the fuse. Return to step 1 to confirm elimination of the fault. B. The voltage is less than 9 V. There is a problem in the wiring between the EH control relay and the fuse. Check splice SP-109 and splice SP-118 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 02 Accessory Power Distribution (55.100.DP-C.20.E.02)

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1908-VCM - Rail 12VF2 - Bucket Extend Input Power Off WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the voltage on CN4A pin 1 and CN4A pin 8 is less than 9 V. Diagnostic Trouble Code 1908 - VCM - Rail 12VF2 - Bucket Extend Input Power Off has an error priority of Red. Bucket functions are disabled while Diagnostic Trouble Code 1908 - VCM - Rail 12VF2 - Bucket Extend Input Power Off is active. Cause: The UCM has sensed that the voltage on CN4A pin 1 and CN4A pin 8 is less than 9 V. The fault is active while the ignition is ON, the engine is not cranking, and Diagnostic Code 1903 - VCM - VCM Supply Voltage Below Operational Limit is not active. Possible failure modes: 1. An open circuit in the wiring. 2. A failure of the UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1908 - VCM - Rail 12VF2 - Bucket Extend Input Power Off is recorded again. Go to step 2. C. Fault code 1908 - VCM - Rail 12VF2 - Bucket Extend Input Power Off is recorded along with fault code 1913 - VCM - Rail 12VS1 - Bucket Curl Input Power Off. Check fuse F-019. Check splice SP-111. Repair as required. Return to step 1 to confirm elimination of the fault. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Inspect the UCM connections and the accessory power distribution fuse block #1 connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM connector CN4A to the accessory power distribution fuse block #1. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The wiring harness is not damaged and all connections are secure. Go to step 3. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 3. Test the UCM connection. Turn the ignition switch OFF. Fabricate a jumper wire that will connect from the positive battery post to UCM connector CN4A pin 1 and CN4A pin 8. Connect the jumper from the positive battery post to UCM connector CN4A pin 1 and CN4A pin 8. Turn the ignition switch ON.

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Go to the fault code screen and refresh the display. The fault code should no longer be active. A. The fault code is not longer active. There is a problem in the wiring from between splice SP-111 and the UCM connector. Repair as required. Return to step 1 to confirm elimination of the fault. B. The fault code is still active. There is a problem with UCM. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 02 Accessory Power Distribution (55.100.DP-C.20.E.02)

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1909-VCM - Rail 12VF3 - Boom Raise/Lower Input Power Off WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the voltage on CN2B pin 9 and CN2B pin 17 is less than 9 V. Diagnostic Trouble Code 1909 - VCM - Rail 12VF3 - Boom Raise/Lower Input Power Off has an error priority of Red. Boom functions are disabled while Diagnostic Trouble Code 1909 - VCM - Rail 12VF3 - Boom Raise/Lower Input Power Off is active. Cause: The UCM has sensed that the voltage on CN2B pin 9 and CN2B pin 17 is less than 9 V. The fault is active while the ignition is ON, the engine is not cranking, and Diagnostic Code 1903 - VCM - VCM Supply Voltage Below Operational Limit is not active. Possible failure modes: 1. Fuse F-022 is blown or missing. 2. An open circuit in the wiring. 3. A failure of the UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1909 - VCM - Rail 12VF3 - Boom Raise/Lower Input Power Off is recorded again. Go to step 2. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Inspect the UCM connections and the accessory power distribution fuse block #1 connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM connector CN2B to the accessory power distribution fuse block #1. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The wiring harness is not damaged and all connections are secure. Go to step 3. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block FUSE2-EH pin D4 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Go to step 4. B. The voltage is less than 9 V. Go to step 5. 4. Test the UCM connection. Turn the ignition switch OFF. 47683911 27/02/2015

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Fabricate a jumper wire that will connect from the positive battery post to UCM connector CN2B pin 9 and CN2B pin 17. Connect the jumper wire from the positive battery post to UCM connector CN2B pin 9 and CN2B pin 17. Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be active. A. The fault code is not longer active. There is a problem in the wiring between fuse F-022 and the UCM connector. Check splice SP-110 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. B. The fault code is still active. There is a problem with UCM. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block FUSE2-EH pin D3 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Replace the fuse. Return to step 1 to confirm elimination of the fault. B. The voltage is less than 9 V. There is a problem in the wiring between the EH control relay and the fuse. Check splice SP-119 and Splice SP-118 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 02 Accessory Power Distribution (55.100.DP-C.20.E.02)

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1910-VCM - Rail 12VH - Loader Pilot Interlock And Port Lock Input Power Off WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the voltage on CN2A pin 7 and CN2A pin 13 is less than 9 V. Diagnostic Trouble Code 1910 - VCM - Rail 12VH - Loader Pilot Interlock And Port Lock Input Power Off has an error priority of Red. Loader hydraulic functions are disabled while Diagnostic Trouble Code 1910 - VCM - Rail 12VH - Loader Pilot Interlock And Port Lock Input Power Off is active. Cause: The UCM has sensed that the voltage on CN2A pin 7 and CN2A pin 13 is less than 9 V. The fault is active while the ignition is ON, the engine is not cranking, and Diagnostic Code 1903 - VCM - VCM Supply Voltage Below Operational Limit is not active. Possible failure modes: 1. Fuse F-025 is blown or missing. 2. An open circuit in the wiring. 3. A failure of the UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1910 - VCM - Rail 12VH - Loader Pilot Interlock And Port Lock Input Power Off is recorded again. Go to step 2. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Inspect the UCM connections and the accessory power distribution fuse block #1 connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM connector CN2A to the accessory power distribution fuse block #1. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The wiring harness is not damaged and all connections are secure. Go to step 3. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block FUSE2-EH pin C4 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Go to step 4. B. The voltage is less than 9 V. Go to step 5. 4. Test the UCM connection. 47683911 27/02/2015

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Turn the ignition switch OFF. Fabricate a jumper wire that will connect from the positive battery post to UCM connector CN2A pin 7 and CN2A pin 13. Connect the jumper from the positive battery post to UCM connector CN2A pin 7 and CN2A pin 13. Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be active. A. The fault code is not longer active. There is a problem in the wiring between fuse F-025 and the UCM connector. Check splice SP-112 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. B. The fault code is still active. There is a problem with UCM. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block FUSE2-EH pin C3 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Replace the fuse. Return to step 1 to confirm elimination of the fault. B. The voltage is less than 9 V. There is a problem in the wiring between the EH control relay and the fuse. Check splice SP-119 and splice SP-118 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 02 Accessory Power Distribution (55.100.DP-C.20.E.02)

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1911-VCM - Rail 12VH1 - Left And Right Pump Reverse Input Power Off WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the voltage on CN2A pin 2 and CN2A pin 3 is less than 9 V. Diagnostic Trouble Code 1911 - VCM - Rail 12VH1 - Left And Right Pump Reverse Input Power Off has an error priority of Red. The reverse ground drive functions are disabled while Diagnostic Trouble Code 1911 - VCM - Rail 12VH1 - Left And Right Pump Reverse Input Power Off is active. Cause: The UCM has sensed that the voltage on CN2A pin 2 and CN2A pin 3 is less than 9 V. The fault is active while the ignition is ON, the engine is not cranking, and Diagnostic Code 1903 - VCM - VCM Supply Voltage Below Operational Limit is not active. Possible failure modes: 1. An open circuit in the wiring. 2. A failure of the UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1911 - VCM - Rail 12VH1 - Left And Right Pump Reverse Input Power Off is recorded again. Go to step 2. C. Fault code 1911 - VCM - Rail 12VH1 - Left And Right Pump Reverse Input Power Off is recorded along with swash plate sensor faults such as 4734 - Right Swash Plate Angle Sensor Pin B Open Or Shorted To Ground and 4744 - Left Swash Plate Angle Sensor Pin B Open Or Shorted To Ground. Check the wiring to fuse F-017. Check fuse F-017 and the associated wiring. Check splice SP-152. Repair as required. Return to step 1 to confirm elimination of the fault. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Verify the connections to the UCM connector are tight and secure. Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment. A. The wiring harness is not damaged and all connections are secure. Go to step 3. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Test the UCM connection. Turn the ignition switch OFF. Fabricate a jumper wire that will connect from the positive battery post to UCM connector CN2A pin 2 and CN2A pin 3. Connect the jumper from the positive battery post to UCM connector CN2A pin 2 and CN2A pin 3.

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Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be active. A. The fault code is not longer active. There is a problem in the wiring from between splice SP-152 and the UCM connector. Repair as required. Return to step 1 to confirm elimination of the fault. B. The fault code is still active. There is a problem with UCM. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 02 Accessory Power Distribution (55.100.DP-C.20.E.02)

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1912-VCM - Rail 12VM - Left And Right Brake Lights And Aux Extend Input Power Off WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the voltage on CN1B pin 31 and CN1B pin 32 is less than 9 V. Diagnostic Trouble Code 1912 - VCM - Rail 12VM - Left And Right Brake Lights And Aux Extend Input Power Off has an error priority of Amber. Auxiliary functions are disabled while Diagnostic Trouble Code 1912 - VCM - Rail 12VM - Left And Right Brake Lights And Aux Extend Input Power Off is active. Cause: The UCM has sensed that the voltage on CN1B pin 31 and CN1B pin 32 is less than 9 V. The fault is active while the ignition is ON, the engine is not cranking, and Diagnostic Code 1903 - VCM - VCM Supply Voltage Below Operational Limit is not active. Possible failure modes: 1. Fuse F-015 is blown or missing. 2. An open circuit in the wiring. 3. A failure of the UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1912 - VCM - Rail 12VM - Left And Right Brake Lights And Aux Extend Input Power Off is recorded again. Go to step 2. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Inspect the UCM connections and the accessory power distribution fuse block #1 connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM connector CN1B to the accessory power distribution fuse block #1. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The wiring harness is not damaged and all connections are secure. Go to step 3. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block #1 FUSE2-EH pin A2 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Go to step 4. B. The voltage is less than 9 V. Go to step 5. 47683911 27/02/2015

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4. Test the UCM connection. Turn the ignition switch OFF. Fabricate a jumper wire that will connect from the positive battery post to UCM connector CN1B pin 31 and CN1B pin 32. Connect the jumper from the positive battery post to UCM connector CN1B pin 31 and CN1B pin 32. Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be active. A. The fault code is not longer active. There is a problem in the wiring between fuse F-015 and the UCM connector. Check splice SP-113 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. B. The fault code is still active. There is a problem with UCM. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block #1 FUSE2-EH pin A1 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Replace the fuse. Return to step 1 to confirm elimination of the fault. B. The voltage is less than 9 V. There is a problem in the wiring between the EH control relay and the fuse. Check splice SP-119 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 02 Accessory Power Distribution (55.100.DP-C.20.E.02)

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1913-VCM - Rail 12VS1 - Bucket Curl Input Power Off WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the voltage on CN3B pin 8 and CN3B pin 9 is less than 9 V. Diagnostic Trouble Code 1913 - VCM - Rail 12VS1 - Bucket Curl Input Power Off has an error priority of Red. Bucket functions are disabled while Diagnostic Trouble Code 1913 - VCM - Rail 12VS1 - Bucket Curl Input Power Off is active. Cause: The UCM has sensed that the voltage on CN3B pin 8 and CN3B pin 9 is less than 9 V. The fault is active while the ignition is ON, the engine is not cranking, and Diagnostic Code 1903 - VCM - VCM Supply Voltage Below Operational Limit is not active. Possible failure modes: 1. An open circuit in the wiring. 2. A failure of the UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1913 - VCM - Rail 12VS1 - Bucket Curl Input Power Off is recorded again. Go to step 2. C. Fault code 1913 - VCM - Rail 12VS1 - Bucket Curl Input Power Off is recorded along with fault code 1908 - VCM - Rail 12VF2 - Bucket Extend Input Power Off. Check Fuse F-019. Check splice SP-111. Repair as required. Return to step 1 to confirm elimination of the fault. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Inspect the UCM connections and the accessory power distribution fuse block #1 connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM connector CN3B to the accessory power distribution fuse block #1. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The wiring harness is not damaged and all connections are secure. Go to step 3. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 3. Test the UCM connection. Turn the ignition switch OFF. Fabricate a jumper wire that will connect from the positive battery post to UCM connector CN3B pin 8 and CN3B pin 9. Connect the jumper from the positive battery post to UCM connector CN3B pin 8 and CN3B pin 9. Turn the ignition switch ON.

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1914-VCM - Rail 12VS2 - Backup Alarm Input Power Off WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the voltage on CN3B pin 3 is less than 9 V. Diagnostic Trouble Code 1914 - VCM - Rail 12VS2 - Backup Alarm Input Power Off has an error priority of Amber. This an informational fault code and no functions are disabled while Diagnostic Trouble Code 1914 - VCM - Rail 12VS2 - Backup Alarm Input Power Off is active. Cause: The UCM has sensed that the voltage on CN3B pin 3 is less than 9 V. The fault is active while the ignition is ON, the engine is not cranking, and Diagnostic Code 1903 - VCM - VCM Supply Voltage Below Operational Limit is not active. Possible failure modes: 1. Fuse F-007 is blown or missing. 2. An open circuit in the wiring. 3. A failure of the UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1914 - VCM - Rail 12VS2 - Backup Alarm Input Power Off is recorded again. Go to step 2. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Inspect the UCM connections and the main power distribution fuse block #1 connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM connector CN3B to the main power distribution fuse block #1. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The wiring harness is not damaged and all connections are secure. Go to step 3. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the main power distribution fuse block FUSE1-EH pin B2 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Go to step 4. B. The voltage is less than 9 V. Go to step 5. 4. Test the UCM connection. Turn the ignition switch OFF. 47683911 27/02/2015

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Fabricate a jumper wire that will connect from the positive battery post to UCM connector CN3B pin 3. Connect the jumper from the positive battery post to UCM connector CN3B pin 3. Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be active. A. The fault code is not longer active. There is a problem in the wiring between fuse F-007 and the UCM connector. Repair as required. Return to step 1 to confirm elimination of the fault. B. The fault code is still active. There is a problem with UCM. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the main power distribution fuse block FUSE1-EH pin B1 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Replace the fuse. Return to step 1 to confirm elimination of the fault. B. The voltage is less than 9 V. There is a problem in the wiring between the EH control relay and the fuse. Check splice SP-119 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 01 Main Power Distribution (55.100.DP-C.20.E.01)

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1915-VCM - Rail 12VT1 - Two Speed Input Power Off WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the voltage on CN3A pin 7 and CN3A pin 13 is less than 9 V. Diagnostic Trouble Code 1915 - VCM - Rail 12VT1 - Two Speed Input Power Off has an error priority of Amber. There are no restrictions while Diagnostic Trouble Code 1915 - VCM - Rail 12VT1 - Two Speed Input Power Off is active. Cause: The UCM has sensed that the voltage on CN3A pin 7 and CN3A pin 13 is less than 9 V. The fault is active while the ignition is ON, the engine is not cranking, and Diagnostic Code 1903 - VCM - VCM Supply Voltage Below Operational Limit is not active. Possible failure modes: 1. Fuse F-027 is blown or missing. 2. An open circuit in the wiring. 3. A failure of the UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code is not recorded again. OK to return the machine to service. B. Fault code 1915 - VCM - Rail 12VT1 - Two Speed Input Power Off is recorded again. Go to step 2. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Inspect the UCM connections and the accessory power distribution fuse block #2 connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM connector CN3A to the accessory power distribution fuse block #2. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The wiring harness is not damaged and all connections are secure. Go to step 3. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block FUSE2-EH pin E4 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Go to step 4. B. The voltage is less than 9 V. Go to step 5. 4. Test the UCM connection. Turn the ignition switch OFF. 47683911 27/02/2015

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Fabricate a jumper wire that will connect from the positive battery post to UCM connector CN3A pin 7 and CN3A pin 13. Connect the jumper from the positive battery post to UCM connector CN3A pin 7 and CN3A pin 13. Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be active. A. The fault code is not longer active. There is a problem in the wiring between fuse F-027 and the UCM connector. Check splice SP-115 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. B. The fault code is still active. There is a problem with UCM. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block FUSE2-EH pin E3 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Replace the fuse. Return to step 1 to confirm elimination of the fault. B. The voltage is less than 9 V. There is a problem in the wiring between the EH control relay and the fuse. Check splice SP-119 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 02 Accessory Power Distribution (55.100.DP-C.20.E.02)

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1916-VCM - Rail 12VU1 - Right And Left Pumps Forward Input Power Off WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the voltage on CN3A pin 21 is less than 9 V. Diagnostic Trouble Code 1916 - VCM - Rail 12VU1 - Right And Left Pumps Forward Input Power Off has an error priority of Red. The forward ground drive functions are disabled while Diagnostic Trouble Code 1916 - VCM - Rail 12VU1 - Right And Left Pumps Forward Input Power Off is active. Cause: The UCM has sensed that the voltage on CN3A pin 21 is less than 9 V. The fault is active while the ignition is ON, the engine is not cranking, and Diagnostic Code 1903 - VCM - VCM Supply Voltage Below Operational Limit is not active. Possible failure modes: 1. Fuse F-021 is blown or missing. 2. An open circuit in the wiring. 3. A failure of the UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1916 - VCM - Rail 12VU1 - Right And Left Pumps Forward Input Power Off is recorded again. Go to step 2. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Verify the connections to the UCM are tight and secure. Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment. A. The wiring harness is not damaged and all connections are secure. Go to step 3. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block FUSE2-EH pin B4 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Go to step 4. B. The voltage is less than 9 V. Go to step 5. 4. Test the UCM connection. Turn the ignition switch OFF. 47683911 27/02/2015

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Fabricate a jumper wire that will connect from the positive battery post to UCM connector CN3A pin 21. Connect the jumper from the positive battery post to UCM connector CN3A pin 21. Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be active. A. The fault code is not longer active. There is a problem in the wiring between fuse F-021 and the UCM connector. Repair as required. Return to step 1 to confirm elimination of the fault. B. The fault code is still active. There is a problem with UCM. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block FUSE2-EH pin B3 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Replace the fuse. Return to step 1 to confirm elimination of the fault. B. The voltage is less than 9 V. There is a problem in the wiring between the EH control relay and the fuse. Check splice SP-119 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 02 Accessory Power Distribution (55.100.DP-C.20.E.02)

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1917-UCM - Rail 12VU2: Park Brake Solenoid Input Power Off WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the voltage on CN3A pin 2 and CN3A pin 3 is less than 9 V. Diagnostic Trouble Code 1917 - UCM - Rail 12VU2: Park Brake Solenoid Input Power Off has an error priority of Red. Ground drive is disabled while Diagnostic Trouble Code 1917 - UCM - Rail 12VU2: Park Brake Solenoid Input Power Off is active. Cause: The UCM has sensed that the voltage on CN3A pin 2 and CN3A pin 3 is less than 9 V. The fault is active while the ignition is ON, the engine is not cranking, and Diagnostic Code 1903 - VCM - VCM Supply Voltage Below Operational Limit is not active. Possible failure modes: 1. Fuse F-016 is blown or missing. 2. An open circuit in the wiring. 3. A failure of the UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code is not recorded again. OK to return the machine to service. B. Fault code 1917 - UCM - Rail 12VU2: Park Brake Solenoid Input Power Off is recorded again. Go to step 2. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Inspect the UCM connections and the accessory power distribution fuse block #1 connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM connector to the accessory power distribution fuse block #1. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The wiring harness is not damaged and all connections are secure. Go to step 3. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block FUSE2-EH pin A4 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Go to step 4. B. The voltage is less than 9 V. Go to step 5. 4. Test the UCM connection. Turn the ignition switch OFF. 47683911 27/02/2015

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Fabricate a jumper wire that will connect from the positive battery post to UCM connector CN3A pin 2 and CN3A pin 3. Connect the jumper from the positive battery post to UCM connector CN3A pin 2 and CN3A pin 3. Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be active. A. The fault code is not longer active. There is a problem in the wiring between fuse F-016 and the UCM connector. Check splice SP-114 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. B. The fault code is still active. There is a problem with UCM. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block FUSE2-EH pin A3 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Replace the fuse. Return to step 1 to confirm elimination of the fault. B. The voltage is less than 9 V. There is a problem in the wiring between the EH control relay and the fuse. Check splice SP-119 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 02 Accessory Power Distribution (55.100.DP-C.20.E.02)

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3007-Engine coolant temperature sensor voltage is higher than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the engine coolant temperature sensor B-9003 signal circuit. If the ECU A-9000 determines that voltage is higher than expected in the engine coolant temperature sensor B-9003 signal circuit, this fault will occur. If this fault is active, the ECU A-9000 will set the engine coolant temperature value to a fixed replacement value of 89.96 °C (193.93 °F). Cause: The engine coolant temperature sensor B-9003 signal voltage is greater than 4.93 V. Possible failure modes: 1. Faulty engine coolant temperature sensor B-9003 wiring, short to a voltage source. 2. Faulty engine coolant temperature sensor B-9003, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check the coolant temperature sensor B-9003 wiring for a short to a voltage source. Disconnect the engine harness (EN) from the coolant temperature sensor B-9003 at connector X-9006. With the key in the OFF position, use a multimeter to perform the following voltage check on the engine harness side : From X-9006 pin 1

To Chassis ground

Value There should be no voltage.

With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness side : From X-9006 pin 1

To Chassis ground

Value There should be less than 5.5 V

A. If the specified values are not measured, there is a short to a voltage source condition in the coolant temperature sensor B-9003 wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If the specified values are not measured, leave connector X-9006 disconnected and continue to Step 3. 3. Check the coolant temperature sensor B-9003 engine harness (EN) wiring for a short circuit. Disconnect the vehicle harness (VE) from the engine interface at connector X-9138. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side :

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From X-9006 X-9006 X-9138 X-9138

pin pin pin pin

1 2 14 13

To X-9138 pin 14 X-9138 pin 13 All pins in connector X-9138 All pins in connector X-9138

Value There should be continuity. There should be continuity. There should be no continuity. There should be no continuity.

A. If the specified values are measured, leave the connector X-9138 and X-9006 disconnected and continue to Step 4. B. If the specified values are not measured, there is an open or short circuit condition in the wiring. Locate and repair the broken or shorted conductor. 4. Check the coolant temperature sensor B-9003 vehicle harness (VE) wiring for a short circuit. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9138 X-9138 X-9138 X-9138

pin pin pin pin

14 13 14 13

To X-9121 pin A57 X-9121 pin A58 All pins in connector X-9138 All pins in connector X-9138

Value There should be continuity. There should be continuity. There should be no continuity. There should be no continuity.

A. If the specified values are measured, continue to Step 5. B. If the specified values are not measured, there is a shorted or broken circuit in the coolant temperature sensor B-9003 wiring in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted or broken conductor. 5. Replace the engine coolant temperature sensor B-9003. Use the EST to verify the status of the this fault. A. If the fault is no longer active, return the machine to service. B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3008-Engine coolant temperature sensor voltage is lower than expected C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors the engine coolant temperature sensor B-9003 signal circuit. If the ECU A-9000 determines that voltage is lower than expected in the engine coolant temperature sensor B-9003 signal circuit, this fault will occur. If this fault is active, the ECU A-9000 will set the engine coolant temperature value to a fixed replacement value of 89.96 °C (193.93 °F). Cause: The engine coolant temperature sensor B-9003 signal voltage is less than 198.00 mV. Possible failure modes: 1. Faulty engine coolant temperature sensor B-9003 wiring, short to ground condition. 2. Faulty engine coolant temperature sensor B-9003, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the coolant temperature sensor B-9003 engine harness (EN) wiring for a short to ground condition. Disconnect the engine harness (EN) from the coolant temperature sensor B-9003 at connector X-9006. Disconnect the vehicle harness (VE) from the engine interface at connector X-9138. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness side : To X-9006 pin 1 X-9006 pin 1 X-9138 pin 14

From X-9006 pin 2 Chassis ground All pins in connector X-9138

Value There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is no continuity, leave connectors X-9006 and X-9138 disconnected and continue to Step 3. B. If there is continuity, there is a short to ground condition in the coolant temperature sensor B-9003 engine harness (EN) wiring. Locate and repair the shorted conductor. 3. Check the coolant temperature sensor B-9003 vehicle harness (VE) wiring for a short to ground condition. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9138 pin 14 X-9121 pin A57

To All pins in connector X-9138 All pins in connector X-9121

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Value There should be no continuity. There should be no continuity.

Electrical systems - FAULT CODES

A. If there is no continuity, leave connector X-9006 disconnected and continue to Step 4. B. If there is continuity, there is a short circuit in the coolant temperature sensor B-9003 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted or broken conductor. 4. Replace the engine coolant temperature sensor B-9003. Use the EST to verify the status of the this fault. A. If the fault is no longer active, return the machine to service. B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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Electrical systems - FAULT CODES

3010-Intake manifold temperature sensor voltage is higher than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the intake manifold temperature sensor R-9000 signal circuit. If the ECU A-9000 determines that the intake manifold temperature sensor R-9000 signal circuit voltage is greater than 4.94 V, this fault will occur. Cause: The ECU A-9000 has determined that the intake manifold temperature sensor R-9000 signal circuit voltage is greater than 4.94 V. Possible failure modes: 1. Faulty intake manifold temperature sensor R-9000 wiring, short to a voltage source. 2. Faulty intake manifold temperature sensor R-9000 wiring, open circuit. 3. Faulty intake manifold temperature sensor R-9000, internal failure. 4. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 7. 2. Check the intake manifold temperature sensor R-9000 wiring for a short to battery condition. Disconnect the engine harness (EN) from the intake manifold temperature sensor R-9000 at connector X-9020. With the key in the OFF position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-9020 pin 1

To Chassis ground

Value There should be no voltage.

With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-9020 pin 1

To Chassis ground

Value There should be less than 5.5 V.

A. If the specified values are not measured, there is a short to a voltage source in the intake manifold temperature sensor R-9000 signal circuit. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If the specified values are measured, leave connector X-9020 disconnected and continue to Step 3. 3. Check the intake manifold temperature sensor R-9000 wiring for an open circuit condition. Disconnect the vehicle harness (VE) from the engine interface at connector X-9138. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121.

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With the key in the OFF position, use a multimeter to perform the following continuity check for an open circuit on the engine harness (EN) side : From To Value X-9020 pin 1 X-9138 pin 20 There should be continuity. X-9020 pin 2 X-9138 pin 19 There should be continuity. NOTE: Wiggle the harness during the check to promote an intermittent electrical connection. With the key in the OFF position, use a multimeter to perform the following continuity check for an open circuit on the vehicle harness (VE) side : From To Value X-9138 pin 20 X-9121 pin A55 There should be continuity. X-9138 pin 19 X-9121 pin A25 There should be continuity. NOTE: Wiggle the harness during the check to promote an intermittent electrical connection. A. If there is no continuity, there is an open circuit in the intake manifold temperature sensor R-9000 wiring. Use the appropriate service manual, if necessary, to locate and repair the broken conductor. B. If there is continuity, leave connector X-9138 and X-9121 disconnected and continue to Step 4. 4. Check the intake manifold temperature sensor R-9000 engine harness (EN) wiring for a short circuit. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From X-9138 pin 20

To All pins in connector X-9138

Value There should be no continuity.

A. If there is continuity, there is a short circuit in the intake manifold temperature sensor R-9000 in the engine harness (EN) wiring. Locate and repair the shorted conductor. B. If there no continuity, continue to Step 5. 5. Check the intake manifold temperature sensor R-9000 vehicle harness (VE) wiring. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9138 pin 20 X-9121 pin A55

To All pins in connector X-9138 All pins in connector X-9121

Value There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit in the intake manifold temperature sensor R-9000 in the vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there no continuity, continue to Step 6. 6. Replace the intake manifold temperature sensor R-9000. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is no longer active, return the machine to service. B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

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B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3011-Intake manifold temperature sensor voltage is lower than expected C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors the intake manifold temperature sensor R-9000 signal circuit. If the ECU A-9000 determines that the intake manifold temperature sensor R-9000 signal circuit voltage is less than 266.40 mV, this fault will occur. Cause: The ECU A-9000 has determined that the intake manifold temperature sensor R-9000 signal circuit voltage is less than 266.40 mV. Possible failure modes: 1. Faulty intake manifold temperature sensor R-9000 wiring, short to ground condition. 2. Faulty intake manifold temperature sensor R-9000, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the intake manifold temperature sensor R-9000 engine harness (EN) wiring. Disconnect the engine harness (EN) from the intake manifold temperature sensor R-9000 at connector X-9020. Disconnect the vehicle harness (VE) from the engine interface at connector X-9138. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From X-9020 pin 1 X-9020 pin 1 X-9138 pin 20

To X-9020 pin 2 Chassis ground All pins in connector X-9138

Value There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit in the intake manifold temperature sensor R-9000 in the engine harness (EN) wiring. Locate and repair the shorted conductor. B. If there no continuity, leave connector X-9020 and connector X-9138 disconnected and continue to Step 3. 3. Check the intake manifold temperature sensor R-9000 vehicle harness (VE) wiring. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9138 pin 20 X-9138 pin 20 X-9121 pin A55

To Chassis ground All pins in connector X-9138 All pins in connector X-9121 47683911 27/02/2015

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Value There should be no continuity. There should be no continuity. There should be no continuity.

Electrical systems - FAULT CODES

A. If there is continuity, there is a short circuit in the intake manifold temperature sensor R-9000 in the vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there no continuity, leave connector X-9020 disconnected and continue to Step 4. 4. Replace the intake manifold temperature sensor R-9000. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is no longer active, return the machine to service. B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3015-Fuel temperature sensor voltage is higher than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the fuel temperature sensor B-9002 signal circuit voltage. If the ECU A-9000 detects a voltage greater than 4.93 V in the signal circuit, this fault will occur. If this fault is not inhibited by another fault, the ECU A-9000 will freeze the fuel temperature value to 39.96 °C (103.93 °F). Cause: The fuel temperature sensor B-9002 signal circuit voltage is greater than 4.93 V. Possible failure modes: 1. Faulty fuel temperature sensor B-9002 wiring, short to a voltage source. 2. Faulty fuel temperature sensor B-9002 wiring, open circuit. 3. Faulty fuel temperature sensor B-9002, internal failure. 4. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 8. 2. Check the fuel temperature sensor B-9002 for an internal failure. Disconnect the engine harness (EN) from the fuel temperature sensor B-9002 at connector X-9005. Use a multimeter to measure the resistance of the fuel temperature sensor B-9002 on the sensor pins : From

Value At approximately 20.0 °C (68.0 °F), there should be between 2351 2648 Ω. NOTE: The fuel temperature sensor B-9002 is a Negative Temperature Coefficient (NTC) thermistor. The thermistor’s conductivity increases with increasing temperature and resistance decreases with increasing temperature. X-9005 pin 1

X-9005 pin 2

A. If there is a nominal resistance value, e.g. greater than 100 Ω, leave connector X-9005 disconnected and continue to Step 3. B. If there is not a nominal resistance value, e.g. 0 Ω, the fuel temperature sensor B-9002 has failed. Replace the fuel temperature sensor B-9002. 3. Check the fuel temperature sensor B-9002 wiring for a short to battery. With the key in the OFF position, use the a multimeter to perform the following voltage check on the engine harness (EN) side : From X-9005 pin 1

To Chassis ground

Value There should be no voltage.

With the key in the ON position, use the a multimeter to perform the following voltage check on the engine harness (EN) side :

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From X-9005 pin 1

To Chassis ground

Value There should be less than 5.5 V.

A. If the specified values are measured, leave connector X-9005 disconnected and continue to Step 4. B. If the specified values are not measured, there is a short to battery or switched battery in the fuel temperature sensor B-9002 wiring. Use the appropriate service manual, if necessary, to locate and repair the failed conductor. 4. Check the fuel temperature sensor B-9002 engine harness (EN) wiring for an open circuit condition. Disconnect the vehicle harness (VE) from the engine interface at connector X-9138. With the key in the OFF position, use the a multimeter to perform the following continuity check on the engine harness (EN) side : From X-9005 pin 1 X-9005 pin 2

To X-9138 pin 16 X-9138 pin 15

Value There should be continuity. There should be continuity.

A. If there is continuity, leave connectors X-9005 and X-9138 disconnected and continue to Step 5. B. If there is no continuity, there is an open circuit in the fuel temperature sensor B-9002 wiring in the engine harness (EN). Locate and repair the broken conductor. 5. Check the fuel temperature sensor B-9002 engine harness (EN) wiring for a short circuit condition. With the key in the OFF position, use the a multimeter to perform the following continuity check on the engine harness (EN) side : From X-9138 pin 16 X-9138 pin 15

To All pins in connector X-9138 All pins in connector X-9138

Value There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit in the fuel temperature sensor B-9002 wiring in the engine harness (EN). Locate and repair the shorted conductor. B. If there is no continuity, leave connectors X-9005 and X-9138 disconnected and continue to Step 6. 6. Check the fuel temperature sensor B-9002 vehicle harness (VE) wiring for an open circuit condition. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key in the OFF position, use the a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9138 pin 16 X-9138 pin 15

To X-9121 pin A38 X-9121 pin A23

Value There should be continuity. There should be continuity.

A. If there is continuity, leave connectors X-9121 and X-9138 disconnected and continue to Step 7. B. If there is no continuity, there is an open circuit in the fuel temperature sensor B-9002 wiring in the vehicle harness (EN). Use the appropriate service manual, if necessary, to locate and repair the broken conductor. 7. Check the fuel temperature sensor B-9002 vehicle harness (VE) wiring for a short circuit condition. With the key in the OFF position, use the a multimeter to perform the following continuity check on the vehicle harness (EN) side : X-9138 X-9138 X-9121 X-9121

pin pin pin pin

From 16 15 A38 A23

To All pins in connector X-9138 All pins in connector X-9138 All pins in connector X-9121 All pins in connector X-9121 47683911 27/02/2015

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Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

Electrical systems - FAULT CODES

A. If there is continuity, there is a short circuit in the fuel temperature sensor B-9002 wiring in the engine harness (EN). Locate and repair the shorted conductor. B. If there is no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 8. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3016-Fuel temperature sensor voltage is lower than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the fuel temperature sensor B-9002 signal circuit voltage. If the ECU A-9000 detects a voltage less than 198.00 mV in the signal circuit, this fault will occur. If this fault is not inhibited by another fault, the ECU A-9000 will freeze the fuel temperature value to 39.96 °C (103.93 °F). Cause: The fuel temperature sensor B-9002 signal circuit voltage is less than 198.00 mV. Possible failure modes: 1. Faulty fuel temperature sensor B-9002 wiring, short to ground condition. 2. Faulty fuel temperature sensor B-9002, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the fuel temperature sensor B-9002 for an internal failure. Disconnect the engine harness (EN) from the fuel temperature sensor B-9002 at connector X-9005. Use a multimeter to measure the resistance of the fuel temperature sensor B-9002 on the sensor pins : From

X-9005 pin 2

A. If there is a nominal resistance value, e.g. greater than 100 Ω, leave connector X-9005 disconnected and continue to Step 3. B. If there is not a nominal resistance value, e.g. 0 Ω, the fuel temperature sensor B-9002 has failed. Replace the fuel temperature sensor B-9002. 3. Check the fuel temperature sensor B-9002 engine harness (EN) wiring for a short to ground condition. Disconnect the vehicle harness (VE) from the engine interface at connector X-9138. With the key in the OFF position, use the a multimeter to perform the following continuity checks for a short to ground condition on the engine harness (EN) side : From X-9005 pin 1 X-9005 pin 1 X-9138 pin 16

To X-9005 pin 2 Chassis ground All pins in connector X-9138

Value There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is no continuity, leave connectors X-9005 and X-9138 disconnected and continue to Step 4. 47683911 27/02/2015

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B. If there is continuity, there is a short in the fuel temperature sensor B-9002 wiring in the engine harness (EN).Locate and repair the failed conductor. 4. Check the fuel temperature sensor B-9002 vehicle harness (VE) wiring for a short to ground condition. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key in the OFF position use the a multimeter to perform the following continuity checks for a short to ground condition on the vehicle harness (VE) side : From X-9138 pin 16 X-9138 pin 16 X-9121 pin A38

To X-9138 pin 15 Chassis ground All pins in connector X-9121

Value There should be no continuity. There should be no continuity. There should be no continuity.

A. If the specified values are not measured, there is a fault in the fuel temperature sensor B-9002 vehicle harness (VE) wiring. Locate and repair the failed conductor. B. If there is no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3019-Intake manifold pressure sensor voltage is higher than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the intake manifold pressure sensor B-9001. If the ECU A-9000 determines that the intake manifold pressure sensor B-9001 signal circuit voltage is greater than 4.92 V, this fault will occur. If this fault is active, the intake manifold pressure value will be frozen at the last valid value for a preliminary failure or jump to a fixed replacement value of 0.98 bar (14.21 psi) if the failure is validated. Cause: The ECU A-9000 has determined that the intake manifold pressure sensor B-9001 signal circuit voltage is greater than 4.92 V. Possible failure modes: 1. Faulty intake manifold pressure sensor B-9001 wiring, short to a voltage source. 2. Faulty intake manifold pressure sensor B-9001 wiring, open circuit. 3. Faulty intake manifold pressure sensor B-9001, internal failure. 4. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 7. 2. Check the intake manifold pressure sensor B-9001 wiring for a short to a voltage source. Disconnect the engine harness (EN) from the intake manifold pressure sensor B-9001 at connector X-9003. With the key in the OFF position, use a multimeter to perform the following voltage check on the engine harness side : From X-9003 pin 4

To Chassis ground

Value There should be no voltage.

With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness side : From X-9003 pin 4

To Chassis ground

Value There should be less than 5.5 V

A. If there is voltage, there is a short to battery or switched battery in the intake manifold pressure sensor B-9001 wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no voltage, leave connector X-9003 disconnected and continue to Step 3. 3. Check the intake manifold pressure sensor B-9001 wiring in the engine harness (EN) for an open circuit. Disconnect the vehicle harness (VE) from the engine interface connector X-9138. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : 47683911 27/02/2015

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From

Value X-9003 pin 4 X-9138 pin 18 There should be continuity. X-9003 pin 3 X-9138 pin 17 There should be continuity. NOTE: Wiggle the harness during the check to promote an intermittent electrical connection. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From To Value X-9138 pin 18 X-9121 pin A40 There should be continuity. X-9138 pin 17 X-9121 pin A10 There should be continuity. NOTE: Wiggle the harness during the check to promote an intermittent electrical connection. A. If there is no continuity, there is an open circuit in the intake manifold pressure sensor B-9001 wiring in the engine harness (EN). Locate and repair the broken conductor. B. If there is continuity, leave connectors X-9003, X-9138, and X-9121 disconnected and continue to Step 4. 4. Check the intake manifold pressure sensor B-9001 wiring in the engine harness (EN) for a short to a voltage source. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From X-9003 pin 4 X-9138 pin 18 X-9138 pin 17

To X-9003 pin 3 All pins in connector X-9138 All pins in connector X-9138

Value There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit in the intake manifold pressure sensor B-9001 wiring in the engine harness (EN). Locate and repair the shorted conductor. B. If there is no continuity, leave connectors X-9003, X-9138, and X-9121 disconnected and continue to Step 5. 5. Check the intake manifold pressure sensor B-9001 wiring in the vehicle harness (VE) for a short circuit. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : X-9138 X-9138 X-9121 X-9121

pin pin pin pin

From 18 17 A40 A10

To All pins in connector X-9138 All pins in connector X-9138 All pins in connector X-9121 All pins in connector X-9121

Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

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A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3024-ECU internal failure - Ambient pressure sensor voltage is higher than expected C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors atmospheric pressure. The ECU A-9000 performs a signal range check of the atmospheric pressure sensor value. If the ECU A-9000 determines that the value is too high, this fault will occur. The atmospheric pressure sensor is internal to the ECU A-9000. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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3025-ECU internal failure - Ambient pressure sensor voltage is lower than expected C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors atmospheric pressure. The ECU A-9000 performs a signal range check of the atmospheric pressure sensor value. If the ECU A-9000 determines that the value is too low, this fault will occur. The atmospheric pressure sensor is internal to the ECU A-9000. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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3027-Oil pressure switch active with engine off WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

To chassis ground

Result There should be continuity.

A. If there is continuity, leave connector X-9016 disconnected and continue with Step 3. B. If there is no continuity, the oil pressure switch S-9016 has failed internally, replace the switch. 3. Check the oil pressure switch S-9016 circuit for an open circuit condition. Carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. Place a jumper wire between connector X-9121 pin A06 and chassis ground. Use a multimeter to check for continuity on the engine harness (EN) side : From X-9016 pin 1

To chassis ground

Result There should be continuity.

A. If there is no continuity, leave the jumper wire in place and connectors X-9016 and X-9121 disconnected and continue with Step 4. B. If there is continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Locate the open circuit condition. Carefully disconnect the vehicle harness (VE) from the engine interface connector X-9138.

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Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9138 pin 3

To chassis ground

Result There should be continuity.

A. If there is continuity, the open circuit condition is the engine harness (EN) between connector X-9138 pin 3 and connector X-9016 pin 1, wire EN-9105. Locate and repair the broken conductor. B. If there is no continuity, the open circuit condition is in the vehicle harness (VE) between connector X-9138 pin 3 and connector X-9121 pin A06, wire VE-9105. Use the appropriate service manual, if necessary, to locate and repair the broken conductor. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3037-Intake manifold pressure sensor voltage is lower than expected C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors the intake manifold pressure sensor B-9001. If the ECU A-9000 determines that the intake manifold pressure sensor B-9001 signal circuit voltage is less than 202.80 mV, this fault will occur. If this fault is active, the intake manifold pressure value will be frozen at the last valid value for a preliminary failure or jump to a fixed replacement value of 0.98 bar (14.21 psi) if the failure is validated. Cause: The ECU A-9000 has determined that the intake manifold pressure sensor B-9001 signal circuit voltage is less than 202.80 mV. Possible failure modes: 1. Faulty intake manifold pressure sensor B-9001 wiring, short to ground condition. 2. Faulty intake manifold pressure sensor B-9001, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the intake manifold pressure sensor B-9001 wiring in the engine harness (EN) for a short to ground condition. Disconnect the engine harness (EN) from the intake manifold pressure sensor B-9001 at connector X-9003. Disconnect the vehicle harness (VE) from the engine interface at connector X-9138. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From X-9003 pin 4 X-9003 pin 4 X-9138 pin 18

To Chassis ground X-9003 pin 1 All pins in connector X-9138

Value There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit in the intake manifold pressure sensor B-9001 wiring in the engine harness (EN). Locate and repair the shorted conductor. B. If there is no continuity, leave connectors X-9003 and X-9138 disconnected and continue to Step 3. 3. Check the intake manifold pressure sensor B-9001 wiring in the vehicle harness (VE) for a short to ground condition. Disconnect the vehicle harness from the ECU A-9000 at connector X-9121. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side :

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From X-9138 pin 18 X-9138 pin 18 X-9121 pin A40

To Chassis ground All pins in connector X-9138 All pins in connector X-9121

Value There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit in the intake manifold pressure sensor B-9001 wiring in the vehicle harness (VE).Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, leave connector X-9003 disconnected and continue to Step 4. 4. Replace the intake manifold pressure sensor B-9001. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is no longer active, return the machine to service. B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3051-Battery voltage is higher than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Electronic Control Unit (ECU) A-9000 monitors battery voltage. If the A-9000 determines that battery voltage has exceeded 16.1 V, this fault will occur. Cause: Battery voltage is greater than 16.1 V. Possible failure modes: 1. Faulty charging system. 2. Faulty A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 4. 2. Check the battery voltage. The engine must be running. Use a multimeter to perform the following voltage check: From Battery (+) terminal

To Battery (–) terminal

Value There should be approximately 12 V

A. If there is not approximately 12 V, continue to Step 3. B. If there is approximately 12 V, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 3. Check the charging system for proper operation. A. If the charging system is not functioning properly, repair the charging system as necessary. B. If the charging system is functioning properly, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation.

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3052-Battery voltage is lower than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Electronic Control Unit (ECU) A-9000 monitors battery voltage. If the A-9000 determines that battery is less than 10.2 V, this fault will occur. Cause: Battery voltage is less than 10.2 V. Possible failure modes: 1. Faulty Battery. 2. Engine cranked for extended period of time. 3. Faulty A-9000 supply wiring. 4. Faulty charging system. 5. Faulty A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the battery voltage. Use a multimeter to perform the following voltage check: From Battery (+) terminal

To Battery (–) terminal

Value There should be approximately 12 V

A. If there is not approximately 12 V, Charge the battery and then perform load test on the battery. If the battery passes the load test, continue to Step 3. If the battery fails the load test, continue to Step 4. B. If there is approximately 12 V, continue to Step 3. 3. Check the charging system for proper operation. A. If the charging system is not functioning properly, repair the charging system as necessary. B. If the charging system is functioning properly, continue to Step 4. 4. Replace the battery. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault has been resolved, perform a parasitic draw test to measure excessive current draw from the battery. If an excessive draw is found, locate and repair as necessary and then return the machine to service.. B. If the fault has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display.

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3059-Main relay stuck error WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit A-9000 controls the main relay K-9102. The main relay K-9102 is powered on by the ECU A-9000 to achieve after-run. The main relay K-9102 is powered off once after-run is completed. If the ECU A-9000 determines that the main relay K-9102 is “stuck” or will not shut off as commanded, this fault will occur. Cause: The ECU A-9000 has determined that the main relay K-9102 will not shut off as commanded. Possible failure modes: 1. Faulty main relay K-9102, wiring. 2. Faulty main relay K-9102, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 7. 2. Check the main relay K-9102 coil for an internal failure. Remove the main relay K-9102. Use a multimeter to measure the resistance on the main relay K-9102 pins : From X-9129 pin 85

To X-9129 pin 86

Value There should be approximately 70 130 Ω.

To Chassis ground

Value There should be no continuity.

A. If there is continuity, there is a short circuit in the main relay K-9102 wiring in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, leave the main relay K-9102 disconnected and continue to Step 4. 4. Check the main relay K-9102 low side driver wiring for a short circuit. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122. With the key in the OFF position, use a multimeter to perform the following continuity checks for a short circuit on the vehicle harness (VE) side : 47683911 27/02/2015

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From X-9122 pin K28

To All pins in connector X-9122

Value There should be no continuity.

A. If there is continuity, there is a short circuit in the main relay K-9102 wiring in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, leave the main relay K-9102 and connector X-9122 disconnected, then continue to Step 5. 5. Check the ECU A-9000 voltage supply wiring for a short to a voltage source. With the key in the OFF position, use a multimeter to perform the following voltage checks for a short to a voltage source on the vehicle harness (VE) side : From X-9122 pin K01 X-9122 pin K03 X-9122 pin K05

To Chassis ground Chassis ground Chassis ground

Value There should be no voltage. There should be no voltage. There should be no voltage.

A. If there is voltage, there is a short to a voltage source in the ECU A-9000 voltage supply wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no voltage, leave the main relay K-9102 and connector X-9122 disconnected, then continue to Step 6. 6. Check the ECU A-9000 voltage supply wiring for a short to a voltage source. Re-connect the main relay K-9102. With the key in the OFF position, use a multimeter to perform the following voltage checks for a short to a voltage source on the vehicle harness (VE) side : From X-9122 pin K01 X-9122 pin K03 X-9122 pin K05

To Chassis ground Chassis ground Chassis ground

Value There should be no voltage. There should be no voltage. There should be no voltage.

A. If there is voltage, the main relay K-9102 has failed. Replace the main relay K-9102. B. If there is no voltage, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 01 - Power distribution and starting (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3061-Cylinder1 - Short circuit Low/High WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the fuel injector power stages for a short circuit condition. If the ECU A-9000 detects a short circuit condition in the injector number 1 Y-9001 circuit, this fault will occur. Cause: The ECU A-9000 has detected a short circuit between the high side driver and low side driver of the fuel injector number 1 Y-9001. Possible failure modes: 1. Faulty fuel injector number 1 Y-9001, wiring. 2. Faulty fuel injector number 1 Y-9001, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify this fault code is still present and in an active state. Use the Easy Engine software provided on the Electronic Service Tool (EST) to check the fault status and to perform the cylinder cut-out test. A. If the fault is still present and active, continue with Step 2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with Step 7. 2. Check the fuel injector number 1 Y-9001 internal resistance. Disconnect the injector harness (INJ) from the fuel injector number 1 Y-9001 at connector X-9030. Use a multimeter to measure the resistance of fuel injector number 1 Y-9001 on the injector pins : From X-9030 pin 1

To X-9030 pin 2

Value There should be between .03 - .05 Ω

A. If there is between .03 - .05 Ω, leave connector X-9030 disconnected and continue to Step 3. B. If the resistance is not between .03 - .05 Ω, fuel injector number 1 Y-9001 solenoid coil has failed. Replace fuel injector number 1 Y-9001. 3. Check the fuel injector number 1 Y-9001 injector harness (INJ) wiring. Disconnect the vehicle harness (VE) from the engine interface at connector X-9139. With the key in the OFF position, use a multimeter to perform the following continuity check on the injector harness (INJ) side : From X-9030 pin 1

To X-9030 pin 2

Value There should be no continuity.

A. If there is no continuity, leave connectors X-9030 and X-9139 disconnected and continue to Step 4. B. If there is continuity, there is a short circuit in the fuel injector number 1 Y-9001 wiring in the injector harness (INJ) between wires INJ-268 and INJ-269. Locate and repair the shorted conductor. 4. Check the fuel injector number 1 Y-9001 vehicle harness (VE) wiring for a short circuit condition. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. 47683911 27/02/2015

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With the key in the OFF position, use a multimeter to perform the following continuity check on vehicle harness (VE) side : From X-9139 pin A

To X-9139 pin B

Value There should be no continuity

A. If there is continuity, there is a short circuit in the fuel injector number 1 Y-9000 wiring in the vehicle harness (VE) between wires VE-9125 and VE-9126. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, continue with Step 5. 5. Check the ECU A-9000 voltage supply wiring. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122. Place a jumper wire between X-9122 pin K28 and chassis ground. This will energize the main relay K-9102. With the key in the ON position, use a multimeter to perform the following voltage checks from the vehicle harness (VE) side : From X-9122 pin K03

chassis ground

X-9122 pin K05

chassis ground

X-9122 pin K01

chassis ground

Value There should be approximately 12.0 V There should be approximately 12.0 V There should be approximately 12.0 V

A. If there is approximately 12.0 V, leave connector X-9122 disconnected and continue to Step 6. B. If there is not approximately 12.0 V, there is a faulty ECU A-9000 voltage supply. Use the appropriate service manual, if necessary, to locate and repair the failed conductor. 6. Check the ECU A-9000 ground supply. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : : From X-9122 pin K02 X-9122 pin K04 X-9122 pin K06

To chassis ground chassis ground chassis ground

Value There should be continuity. There should be continuity. There should be continuity.

A. If there is no continuity, there is a faulty ECU A-9000 ground supply. Use the appropriate service manual, if necessary, to locate and repair the failed conductor. B. If there is continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04) Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3063-Short circuit error of injector in cylinder 1 WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the fuel injector power stages for a short circuit condition. If the ECU A-9000 detects a short circuit condition in the injector number 1 Y-9001 circuit, this fault will occur. Cause: The ECU A-9000 has detected a short circuit in the fuel injector number 1 Y-9001 circuit. Possible failure modes: 1. Faulty fuel injector number 1 Y-9001, wiring. 2. Faulty fuel injector number 1 Y-9001, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify this fault code is still present and in an active state. Use the Easy Engine software provided on the Electronic Service Tool (EST) to check the fault status and to perform the cylinder cut-out test. A. If the fault is still present and active, continue with Step 2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with Step 8. 2. Check the fuel injector number 1 Y-9001 internal resistance. Disconnect the injector harness (INJ) from the fuel injector number 1 Y-9001 at connector X-9030. Use a multimeter to measure the resistance of fuel injector number 1 Y-9001 on the injector pins : From X-9030 pin 1

To X-9030 pin 2

Value There should be between .03 - .05 Ω

A. If there is between .03 - .05 Ω, leave connector X-9030 disconnected and continue to Step 3. B. If the resistance is not between .03 - .05 Ω, fuel injector number 1 Y-9001 solenoid coil has failed. Replace fuel injector number 1 Y-9001. 3. Check the fuel injector number 1 Y-9001 injector harness (INJ) wiring for a short to a voltage source. With the key in the OFF position, use a multimeter to perform the following voltage check on the injector harness (INJ) side : From X-9030 pin 1 X-9030 pin 2

To Chassis ground Chassis ground

Value There should be no voltage. There should be no voltage.

With the key in the ON position, use a multimeter to perform the following voltage check on the injector harness (INJ) side : From X-9030 pin 1 X-9030 pin 2

To Chassis ground Chassis ground

Value There should be no voltage. There should be no voltage.

A. If there is no voltage, leave connector X-9030 disconnected and continue to Step 4.

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B. If there is voltage, there is a short to battery or switched battery in the fuel injector number 1 Y-9001 wiring in the injector harness (INJ). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. 4. Check the fuel injector number 1 Y-9001 injector harness (INJ) wiring for a short to ground condition. Disconnect the vehicle harness (VE) from the engine interface at connector X-9139. With the key in the OFF position, use a multimeter to perform the following continuity checks on the injector harness (INJ) side : From X-9030 X-9030 X-9030 X-9139 X-9139

pin pin pin pin pin

1 1 2 A B

To X-9030 pin 2 Chassis ground Chassis ground All pins in connector X-9139 All pins in connector X-9139

Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is no continuity, leave connectors X-9030 and X-9139 disconnected and continue to Step 5. B. If there is continuity, there is a short circuit in the fuel injector number 1 Y-9001 wiring in the injector harness (INJ). Locate and repair the shorted conductor. 5. Check the fuel injector number 1 Y-9001 vehicle harness (VE) wiring for a short circuit condition. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121 With the key in the OFF position, use a multimeter to perform the following continuity checks on vehicle harness (VE) side : From X-9139 X-9139 X-9139 X-9139 X-9139

pin pin pin pin pin

A A B A B

To X-9139 pin B Chassis ground Chassis ground All pins in connector X-9139 All pins in connector X-9139

Value There should be no continuity There should be no continuity There should be no continuity There should be no continuity There should be no continuity

A. If there is continuity, there is a short circuit in the fuel injector number 1 Y-9001 wiring in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, continue with Step 6. 6. Check the ECU A-9000 voltage supply wiring. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122. Place a jumper wire between X-9122 pin K28 and chassis ground. This will energize the main relay K-9102. With the key in the ON position, use a multimeter to perform the following voltage checks from the vehicle harness (VE) side : From X-9122 pin K03

chassis ground

X-9122 pin K05

chassis ground

X-9122 pin K01

chassis ground

Value There should be approximately 12.0 V There should be approximately 12.0 V There should be approximately 12.0 V

A. If there is approximately 12.0 V, leave connector X-9122 disconnected and continue to Step 7. B. If there is not approximately 12.0 V, there is a faulty ECU A-9000 voltage supply. Use the appropriate service manual, if necessary, to locate and repair the failed conductor. 7. Check the ECU A-9000 ground supply. 47683911 27/02/2015

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With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : : From X-9122 pin K02 X-9122 pin K04 X-9122 pin K06

To chassis ground chassis ground chassis ground

Value There should be continuity. There should be continuity. There should be continuity.

A. If there is no continuity, there is a faulty ECU A-9000 ground supply. Use the appropriate service manual, if necessary, to locate and repair the failed conductor. B. If there is continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 8. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04) Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3069-Cylinder3 - Short circuit Low/High WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the fuel injector power stages for a short circuit condition. If the ECU A-9000 detects a short circuit condition in the injector number 3 Y-9003 circuit, this fault will occur. Cause: The ECU A-9000 has detected a short circuit between the high side driver and low side driver of the fuel injector number 3 Y-9003. Possible failure modes: 1. Faulty fuel injector number 3 Y-9003, wiring. 2. Faulty fuel injector number 3 Y-9003, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify this fault code is still present and in an active state. Use the Easy Engine software provided on the Electronic Service Tool (EST) to check the fault status and to perform the cylinder cut-out test. A. If the fault is still present and active, continue with Step 2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with Step 7. 2. Check the fuel injector number 3 Y-9003 internal resistance. Disconnect the injector harness (INJ) from the fuel injector number 3 Y-9003 at connector X-9031. Use a multimeter to measure the resistance of fuel injector number 3 Y-9003 on the injector pins : From X-9031 pin 1

To X-9031 pin 2

Value There should be between .03 - .05 Ω

A. If there is between .03 - .05 Ω, leave connector X-9031 disconnected and continue to Step 3. B. If the resistance is not between .03 - .05 Ω, fuel injector number 3 Y-9003 solenoid coil has failed. Replace fuel injector number 3 Y-9003. 3. Check the fuel injector number 3 Y-9003 injector harness (INJ) wiring. Disconnect the vehicle harness (VE) from the engine interface at connector X-9139. With the key in the OFF position, use a multimeter to perform the following continuity check on the injector harness (INJ) side : From X-9031 pin 1

To X-9031 pin 2

Value There should be no continuity.

A. If there is no continuity, leave connectors X-9031 and X-9139 disconnected and continue to Step 4. B. If there is continuity, there is a short circuit in the fuel injector number 3 Y-9003 wiring in the injector harness (INJ) between wires INJ-270 and INJ-271. Locate and repair the shorted conductor. 4. Check the fuel injector number 3 Y-9003 vehicle harness (VE) wiring for a short circuit condition. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. 47683911 27/02/2015

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With the key in the OFF position, use a multimeter to perform the following continuity check on vehicle harness (VE) side : From X-9139 pin D

To X-9139 pin C

Value There should be no continuity

A. If there is continuity, there is a short circuit in the fuel injector number 3 Y-9000 wiring in the vehicle harness (VE) between wires VE-9128 and VE-9127. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, continue with Step 5. 5. Check the ECU A-9000 voltage supply wiring. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122. Place a jumper wire between X-9122 pin K28 and chassis ground. This will energize the main relay K-9102. With the key in the ON position, use a multimeter to perform the following voltage checks from the vehicle harness (VE) side : From X-9122 pin K03

chassis ground

X-9122 pin K05

chassis ground

X-9122 pin K01

chassis ground

Value There should be approximately 12.0 V There should be approximately 12.0 V There should be approximately 12.0 V

To chassis ground chassis ground chassis ground

Value There should be continuity. There should be continuity. There should be continuity.

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3071-Short circuit error of injector in cylinder 3 WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the fuel injector power stages for a short circuit condition. If the ECU A-9000 detects a short circuit condition in the injector number 3 Y-9003 circuit, this fault will occur. Cause: The ECU A-9000 has detected a short circuit in the fuel injector number 3 Y-9003 circuit. Possible failure modes: 1. Faulty fuel injector number 3 Y-9003, wiring. 2. Faulty fuel injector number 3 Y-9003, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify this fault code is still present and in an active state. Use the Easy Engine software provided on the Electronic Service Tool (EST) to check the fault status and to perform the cylinder cut-out test. A. If the fault is still present and active, continue with Step 2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with Step 8. 2. Check the fuel injector number 3 Y-9003 internal resistance. Disconnect the injector harness (INJ) from the fuel injector number 3 Y-9003 at connector X-9031. Use a multimeter to measure the resistance of fuel injector number 3 Y-9003 on the injector pins : From X-9031 pin 1

To X-9031 pin 2

Value There should be between .03 - .05 Ω

A. If there is between .03 - .05 Ω, leave connector X-9031 disconnected and continue to Step 3. B. If the resistance is not between .03 - .05 Ω, fuel injector number 3 Y-9003 solenoid coil has failed. Replace fuel injector number 3 Y-9003. 3. Check the fuel injector number 3 Y-9003 injector harness (INJ) wiring for a short to a voltage source. With the key in the OFF position, use a multimeter to perform the following voltage check on the injector harness (INJ) side : From X-9031 pin 1 X-9031 pin 2

To Chassis ground Chassis ground

Value There should be no voltage. There should be no voltage.

With the key in the ON position, use a multimeter to perform the following voltage check on the injector harness (INJ) side : From X-9031 pin 1 X-9031 pin 2

To Chassis ground Chassis ground

Value There should be no voltage. There should be no voltage.

A. If there is no voltage, leave connector X-9031 disconnected and continue to Step 4.

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B. If there is voltage, there is a short to battery or switched battery in the fuel injector number 3 Y-9003 wiring in the injector harness (INJ). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. 4. Check the fuel injector number 3 Y-9003 injector harness (INJ) wiring for a short to ground condition. Disconnect the vehicle harness (VE) from the engine interface at connector X-9139. With the key in the OFF position, use a multimeter to perform the following continuity checks on the injector harness (INJ) side : From X-9031 X-9031 X-9031 X-9139 X-9139

pin pin pin pin pin

1 1 2 D C

To X-9031 pin 2 Chassis ground Chassis ground All pins in connector X-9139 All pins in connector X-9139

Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is no continuity, leave connectors X-9031 and X-9139 disconnected and continue to Step 5. B. If there is continuity, there is a short circuit in the fuel injector number 3 Y-9003 wiring in the injector harness (INJ). Locate and repair the shorted conductor. 5. Check the fuel injector number 3 Y-9003 vehicle harness (VE) wiring for a short circuit condition. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key in the OFF position, use a multimeter to perform the following continuity checks on vehicle harness (VE) side : From X-9139 X-9139 X-9139 X-9139 X-9139

pin pin pin pin pin

D D C D C

To X-9139 pin C Chassis ground Chassis ground All pins in connector X-9139 All pins in connector X-9139

Value There should be no continuity There should be no continuity There should be no continuity There should be no continuity There should be no continuity

A. If there is continuity, there is a short circuit in the fuel injector number 3 Y-9003 wiring in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, continue with Step 6. 6. Check the ECU A-9000 voltage supply wiring. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122. Place a jumper wire between X-9122 pin K28 and chassis ground. This will energize the main relay K-9102. With the key in the ON position, use a multimeter to perform the following voltage checks from the vehicle harness (VE) side : From X-9122 pin K03

chassis ground

X-9122 pin K05

chassis ground

X-9122 pin K01

chassis ground

Value There should be approximately 12.0 V There should be approximately 12.0 V There should be approximately 12.0 V

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With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : : From X-9122 pin K02 X-9122 pin K04 X-9122 pin K06

To chassis ground chassis ground chassis ground

Value There should be continuity. There should be continuity. There should be continuity.

A. If there is no continuity, there is a faulty ECU A-9000 ground supply. Use the appropriate service manual, if necessary, to locate and repair the failed conductor. B. If there is continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 8. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04) Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3077-Cylinder2 - Short circuit Low/High WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the fuel injector power stages for a short circuit condition. If the ECU A-9000 detects a short circuit condition in the injector number 2 Y-9002 circuit, this fault will occur. Cause: The ECU A-9000 has detected a short circuit between the high side driver and low side driver of the fuel injector number 2 Y-9002. Possible failure modes: 1. Faulty fuel injector number 2 Y-9002, wiring. 2. Faulty fuel injector number 2 Y-9002, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify this fault code is still present and in an active state. Use the Easy Engine software provided on the Electronic Service Tool (EST) to check the fault status and to perform the cylinder cut-out test. A. If the fault is still present and active, continue with Step 2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with Step 7. 2. Check the fuel injector number 2 Y-9002 internal resistance. Disconnect the injector harness (INJ) from the fuel injector number 2 Y-9002 at connector X-9033. Use a multimeter to measure the resistance of fuel injector number 2 Y-9002 on the injector pins : From X-9033 pin 1

To X-9033 pin 2

Value There should be between .03 - .05 Ω

A. If there is between .03 - .05 Ω, leave connector X-9033 disconnected and continue to Step 3. B. If the resistance is not between .03 - .05 Ω, fuel injector number 2 Y-9002 solenoid coil has failed. Replace fuel injector number 2 Y-9002. 3. Check the fuel injector number 2 Y-9002 injector harness (INJ) wiring. Disconnect the vehicle harness (VE) from the engine interface at connector X-9139. With the key in the OFF position, use a multimeter to perform the following continuity check on the injector harness (INJ) side : From X-9033 pin 1

To X-9033 pin 2

Value There should be no continuity.

A. If there is no continuity, leave connectors X-9033 and X-9139 disconnected and continue to Step 4. B. If there is continuity, there is a short circuit in the fuel injector number 2 Y-9002 wiring in the injector harness (INJ) between wires INJ-574 and INJ-575. Locate and repair the shorted conductor. 4. Check the fuel injector number 2 Y-9002 vehicle harness (VE) wiring for a short circuit condition. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. 47683911 27/02/2015

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With the key in the OFF position, use a multimeter to perform the following continuity check on vehicle harness (VE) side : From X-9139 pin H

To X-9139 pin G

Value There should be no continuity

A. If there is continuity, there is a short circuit in the fuel injector number 2 Y-9000 wiring in the vehicle harness (VE) between wires VE-9132 and VE-9131. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, continue with Step 5. 5. Check the ECU A-9000 voltage supply wiring. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122. Place a jumper wire between X-9122 pin K28 and chassis ground. This will energize the main relay K-9102. With the key in the ON position, use a multimeter to perform the following voltage checks from the vehicle harness (VE) side : From X-9122 pin K03

chassis ground

X-9122 pin K05

chassis ground

X-9122 pin K01

chassis ground

Value There should be approximately 12.0 V There should be approximately 12.0 V There should be approximately 12.0 V

To chassis ground chassis ground chassis ground

Value There should be continuity. There should be continuity. There should be continuity.

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3079-Short circuit error of injector in cylinder 2 WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the fuel injector power stages for a short circuit condition. If the ECU A-9000 detects a short circuit condition in the injector number 2 Y-9002 circuit, this fault will occur. Cause: The ECU A-9000 has detected a short circuit in the fuel injector number 2 Y-9002 circuit. Possible failure modes: 1. Faulty fuel injector number 2 Y-9002, wiring. 2. Faulty fuel injector number 2 Y-9002, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify this fault code is still present and in an active state. Use the Easy Engine software provided on the Electronic Service Tool (EST) to check the fault status and to perform the cylinder cut-out test. A. If the fault is still present and active, continue with Step 2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with Step 8. 2. Check the fuel injector number 2 Y-9002 internal resistance. Disconnect the injector harness (INJ) from the fuel injector number 2 Y-9002 at connector X-9033. Use a multimeter to measure the resistance of fuel injector number 2 Y-9002 on the injector pins : From X-9033 pin 1

To X-9033 pin 2

Value There should be between .03 - .05 Ω

A. If there is between .03 - .05 Ω, leave connector X-9033 disconnected and continue to Step 3. B. If the resistance is not between .03 - .05 Ω, fuel injector number 2 Y-9002 solenoid coil has failed. Replace fuel injector number 2 Y-9002. 3. Check the fuel injector number 2 Y-9002 injector harness (INJ) wiring for a short to a voltage source. With the key in the OFF position, use a multimeter to perform the following voltage check on the injector harness (INJ) side : From X-9033 pin 1 X-9033 pin 2

To Chassis ground Chassis ground

Value There should be no voltage. There should be no voltage.

With the key in the ON position, use a multimeter to perform the following voltage check on the injector harness (INJ) side : From X-9033 pin 1 X-9033 pin 2

To Chassis ground Chassis ground

Value There should be no voltage. There should be no voltage.

A. If there is no voltage, leave connector X-9033 disconnected and continue to Step 4.

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B. If there is voltage, there is a short to battery or switched battery in the fuel injector number 2 Y-9002 wiring in the injector harness (INJ). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. 4. Check the fuel injector number 2 Y-9002 injector harness (INJ) wiring for a short to ground condition. Disconnect the vehicle harness (VE) from the engine interface at connector X-9139. With the key in the OFF position, use a multimeter to perform the following continuity checks on the injector harness (INJ) side : From X-9033 X-9033 X-9033 X-9139 X-9139

pin pin pin pin pin

1 1 2 H G

To X-9033 pin 2 Chassis ground Chassis ground All pins in connector X-9139 All pins in connector X-9139

Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is no continuity, leave connectors X-9033 and X-9139 disconnected and continue to Step 5. B. If there is continuity, there is a short circuit in the fuel injector number 2 Y-9002 wiring in the injector harness (INJ). Locate and repair the shorted conductor. 5. Check the fuel injector number 2 Y-9002 vehicle harness (VE) wiring for a short circuit condition. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key in the OFF position, use a multimeter to perform the following continuity checks on vehicle harness (VE) side : From X-9139 X-9139 X-9139 X-9139 X-9139

pin pin pin pin pin

H H G H G

To X-9139 pin G Chassis ground Chassis ground All pins in connector X-9139 All pins in connector X-9139

Value There should be no continuity There should be no continuity There should be no continuity There should be no continuity There should be no continuity

A. If there is continuity, there is a short circuit in the fuel injector number 2 Y-9002 wiring in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, continue with Step 6. 6. Check the ECU A-9000 voltage supply wiring. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122. Place a jumper wire between X-9122 pin K28 and chassis ground. This will energize the main relay K-9102. With the key in the ON position, use a multimeter to perform the following voltage checks from the vehicle harness (VE) side : From X-9122 pin K03

chassis ground

X-9122 pin K05

chassis ground

X-9122 pin K01

chassis ground

Value There should be approximately 12.0 V There should be approximately 12.0 V There should be approximately 12.0 V

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With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : : From X-9122 pin K02 X-9122 pin K04 X-9122 pin K06

To chassis ground chassis ground chassis ground

Value There should be continuity. There should be continuity. There should be continuity.

A. If there is no continuity, there is a faulty ECU A-9000 ground supply. Use the appropriate service manual, if necessary, to locate and repair the failed conductor. B. If there is continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 8. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04) Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3081-Cylinder4 - Short circuit Low/High WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the fuel injector power stages for a short circuit condition. If the ECU A-9000 detects a short circuit condition in the injector number 4 Y-9004 circuit, this fault will occur. Cause: The ECU A-9000 has detected a short circuit between the high side driver and low side driver of the fuel injector number 4 Y-9004. Possible failure modes: 1. Faulty fuel injector number 4 Y-9004, wiring. 2. Faulty fuel injector number 4 Y-9004, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify this fault code is still present and in an active state. Use the Easy Engine software provided on the Electronic Service Tool (EST) to check the fault status and to perform the cylinder cut-out test. A. If the fault is still present and active, continue with Step 2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with Step 7. 2. Check the fuel injector number 4 Y-9004 internal resistance. Disconnect the injector harness (INJ) from the fuel injector number 4 Y-9004 at connector X-9032. Use a multimeter to measure the resistance of fuel injector number 4 Y-9004 on the injector pins : From X-9032 pin 1

To X-9032 pin 2

Value There should be between .03 - .05 Ω

A. If there is between .03 - .05 Ω, leave connector X-9032 disconnected and continue to Step 3. B. If the resistance is not between .03 - .05 Ω, fuel injector number 4 Y-9004 solenoid coil has failed. Replace fuel injector number 4 Y-9004. 3. Check the fuel injector number 4 Y-9004 injector harness (INJ) wiring. Disconnect the vehicle harness (VE) from the engine interface at connector X-9139. With the key in the OFF position, use a multimeter to perform the following continuity check on the injector harness (INJ) side : From X-9032 pin 1

To X-9032 pin 2

Value There should be no continuity.

A. If there is no continuity, leave connectors X-9032 and X-9139 disconnected and continue to Step 4. B. If there is continuity, there is a short circuit in the fuel injector number 4 Y-9004 wiring in the injector harness (INJ) between wires INJ-572 and INJ-573. Locate and repair the shorted conductor. 4. Check the fuel injector number 4 Y-9004 vehicle harness (VE) wiring for a short circuit condition. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. 47683911 27/02/2015

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With the key in the OFF position, use a multimeter to perform the following continuity check on vehicle harness (VE) side : From X-9139 pin E

To X-9139 pin F

Value There should be no continuity

A. If there is continuity, there is a short circuit in the fuel injector number 4 Y-9000 wiring in the vehicle harness (VE) between wires VE-9129 and VE-9130. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, continue with Step 5. 5. Check the ECU A-9000 voltage supply wiring. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122. Place a jumper wire between X-9122 pin K28 and chassis ground. This will energize the main relay K-9102. With the key in the ON position, use a multimeter to perform the following voltage checks from the vehicle harness (VE) side : From X-9122 pin K03

chassis ground

X-9122 pin K05

chassis ground

X-9122 pin K01

chassis ground

Value There should be approximately 12.0 V There should be approximately 12.0 V There should be approximately 12.0 V

To chassis ground chassis ground chassis ground

Value There should be continuity. There should be continuity. There should be continuity.

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3083-Short circuit error of injector in cylinder 4 WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the fuel injector power stages for a short circuit condition. If the ECU A-9000 detects a short circuit condition in the injector number 4 Y-9004 circuit, this fault will occur. Cause: The ECU A-9000 has detected a short circuit in the fuel injector number 4 Y-9004 circuit. Possible failure modes: 1. Faulty fuel injector number 4 Y-9004, wiring. 2. Faulty fuel injector number 4 Y-9004, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify this fault code is still present and in an active state. Use the Easy Engine software provided on the Electronic Service Tool (EST) to check the fault status and to perform the cylinder cut-out test. A. If the fault is still present and active, continue with Step 2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with Step 8. 2. Check the fuel injector number 4 Y-9004 internal resistance. Disconnect the injector harness (INJ) from the fuel injector number 4 Y-9004 at connector X-9032. Use a multimeter to measure the resistance of fuel injector number 4 Y-9004 on the injector pins : From X-9032 pin 1

To X-9032 pin 2

Value There should be between .03 - .05 Ω

A. If there is between .03 - .05 Ω, leave connector X-9032 disconnected and continue to Step 3. B. If the resistance is not between .03 - .05 Ω, fuel injector number 4 Y-9004 solenoid coil has failed. Replace fuel injector number 4 Y-9004. 3. Check the fuel injector number 4 Y-9004 injector harness (INJ) wiring for a short to a voltage source. With the key in the OFF position, use a multimeter to perform the following voltage check on the injector harness (INJ) side : From X-9032 pin 1 X-9032 pin 2

To Chassis ground Chassis ground

Value There should be no voltage. There should be no voltage.

With the key in the ON position, use a multimeter to perform the following voltage check on the injector harness (INJ) side : From X-9032 pin 1 X-9032 pin 2

To Chassis ground Chassis ground

Value There should be no voltage. There should be no voltage.

A. If there is no voltage, leave connector X-9032 disconnected and continue to Step 4.

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B. If there is voltage, there is a short to battery or switched battery in the fuel injector number 4 Y-9004 wiring in the injector harness (INJ). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. 4. Check the fuel injector number 4 Y-9004 injector harness (INJ) wiring for a short to ground condition. Disconnect the vehicle harness (VE) from the engine interface at connector X-9139. With the key in the OFF position, use a multimeter to perform the following continuity checks on the injector harness (INJ) side : From X-9032 X-9032 X-9032 X-9139 X-9139

pin pin pin pin pin

1 1 2 E F

To X-9032 pin 2 Chassis ground Chassis ground All pins in connector X-9139 All pins in connector X-9139

Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is no continuity, leave connectors X-9032 and X-9139 disconnected and continue to Step 5. B. If there is continuity, there is a short circuit in the fuel injector number 4 Y-9004 wiring in the injector harness (INJ). Locate and repair the shorted conductor. 5. Check the fuel injector number 4 Y-9004 vehicle harness (VE) wiring for a short circuit condition. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key in the OFF position, use a multimeter to perform the following continuity checks on vehicle harness (VE) side : From X-9139 X-9139 X-9139 X-9139 X-9139

pin pin pin pin pin

E E F E F

To X-9139 pin F Chassis ground Chassis ground All pins in connector X-9139 All pins in connector X-9139

Value There should be no continuity There should be no continuity There should be no continuity There should be no continuity There should be no continuity

A. If there is continuity, there is a short circuit in the fuel injector number 4 Y-9004 wiring in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, continue with Step 6. 6. Check the ECU A-9000 voltage supply wiring. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122. Place a jumper wire between X-9122 pin K28 and chassis ground. This will energize the main relay K-9102. With the key in the ON position, use a multimeter to perform the following voltage checks from the vehicle harness (VE) side : From X-9122 pin K03

chassis ground

X-9122 pin K05

chassis ground

X-9122 pin K01

chassis ground

Value There should be approximately 12.0 V There should be approximately 12.0 V There should be approximately 12.0 V

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With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : : From X-9122 pin K02 X-9122 pin K04 X-9122 pin K06

To chassis ground chassis ground chassis ground

Value There should be continuity. There should be continuity. There should be continuity.

A. If there is no continuity, there is a faulty ECU A-9000 ground supply. Use the appropriate service manual, if necessary, to locate and repair the failed conductor. B. If there is continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 8. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04) Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3088-Crankshaft speed sensor values are not plausible WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) monitors the crankshaft position sensor characteristics for angle, speed determination, signal plausibility, and quality. If the ECU determines that there are no crankshaft position signals detected for at least 4 engine revolutions, this fault will occur. Cause: The ECU has determined that there is no crankshaft position signals detected for at least 4 engine revolutions. Possible failure modes: 1. The crankshaft position sensor is not fully seated or is loose. 2. The crankshaft tone wheel is damaged or misaligned. 3. A short circuit in the crankshaft position sensor wiring. 4. An internal failure in the crankshaft position sensor. 5. A faulty ECU. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 8. 2. Check the physical integrity of the crankshaft position sensor . The sensor should be fully seated and mounted tightly. Remove the crankshaft position sensor and inspect the crankshaft tool wheel. The tone wheel should not be damaged or loose. A. If the sensor or tone wheel is damaged or is not mounted/secured properly, repair as necessary. B. If the sensor and tone wheel are not damaged and are mounted/secured properly, continue to step 3. 3. Check the crankshaft position sensor internal resistance. Disconnect the crankshaft position sensor. Use a multimeter to measure the resistance of the crankshaft position sensor on the sensor pins : From Crankshaft position sensor pin 1

To Crankshaft position sensor pin 2

Value There should be between 774 946 Ω.

A. If there is between 774 - 946 Ω, leave the crankshaft position sensor disconnected and continue to step 4. B. If there is not between 774 - 946 Ω, the crankshaft position sensor has failed. Replace the crankshaft position sensor and retest. 4. Check the crankshaft position sensor wiring for a short circuit to battery. With the key in the OFF position, use a multimeter to perform the following voltage check :

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From To Crankshaft position sensor connector Chassis ground pin 1

Value There should be no voltage.

With the key in the ON position, use a multimeter to perform the following voltage check : From To Crankshaft position sensor connector Chassis ground pin 1

Value There should be no voltage.

A. If there is no voltage, leave the crankshaft position sensor disconnected and continue to step 5. B. If there is voltage, there is a short circuit to battery or switched battery in the crankshaft position sensor wiring. Locate and repair the shorted conductor. Repair or replace the harness as required. 5. Check the crankshaft position sensor engine harness wiring. Disconnect the engine interface connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity checks : From To Value Crankshaft position sensor connector Crankshaft position sensor connector There should be no continuity. pin 1 pin 2 There should be no continuity. Crankshaft position sensor connector Chassis ground pin 1 There should be no continuity. Crankshaft position sensor connector Chassis ground pin 2 With the key in the OFF position, use a multimeter to perform the following continuity checks : From Crankshaft position sensor connector X-017 pin 9 pin 1 Crankshaft position sensor connector X-017 pin 10 pin 2

Value There should be continuity. There should be continuity.

With the key in the OFF position, use a multimeter to perform the following continuity checks : From X-017 pin 9 X-017 pin 10

To All pins in connector X-017 All pins in connector X-017

Value There should be no continuity. There should be no continuity.

A. If the specified values are measured, leave the crankshaft position sensor disconnected. Leave connector X-017 disconnected and continue to step 6. B. If the specified values are not measured, there is a fault in the crankshaft position sensor wiring. Locate and repair the failed conductor. Repair or replace the harness as required. 6. Check the crankshaft position sensor wiring. Disconnect the ECU connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity check : From X-017 pin 9

To X-017 pin 10

Value There should be no continuity.

With the key in the OFF position, use a multimeter to perform the following continuity checks : From X-017 pin 9 X-017 pin 10

To X-016 pin 59 X-016 pin 44

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Value There should be continuity. There should be continuity.

Electrical systems - FAULT CODES

With the key in the OFF position, use a multimeter to perform the following continuity checks : From X-017 pin 9 X-017 pin 10

To All pins in connector X-017 All pins in connector X-017

Value There should be no continuity. There should be no continuity.

A. If the specified values are measured, leave the crankshaft position sensor disconnected. Leave connectors X-017 and X-016 disconnected and continue to step 7. B. If the specified values are not measured, there is a fault in the crankshaft position sensor wiring. Locate and repair the failed conductor. Repair or replace the harness as required. 7. Replace the crankshaft position sensor . Use the Electronic Service Tool (EST) to verify the status of this fault, 3088 - Crankshaft speed sensor values are not plausible. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, check the ECU for the appropriate software and re-flash, if necessary. 8. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 Engine F5C T4 (Engine) (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 06 Engine F5C T4 (Engine) (55.100.DP-C.20.E.06)

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3089-Crankshaft speed sensor pattern is not plausible WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) monitors the crankshaft position sensor characteristics for angle, speed determination, signal plausibility, and quality. If the ECU detects greater than 80 crankshaft position signal plausibility errors, this fault will occur. Cause: The ECU has detected more than 80 crankshaft position signal plausibility errors. Possible failure modes: 1. The crankshaft position sensor is not fully seated or is loose. 2. The crankshaft tone wheel is damaged or misaligned. 3. There is a short circuit in the crankshaft position sensor wiring. 4. An internal failure in the crankshaft position sensor. 5. A faulty ECU. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 8. 2. Check the physical integrity of the crankshaft position sensor . The sensor should be fully seated and mounted tightly. Remove the crankshaft position sensor and inspect the crankshaft tone wheel. The tone wheel should not be damaged or loose. A. If the sensor or tone wheel is damaged or is not mounted/secured properly, repair as necessary. B. If the sensor and tone wheel are not damaged and are mounted/secured properly, continue to step 3. 3. Check the crankshaft position sensor internal resistance. Disconnect the crankshaft position sensor. Use a multimeter to measure the resistance of the crankshaft position sensor on the sensor pins : From Crankshaft position sensor pin 1

To Crankshaft position sensor pin 2

Value There should be between 774 946 Ω.

To Chassis ground 47683911 27/02/2015

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Value There should be no voltage.

Electrical systems - FAULT CODES

With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-017 pin 9

To Chassis ground

Value There should be no voltage.

A. If there is no voltage, leave the crankshaft position sensor disconnected and continue to step 5. B. If there is voltage, there is a short circuit to battery or switched switch battery in the crankshaft position sensor wiring. Locate and repair the shorted conductor. Repair or replace the wiring as required. 5. Check the crankshaft position sensor engine wiring. Disconnect the engine interface connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity checks : From Crankshaft position sensor pin 1 Crankshaft position sensor pin 1 Crankshaft position sensor pin 2

To Crankshaft position sensor pin 2 Chassis ground Chassis ground

Value There should be no continuity. There should be no continuity. There should be no continuity.

With the key in the OFF position, use a multimeter to perform the following continuity checks : From Crankshaft position sensor pin 1 Crankshaft position sensor pin 2

To X-017 pin 9 X-017 pin 10

Value There should be continuity. There should be continuity.

With the key in the OFF position, use a multimeter to perform the following continuity checks : From X-017 pin 9 X-017 pin 10

To All pins in connector X-017 All pins in connector X-017

Value There should be no continuity. There should be no continuity.

A. If the specified values are measured, leave the crankshaft position sensor disconnected. Leave connector X-017 disconnected and continue to step 6. B. If the specified values are not measured, there is a problem in the crankshaft position sensor wiring. Locate and repair the failed conductor. Repair or replace the harness as required. 6. Check the crankshaft position sensor wiring. Disconnect the ECU connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity check : From X-017 pin 9

To X-017 pin 10

Value There should be no continuity.

With the key in the OFF position, use a multimeter to perform the following continuity checks : From X-017 pin 9 X-017 pin 10

To X-016 pin 59 X-016 pin 44

Value There should be continuity. There should be continuity.

With the key in the OFF position, use a multimeter to perform the following continuity checks : From X-017 pin 9 X-017 pin 10

To All pins in connector X-017 All pins in connector X-017

Value There should be no continuity. There should be no continuity.

A. If the specified values are measured, leave the crankshaft position sensor disconnected. Leave connectors X-017 and X-016 disconnected and continue to step 7.

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B. If the specified values are not measured, there is a problem in the crankshaft position sensor wiring. Locate and repair the failed conductor. Repair or replace the harness as required. 7. Replace the crankshaft position sensor. Use the Electronic Service Tool (EST) to verify the status of this fault, 3089 - Crankshaft speed sensor pattern is not plausible. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, check the ECU for the appropriate software and re-flash, if necessary. 8. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 Engine F5C T4 (Engine) (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 06 Engine F5C T4 (Engine) (55.100.DP-C.20.E.06)

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3090-Camshaft speed sensor values are not plausible WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) monitors the camshaft position sensor characteristics for angle, speed determination, signal plausibility, and quality. If the ECU determines that no camshaft edge is detected for at least four crankshaft revolutions, this fault will occur. Cause: The ECU has detected no camshaft edge for at least four crankshaft revolutions. Possible failure modes: 1. An improperly seated or mounted camshaft position sensor. 2. A problem in the camshaft position sensor wiring. 3. A faulty camshaft position sensor. 4. A faulty ECU. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. Check the physical integrity of the camshaft speed sensor. The sensor should be fully seated and mounted tightly. A. If the sensor is not mounted/secured properly, repair as necessary. B. If the sensor is not damaged and is mounted/secured properly, continue to step 3. 3. Check the camshaft position sensor wiring. Disconnect the camshaft position sensor. Disconnect the engine interface connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity check. : From Camshaft position sensor connector X-017 pin 4 pin 2 Camshaft position sensor connector X-017 pin 8 pin 1 Camshaft position sensor connector X-017 pin 12 pin 3

Value There should be continuity. There should be continuity. There should be continuity.

With the key in the OFF position, use a multimeter to perform the following continuity check : From To Camshaft position sensor connector Chassis ground pin 2

Value There should be no continuity.

With the key in the OFF position, use a multimeter to perform the following continuity check : 47683911 27/02/2015

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From X-017 pin 4

To All pins in connector X-017

Value There should be no continuity.

With the key in the ON position, use a multimeter to perform the following voltage check : From To Camshaft position sensor connector Chassis ground pin 2

Value There should be no voltage.

A. If the specified values are measured, leave the camshaft position sensor disconnected. Leave connector X-017 disconnected and continue to step 4. B. If the specified values are not measured, there is a problem in the wiring. Locate and repair the failed conductor or conductors. Repair or replace the harness as required. 4. Check the camshaft position sensor wiring in the harness. Disconnect the ECU connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity check : From X-017 pin 4 X-017 pin 8 X-017 pin 12

To X-016 pin 14 X-016 pin 28 X-016 pin 13

Value There should be continuity. There should be continuity. There should be continuity.

With the key in the OFF position, use a multimeter to perform the following continuity check : From X-016 pin 14

To Chassis ground

Value There should be no continuity.

With the key in the OFF position, use a multimeter to perform the following continuity check : From X-017 pin 4

To All pins in connector X-017

Value There should be no continuity.

With the key in the ON position, use a multimeter to perform the following voltage check : From X-016 pin 14

To Chassis ground

Value There should be no voltage.

A. If the specified values are measured, leave the camshaft position sensor disconnected and continue to step 5. B. If the specified values are not measured, there is a problem in the camshaft position sensor wiring. Locate and repair the failed conductor or conductors. Repair or replace the harness as required. 5. Replace the camshaft position sensor. Use the Electronic Service Tool (EST) to verify the status of this fault, 3090 - Camshaft speed sensor values are not plausible. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, check the ECU for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. 47683911 27/02/2015

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Wiring harnesses - Electrical schematic sheet 07 Engine F5C T4 (Engine) (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 06 Engine F5C T4 (Engine) (55.100.DP-C.20.E.06)

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3091-Camshaft speed sensor pattern is not plausible WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) monitors the camshaft position sensor characteristics for angle, speed determination, signal plausibility, and quality. If the ECU determines that the camshaft signal does not match the expected pattern (edge, distance, level) or not all expected camshaft edges are detected during an engine revolution, this fault will occur. Cause: The ECU has detected a camshaft pattern signal error. Possible failure modes: 1. A problem in the camshaft position sensor wiring. 2. An improperly seated or mounted camshaft position sensor. 3. A faulty camshaft position sensor. 4. A faulty ECU. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. Check the physical integrity of the camshaft speed sensor. The sensor should be fully seated and mounted tightly. A. If the sensor is not mounted/secured properly, repair as necessary. B. If the sensor is not damaged and is mounted/secured properly, continue to step 3. 3. Check the camshaft position sensor wiring. Disconnect the camshaft position sensor. Disconnect the engine interface connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity check : From

To Value Camshaft position sensor connector There should be continuity. pin 2 There should be no continuity. Camshaft position sensor connector Chassis ground pin 2 X-017 pin 4 All pins in connector X-017 There should be no continuity. X-017 pin 4

With the key in the ON position, use a multimeter to perform the following voltage check : From To Camshaft position sensor connector Chassis ground pin 2

Value There should be no voltage.

A. If the specified values are measured, leave the camshaft position sensor disconnected. Leave connector X-017 disconnected and continue to step 4.

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B. If the specified values are not measured, there is failure in the camshaft position sensor wiring. Locate and repair the failed conductor. Repair or replace the harness as required. 4. Check the camshaft position sensor wiring. Disconnect the ECU connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity check : From X-017 pin 4 X-017 pin 4 X-017 pin 4

To X-016 pin 14 Chassis ground All pins in connector X-017

Value There should be continuity. There should be no continuity.

With the key in the ON position, use a multimeter to perform the following voltage check : From X-016 pin 14

To Chassis ground

Value There should be no voltage.

A. If the specified values are measured, leave the camshaft position sensor disconnected and continue to step 5. B. If the specified values are not measured, there is a problem in the camshaft position sensor wiring. Locate and repair the failed conductor. Rapair or replace the harness as required. 5. Replace the camshaft position sensor. Use the Electronic Service Tool (EST) to verify the status of this fault, 3091 - Camshaft speed sensor pattern is not plausible. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 Engine F5C T4 (Engine) (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 06 Engine F5C T4 (Engine) (55.100.DP-C.20.E.06)

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3093-Compared camshaft and crankshaft speed sensor values are not plausible WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) monitors the camshaft position sensor and the crankshaft position sensor characteristics for angle, speed determination, signal plausibility, and quality. If the ECU determines that the offset between the crankshaft signal and the expected camshaft first edge is less or greater than 10.00 ° for longer than four consecutive cycles, this fault will occur. Possible failure modes: 1. The camshaft position sensor is improperly mounted or not seated properly. 2. The crankshaft position sensor is improperly mounted or not seated properly. 3. A loose or damaged camshaft tone wheel. 4. A loose or damaged crankshaft tone wheel. 5. The engine is not timed properly. 6. A faulty ECU. Wiring harnesses - Electrical schematic sheet 07 Engine F5C T4 (Engine) (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 06 Engine F5C T4 (Engine) (55.100.DP-C.20.E.06)

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3096-CAN A Bus off failure WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on two separate Controller Area Networks (CAN). Proper configuration and monitoring of the two twisted pair configured networks is also a function of the ECU A-9000. CAN Node A Bus is the main vehicle interface bus. The ECU A-9000 provides a CAN termination resistor for the CAN Node A Bus, internal to the ECU A-9000. If the ECU A-9000 senses that CAN Node A Bus is not functioning properly, this fault will occur. Cause: ECU A-9000 has sensed a Bus Off state to be present at the CAN Node A. Possible failure modes: 1. Faulty supply voltage or ground, missing. 2. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit. 3. Faulty ECU A-9000, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check for other vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If other vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that 3096 - ECM Busoff on vehicle CAN is also resolved. B. If other vehicle CAN faults do not exist, continue with Step 3. 3. Check the ECU A-9000 supply voltage. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9122. To energize the Main relay K-9102, place a jumper wire between the vehicle harness (VE) side of connector X-9122 pin K28 and chassis ground. Use a multimeter to check for voltage on the vehicle (VE) harness side: From X-9122 pin K01 X-9122 pin K03 X-9122 pin K05

To chassis ground chassis ground chassis ground

Value There should be 12.0 V . There should be 12.0 V . There should be 12.0 V .

A. If the voltage is present on all of the checks, leave connector X-9122 disconnected and continue with Step 4. B. If the voltage is not present for one or more of the checks, see the appropriate vehicle service manual and electrical schematics, if necessary, to locate and restore supply power to the ECU A-9000. 4. Check the ECU A-9000 ground circuits. Use a multimeter to check for continuity on the vehicle (VE) harness side: 47683911 27/02/2015

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From X-9122 pin K02 X-9122 pin K04 X-9122 pin K06

To chassis ground chassis ground chassis ground

Value There should be continuity. There should be continuity. There should be continuity.

A. If there is continuity on all of the checks, leave connector X-9122 disconnected and continue with Step 5. B. If there is no continuity for one or more of the checks, see the appropriate vehicle service manual and electrical schematics, if necessary, to locate and restore the ground circuits to the ECU A-9000. 5. Determine the condition of the ECU A-9000 CAN circuit. With the key switch in the OFF position, use a multimeter to measure the resistance of the CAN connection on the vehicle (VE) harness side: From X-9122 pin K24 X-9122 pin K24 X-9122 pin K25

To X-9122 pin K25 chassis ground chassis ground

Value There should be 120 Ω. There should not be continuity There should not be continuity

Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU A-9000: From X-9122 pin K24

To X-9122 pin K25

Value There should be 120 Ω.

A. If the measured resistances are correct and neither conductor is grounded, check the ECU A-9000 for the appropriate software and re-flash, if necessary. B. If the measured resistances are not correct or one or both of the conductors is grounded, see the appropriate vehicle service manual and electrical schematics, if necessary, to locate and restore the termination resistance to the CAN circuit. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3102-Fuel rail pressure sensor voltage is lower than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

To Chassis ground X-9026 pin 1 All pins in connector X-9138

Value There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit in the rail pressure sensor B-9004 engine harness (EN) wiring. Locate and repair the shorted conductor. B. If there is no continuity, leave connectors X-9026 and X-9138 disconnected and continue to Step 3. 3. Check the rail pressure sensor B-9004 vehicle harness (VE) wiring for a short circuit condition. Disconnect the vehicle harness from the ECU A-9000 at connector X-9121. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9138 pin 6 X-9121 pin A41

To All pins in connector X-9138 All pins in connector X-9121 47683911 27/02/2015

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Value There should be no continuity. There should be no continuity.

Electrical systems - FAULT CODES

A. If there is continuity, there is a short circuit in the rail pressure sensor B-9004 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the broken conductor. B. If there is no continuity, continue to Step 4. 4. Replace the rail pressure sensor B-9004. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is no longer active, return the machine to service. B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3104-Fuel pressure relief valve is open WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) monitors the fuel metering unit Y-9000 signal circuit. If the ECU A-9000 detects a short to a voltage source in the fuel metering unit Y-9000 low side driver circuit, this fault will occur. Cause: There is a short to a voltage source in the fuel metering unit Y-9000 low side driver circuit. Possible failure modes: 1. Faulty fuel metering unit Y-9000 wiring, short to a voltage source. 2. Faulty fuel metering unit Y-9000, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Test the fuel metering unit Y-9000 internal resistance. Disconnect the engine harness (EN) from the fuel metering unit Y-9000 at connector X-9007. Use a multimeter to measure the resistance on the fuel metering unit Y-9000 pins : From X-9007 pin 1

To X-9007 pin 2

Value There should be between 2.6 - 3.2 Ω at approximately 20.0 °C (68.0 °F).

A. If there is between 2.6 - 3.2 Ω, leave connector X-9007 disconnected and continue to Step 3. B. If there is not between 2.6 - 3.2 Ω, the fuel metering unit Y-9000 has failed. Replace the fuel metering unit Y-9000. 3. Check the fuel metering unit Y-9000 low side driver wiring for a short to battery condition. With the key in the OFF position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-9007 pin 2

To Chassis ground

Value There should be no voltage.

With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-9007 pin 2

To Chassis ground

Value There should be no voltage.

A. If there is voltage, there is a short circuit to battery or switched battery in the fuel metering unit Y-9000 low side driver circuit wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor.

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B. If there is no voltage, leave connector X-9007 disconnected and continue to Step 4. 4. Check the fuel metering unit Y-9000 low side driver engine harness (EN) wiring for a short circuit condition. Disconnect the vehicle harness (VE) from the engine interface at connector X-9138. With the key in the OFF position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-9138 pin 2

To All pins in connector X-9138.

Value There should be no continuity.

A. If there is no continuity, leave connector X-9138 disconnected and continue to Step 5. B. If there is continuity, there is a short circuit condition in the fuel metering unit Y-9000 low side driver engine harness (EN) wiring. Locate and repair the shorted conductor. 5. Check the fuel metering unit Y-9000 low side driver vehicle harness (VE) wiring for a short circuit condition. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key in the OFF position, use a multimeter to perform the following continuity check from the vehicle harness (VE) side : From X-9138 pin 2 X-9121 pin A60

To All pins in connector X-9138. All pins in connector X-9121.

Value There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit condition in the fuel metering unit Y-9000 low side driver vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3105-Fuel pressure relief valve is forced to open, perform pressure increase C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Common rail Relief valve - Configure - Reset ECU data (10.218), if necessary. NOTE: If the rail pressure sensor B-9004 is replaced, it is necessary to perform the Replacement of the Rail Pressure sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Common rail pressure sensor - Configure - Reset ECU data (Rail pressure sensor) (55.010), if necessary. Context: The Engine Control Unit (ECU) A-9000, if necessary, will set the engine into limp home mode. This process is achieved in two steps by the ECU A-9000, a pressure increase and a pressure shock. The ECU A-9000 will execute step one by a fuel pressure increase. This is achieved by fully opening the fuel metering unit Y-9000, thus allowing maximum fuel delivery. If this fault is active, the ECU A-9000 has performed step one for achieving limp home mode, a fuel pressure increase. Other active faults may have caused this fault to occur. For more information regarding fuel system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218). Cause: The ECU A-9000 has performed a fuel pressure increase to achieve limp home mode.

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3106-Fuel pressure relief valve reached maximum allowed opening count WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Common rail Relief valve - Configure - Reset ECU data (10.218), if necessary. NOTE: If the rail pressure sensor B-9004 is replaced, it is necessary to perform the Replacement of the Rail Pressure sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Common rail pressure sensor - Configure - Reset ECU data (Rail pressure sensor) (55.010), if necessary. Context: The Engine Control Unit (ECU) A-9000 monitors the fuel Pressure Relief Valve (PRV). If the ECU A-9000 determines that the PRV has exceeded its maximum open count, 50 times, this fault will occur. If the PRV has opened more than 50 times, the PRV must be replaced. Other active faults may have caused this fault to occur. For more information regarding fuel system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218). Cause: The ECU A-9000 has determined that the PRV has opened more than 50 times. Possible failure modes: 1. Faulty fuel metering unit Y-9000, stuck open. 2. Faulty rail pressure sensor B-9004, drifted signal. 3. Faulty PRV, opening pressure too low. 4. Faulty fuel back-flow, clogged or damaged. 5. Faulty ECU A-9000, software.

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3107-Fuel metering unit is shorted to battery voltage at the low side WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

To X-9007 pin 2

Value There should be between 2.6 - 3.2 Ω at approximately 20.0 °C (68.0 °F).

To Chassis ground

Value There should be no voltage.

With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-9007 pin 2

To Chassis ground

Value There should be no voltage.

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To All pins in connector X-9138.

Value There should be no continuity.

To All pins in connector X-9138. All pins in connector X-9121.

Value There should be no continuity. There should be no continuity.

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3108-Fuel metering unit is shorted to ground at the low side WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the fuel metering unit Y-9000 low side driver circuit. If the ECU A-9000 detects a short to ground in the fuel metering unit Y-9000 low side driver circuit, this fault will occur. Cause: The ECU A-9000 has detected a short to ground condition in the fuel metering unit Y-9000 low side driver circuit. Possible failure modes: 1. Faulty fuel metering unit Y-9000 wiring, short to ground condition. 2. Faulty fuel metering unit Y-9000, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Test the fuel metering unit Y-9000 internal resistance and for a grounded condition. Disconnect the engine harness (EN) from the fuel metering unit Y-9000 at connector X-9007. Use a multimeter to perform the following continuity and resistance check on the fuel metering unit Y-9000 pins : From X-9007 pin 2 X-9007 pin 1

To Chassis ground X-9007 pin 2

Value There should be no continuity. There should be between 2.6 - 3.2 Ω at approximately 20 °C (68 °F).

A. If there is between 2.6 - 3.2 Ω and there is no continuity to ground, leave connector X-9007 disconnected and continue to Step 3. B. If the specified values are not measured, the fuel metering unit Y-9000 has a grounded condition or has failed internally. Replace the fuel metering unit Y-9000. 3. Check the fuel metering unit Y-9000 engine harness (EN) wiring for a short to ground condition. Disconnect the vehicle harness (VE) from the engine interface at connector X-9138. With the key switch in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From X-9138 pin 2 X-9138 pin 2

To Chassis ground All pins in connector X-9138

Value There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit in the fuel metering unit Y-9000 engine harness (EN) wiring. Locate and repair the shorted conductor. B. If there is no continuity, leave connector X-9138 disconnected and continue to Step 4. 4. Check the fuel metering unit Y-9000 vehicle harness (VE) wiring for a short to ground condition. 47683911 27/02/2015

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Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key switch in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9138 pin 2 X-9138 pin 2 X-9121 pin A60

To Chassis ground All pins in connector X-9138 All pins in connector X-9121.

Value There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit condition in the fuel metering unit Y-9000 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, check the ECU A-9000 for the appropriate service manual and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3110-Rail pressure sensor value is above maximum offset C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

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3111-Rail pressure sensor value is below minimum offset C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

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3112-Fuel rail pressure sensor voltage is higher than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

To Chassis ground

Value There should be no voltage.

With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-9026 pin 2

To Chassis ground

Value There should be less than 5.5 V

A. If the specified values are not measured, there is a short to battery or switched battery in the rail pressure sensor B-9004 wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If the specified values are measured, leave connector X-9026 disconnected and continue to Step 3. 3. Check the rail pressure sensor B-9004 engine harness (EN) wiring for an open circuit. Disconnect the vehicle harness (VE) from the engine interface at connector X-9138.

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With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From X-9026 pin 2 X-9026 pin 3

To X-9138 pin 6 X-9138 pin 7

Value There should be continuity. There should be continuity.

Disconnect the vehicle harness from the ECU A-9000 at connector X-9121. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9138 pin 6 X-9138 pin 7

To X-9121 pin A41 X-9121 pin A11

Value There should be continuity. There should be continuity.

A. If there is no continuity, there is an open circuit in the rail pressure sensor B-9004 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the broken conductor. B. If there is continuity, leave connectors X-9138, X-9026, and X-9121 disconnected and continue to Step 4. 4. Check the rail pressure sensor B-9004 engine harness (EN) wiring for a short to a voltage source. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From X-9026 pin 2 X-9138 pin 6

To X-9026 pin 3 All pins in connector X-9138

Value There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit in the rail pressure sensor B-9004 engine harness (EN) wiring. Locate and repair the shorted conductor. B. If there is no continuity, leave connectors X-9138, X-9026, and X-9121 disconnected and continue to Step 5. 5. Check the rail pressure sensor B-9004 vehicle harness (VE) wiring for a short to a voltage source. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9138 pin 6 X-9121 pin A41

To All pins in connector X-9138 All pins in connector X-9121

Value There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit in the rail pressure sensor B-9004 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the broken conductor. B. If there is no continuity, leave connector X-9026 disconnected and continue to Step 6. 6. Replace the rail pressure sensor B-9004. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is no longer active, return the machine to service. B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

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3137-Fuel metering unit has an open load error WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the fuel metering unit Y-9000 signal circuit. If the ECU A-9000 detects an open load error in the fuel metering unit Y-9000 signal circuit, this fault will occur. Cause: There is open load detected in the fuel metering unit Y-9000 signal circuit. Possible failure modes: 1. Faulty fuel metering unit Y-9000 wiring, open circuit. 2. Faulty fuel metering unit Y-9000, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Test the fuel metering unit Y-9000 internal resistance. Disconnect the engine harness (EN) from the fuel metering unit Y-9000 at connector X-9007. Use a multimeter to measure the resistance on the fuel metering unit Y-9000 pins : From X-9007 pin 1

To X-9007 pin 2

Value There should be between 2.6 - 3.2 Ω at approximately 20.0 °C (68.0 °F).

A. If there is between 2.6 - 3.2 Ω, leave connector X-9007 disconnected and continue to Step 3. B. If there is not between 2.6 - 3.2 Ω, the fuel metering unit Y-9000 has failed. Replace the fuel metering unit Y-9000. 3. Check the fuel metering unit Y-9000 engine harness (EN) wiring for an open circuit. Disconnect the vehicle harness (VE) from the engine interface at connector X-9138. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From

X-9007 pin 1 X-9007 pin 2

X-9138 pin 1 X-9138 pin 2

Value NOTE: Wiggle the harness during the check to promote an intermittent electrical connection. There should be continuity. There should be continuity.

A. If there is continuity, leave connector X-9138 disconnected and continue to Step 4.

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B. If there is no continuity, there is an open circuit condition in the fuel metering unit Y-9000 engine harness (EN) wiring. Locate and repair the broken conductor. 4. Check the fuel metering unit Y-9000 vehicle harness (VE) wiring for an open circuit. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From

X-9138 pin 1 X-9138 pin 2

X-9121 pin A15 X-9121 pin A60

Value NOTE: Wiggle the harness during the check to promote an intermittent electrical connection. There should be continuity. There should be continuity.

A. If there is no continuity, there is an open circuit condition in the fuel metering unit Y-9000 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the broken conductor. B. If there is continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3141-Fuel pump pressure has exceeded desired pressure limits WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Common rail Relief valve - Configure - Reset ECU data (10.218), if necessary. NOTE: If the rail pressure sensor B-9004 is replaced, it is necessary to perform the Replacement of the Rail Pressure sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Common rail pressure sensor - Configure - Reset ECU data (Rail pressure sensor) (55.010), if necessary. Context: The Engine Control Unit (ECU) Y-9000 monitors fuel rail pressure. If the ECU A-9000 determines that the requested fuel pressure can not be reached, a leakage in the fuel system is assumed and this fault will occur. For more information regarding fuel system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218). Cause: The ECU A-9000 has determined that a fuel system leakage is present. Possible failure modes: 1.

Faulty fuel filters, clogged.

Faulty low pressure fuel lines, clogged or damaged.

Faulty high pressure fuel lines, clogged or damaged.

Faulty electric fuel pump (if equipped).

Faulty charge gear pump, low efficiency.

Faulty high pressure pump, low efficiency or excessive leak-off.

Faulty fuel injectors, external or internal leakage.

Faulty Pressure Relief Valve (PRV), leaking or stuck open.

Faulty rail pressure sensor B-9004 or sensor leaking.

10. Faulty fuel metering unit Y-9000 11. Faulty ECU A-9000, software.

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3146-Water in fuel detected or water in fuel circuit failure WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: This fault code is for the Water in Fuel switch with black connector housing. Context: The Engine Control Unit (ECU) A-9000 monitors the voltage output from the water in fuel switch S-9102 to determine if water is present in the fuel supply. If water is detected in the fuel, warnings will be displayed to alert the operator of potential engine damage if operation continues. High voltage signal from the water in fuel switch S-9102 indicates water present. Cause: This fault code is displayed to warn the operator that the Engine Control Unit (ECU) A-9000 has detected excess water in the fuel system or a fault in the water in fuel switch circuit. Possible failure modes: 1. Excess water in the fuel supply. 2. Faulty water in fuel switch S-9102, wiring or internal (mechanical and/or electrical) failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify this fault code is still present and in an active state. Use the Easy Engine software provided on the Electronic Service Tool (EST) to check the fault status. A. If the fault is still present and active, continue with Step 2. B. If the fault is no longer present or is in an inactive state, Continue with Step 7. 2. Check fuel for water contamination. A. If there is water contamination, continue with Step 3. B. If there is no water contamination, Continue with Step 4. 3. Verify proper water in fuel switch S-9102 operation. Purge fuel supply system, replace fuel filter(s) and refill with fuel that is free of water contamination. Start and run engine for 5 minutes. Check for code to return to active status. A. If code returns in an active status, replace water in fuel switch S-9102. B. If code remains inactive, return the machine to service. 4. Check for open, short and grounded circuit conditions in the water in fuel switch S-9102 circuit. Disconnect the water in fuel switch S-9102 at connector X-9125. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9122. With the key switch in the OFF position, use a multimeter to perform the following tests, on the vehicle (VE) harness from : From X-9125 pin 1 X-9125 pin 2

To X-9122 pin K30 Chassis ground

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Value There should be continuity. There should be continuity.

Electrical systems - FAULT CODES

From X-9125 pin 3

To Refer to the appropriate vehicle schematics.

Value There should be continuity.

Then use the multimeter to perform the following tests, on the vehicle (VE) harness from : From X-9125 pin 1 X-9125 pin 1 X-9125 pin 2

To X-9125 pin 2 X-9125 pin 3 X-9125 pin 3

Value There should be no continuity There should be no continuity There should be no continuity

Then use the multimeter to perform the following tests, on the vehicle (VE) harness from : From X-9125 pin 1 X-9125 pin 3

To Chassis ground Chassis ground

Value There should be no continuity There should be no continuity

A. If the results are not as expected for any of the wiring tests listed above, there is an open, short or grounded circuit condition in the vehicle harness (VE) wiring. Use the appropriate vehicle service manual and schematics to diagnose and repair the wiring. B. If the results are as expected in all of the wiring tests listed above, the wiring is ok. Leave connectors X-9122 and X-9125 disconnected and continue with Step 5. 5. Check for key switch voltage supply to water in fuel switch S-9102. With the key switch in an ON position, use a multimeter to perform the following test, on the vehicle (VE) harness side from : From X-9125 pin 3 X-9125 pin 1

To Chassis ground Chassis ground

Value There should be key switch voltage. There should be no key switch voltage.

A. If there is key switch voltage present in the first check and not present in the second check, continue with Step 6. B. If key switch voltage is not present in the first check or present in the second check, use the appropriate vehicle service manual and schematics to diagnose and repair the wiring. 6. Replace the water in fuel switch S-9102, then check to see if this fault has been resolved. A. If the fault is resolved, return the machine to service. B. If the fault is not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3157-ECM Not Detected On CAN Bus - The Engine Dataset Registration Information Was Not Available From The Engine Within The Time Required. C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Cause: Engine configuration does not match the instrument cluster configuration stored. Possible failure modes: 1. Configuration error 2. Problem in the CAN bus wiring. Solution: 1. Verify the harness is not damaged. Turn the ignition switch OFF. Verify the connections to the ECU, the instrument cluster, the diagnostic connector, the UCM (if installed) and the optional Telematics unit are tight and secure. Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment from the ECU to the instrument cluster. Verify all data link drops are free of damage, abrasion, corrosion, and incorrect attachment. Verify the ground circuits to the control modules are tight and secure. Inspect the rear engine relay box. A. The CAN bus harness is not damaged and all connections are secure. Go to step 1. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness as required. Go to step 2 to confirm elimination of fault. 2. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 3157 and/or 3158 are active. No other fault codes are active. The engine configuration does not match the instrument cluster configuration stored. Correct the configuration error. Verify all modules on the CAN bus have the latest software versions. B. Fault code 3157 and other CAN Data Link fault codes such as 9151 - 9154, 9405, 9406, 9410, or 1051 through 1059 are present and ACTIVE. This is an indication of a problem in the CAN Data Link circuit. Refer to 1051-No CAN Communication With Engine Controller (55.408), step 3.

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3158-The Engine Dataset Installed Does Not Match The Dataset Registered For This Machine. Register The New Dataset If The Dataset Has Just Been Updated C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Cause: The engine configuration does not match the instrument cluster configuration stored. Possible failure modes: 1. Configuration error Solution: 1. The engine configuration does not match the instrument cluster configuration stored. Correct the configuration error.

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3166-Fuel filter heater actuator is shorted to battery voltage WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 controls the fuel filter heater relay K-9100 using a low side driver. If the ECU A-9000 detects a short circuit to battery in the low side driver circuit, this fault will occur. Cause: The ECU A-9000 has detected a short circuit to battery in the fuel filter heater relay K-9100 low side driver circuit. Possible failure modes: 1. Faulty fuel filter heater relay K-9100, wiring or internal failure. 2. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check the fuel filter heater relay K-9100 coil. Remove the fuel filter heater relay K-9100. Using a multimeter, perform the following resistance check on the fuel filter heater relay K-9100 pins from : From X-9115 pin 85

To X-9115 pin 86

Value There should be approximately 70 130 Ω.

A. If there is approximately 70 - 130 Ω, leave the relay disconnected and continue to Step 3. B. If there is not approximately 70 - 130 Ω, the relay has failed. Replace the relay. 3. Check the fuel filter heater relay K-9100 low side driver vehicle harness (VE) wiring for a short circuit. With the key in the ON position, use a multimeter to perform the following voltage check from the vehicle harness (VE) side of the connector from : From X-9115 pin 85

To Chassis ground

Value There should be no voltage.

With the key in the OFF position, use a multimeter to perform the following continuity check from the vehicle harness (VE) side of the connector from : From X-9115 pin 85 X-9115 pin 85 X-9115 pin 85

To Chassis ground X-9115 pin 86 X-9115 pin 30

Value There should be no voltage. There should be no continuity. There should be no continuity.

A. If the specified values are not measured, there is a short circuit in the fuel filter heater relay K-9100 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If the specified values are measured, leave the connector disconnected and continue to Step 4.

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4. Check the fuel filter heater relay K-9100 low side driver vehicle harness (VE) wiring for a short circuit. Disconnect the ECU A-9000 connector X-9122. With the key in the OFF position, use a multimeter to perform the following continuity check from the vehicle harness (VE) side of the connector from : From X-9122 pin K70

To All pins in connector X-9122

Value There should be no continuity.

A. If there is continuity, there is a short circuit in the fuel filter heater relay K-9100 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, continue to Step 5. 5. Replace the fuel filter heater relay K-9100. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is no longer active, return the machine to service. B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3167-Fuel filter heater actuator is shorted to ground WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 controls the fuel filter heater relay K-9100 using a low side driver. If the ECU A-9000 detects a short circuit to ground in the low side driver circuit, this fault will occur. Cause: The ECU A-9000 has detected a short circuit to ground in the fuel filter heater relay K-9100 low side driver circuit. Possible failure modes: 1. Faulty fuel filter heater relay K-9100, wiring or internal failure. 2. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the fuel filter heater relay K-9100 coil. Remove the fuel filter heater relay K-9100. Using a multimeter, perform the following resistance check on the fuel filter heater relay K-9100 pins from : From X-9115 pin 85

To X-9115 pin 86

Value There should be approximately 70 130 Ω.

A. If there is approximately 70 - 130 Ω, leave the relay disconnected and continue to Step 3. B. If there is not approximately 70 - 130 Ω, the relay has failed. Replace the relay. 3. Check the fuel filter heater relay K-9100 low side driver vehicle harness (VE) wiring for a short circuit. Disconnect the ECU A-9000 connector X-9122. With the key in the OFF position, use a multimeter to perform the following continuity check from the vehicle harness (VE) side of the connector from : From X-9122 pin K70 X-9122 pin K70

To Chassis ground All pins in connector X-9122

Value There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit to ground in the fuel filter heater relay K-9100 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, continue to Step 4. 4. Replace the fuel filter heater relay K-9100. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is no longer active, return the machine to service.

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B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3168-Fuel filter heater actuator has an open load error WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 controls the fuel filter heater relay K-9100 using a low side driver. If the ECU A-9000 detects an open circuit in the low side driver circuit, this fault will occur. Cause: The ECU A-9000 has detected an open circuit in the fuel filter heater relay K-9100 low side driver circuit. Possible failure modes: 1. Faulty fuel filter heater relay K-9100, wiring or internal failure. 2. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the fuel filter heater relay K-9100 coil. Remove the fuel filter heater relay K-9100. Using a multimeter, perform the following resistance check on the fuel filter heater relay K-9100 pins from : From X-9115 pin 85

To X-9115 pin 86

Value There should be approximately 70 130 Ω.

A. If there is approximately 70 - 130 Ω, leave the relay disconnected and continue to Step 3. B. If there is not approximately 70 - 130 Ω, the relay has failed. Replace the relay. 3. Check the fuel filter heater relay K-9100 low side driver vehicle harness (VE) wiring for an open circuit. Disconnect the ECU A-9000 connector X-9122. With the key in the OFF position, use a multimeter to perform the following voltage check from the vehicle harness (VE) side of the connector from : From

X-9115 pin 85

X-9122 pin K70

Value NOTE: Shake the harness during the check to promote an intermittent electrical connection. There should be continuity.

A. If there is no continuity, there is an open circuit in the fuel filter heater relay K-9100 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the broken conductor. B. If there is continuity., leave the connector disconnected and continue to Step 4. 4. Replace the fuel filter heater relay K-9100.

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Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is no longer active, return the machine to service. B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3169-Fuel filter heater ECU driver has an over temperature error WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 controls the fuel filter heater relay K-9100 using a low side driver. If the ECU A-9000 detects an over temperature/current condition in the low side driver circuit, this fault will occur. Cause: The ECU A-9000 has detected an over temperature/current condition in the fuel filter heater relay K-9100 low side driver circuit. Possible failure modes: 1. Faulty fuel filter heater relay K-9100 wiring, short circuit. 2. Faulty fuel filter heater relay K-9100, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check the fuel filter heater relay K-9100 coil. Remove the fuel filter heater relay K-9100. Use a multimeter to measure the resistance on the fuel filter heater relay K-9100 pins : From X-9115 pin 85

To X-9115 pin 86

Value There should be approximately 70 130 Ω.

A. If there is approximately 70 - 130 Ω, leave the fuel filter heater relay K-9100 disconnected and continue to Step 3. B. If there is not approximately 70 - 130 Ω, the fuel filter heater relay K-9100 has failed. Replace the fuel filter heater relay K-9100. 3. Check the fuel filter heater relay K-9100 low side driver vehicle harness (VE) wiring for a short circuit. With the key in the OFF position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From X-9115 pin 85

To Chassis ground

Value There should be no voltage.

With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From X-9115 pin 85

To Chassis ground

Value There should be no voltage.

A. If there is voltage, there is a short circuit in the fuel filter heater relay K-9100 low side driver circuit in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. 47683911 27/02/2015

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B. If there is no voltage, leave the fuel filter heater relay K-9100 disconnected and continue to Step 4. 4. Check the fuel filter heater relay K-9100 low side driver vehicle harness (VE) wiring for a short circuit. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9115 pin 85

To X-9115 pin 86

Value There should be no continuity.

A. If there is continuity, there is a short circuit in the fuel filter heater relay K-9100 low side driver circuit in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, continue to Step 5. 5. Check the fuel filter heater relay K-9100 low side driver vehicle harness (VE) wiring for a short circuit. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9122 pin K70

To All pins in connector X-9122

Value There should be no continuity.

A. If there is continuity, there is a short circuit in the fuel filter heater relay K-9100 wiring in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3176-High pressure pump fuel delivery quantity in over run exceeds a maximum threshold WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the high pressure fuel system for leakage during overrun. If the ECU A-9000 detects that the high pressure pump quantity in overrun exceeds the expected threshold, this fault will occur. Cause: The ECU A-9000 has determined that the high pressure fuel pump quantity is higher than the expected fuel quantity threshold. Possible failure modes: 1. Faulty fuel metering unit Y-9000, internal failure. 2. Faulty high pressure fuel pump, internal failure. 3. Faulty ECU A-9000, software.

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3177-Engine over speed condition detected C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: This fault is intended for information purposes only and does not require any further action. Other active faults may have caused this fault to occur. Diagnose any other active faults first and then return to this fault, 3177 - Engine over speed condition detected. The Engine Control Unit (ECU) A-9000 monitors for an engine overspeed condition. An engine overspeed condition can occur from such conditions as downhill travel. If an engine speed of at least 3100 RPM has been detected for at least 0.05 s, this fault will occur.

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3179-CAN communication failure between vehicle controller and ECU - BC2ECU2 message WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on two separate Controller Area Networks (CAN). Proper configuration and monitoring of the two twisted pair configured networks is also a function of the ECU A-9000. CAN Node A Bus is the main vehicle interface bus. The ECU A-9000 provides a CAN termination resistor for the CAN Node A Bus, internal to the ECU A-9000. If the ECU A-9000 senses that CAN Node A Bus is not functioning properly, this fault will occur. Cause: ECU A-9000 has sensed a timeout of required vehicle controller data provided on CAN Node A. Possible failure modes: 1. Faulty supply voltage or ground, missing. 2. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit. 3. Faulty ECU A-9000, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check for other vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If other vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that 3179 - CAN communication failure between vehicle controller and ECU - BC2ECU2 message is also resolved. B. If other vehicle CAN faults do not exist, continue with Step 3. 3. Check the ECU A-9000 supply voltage. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9122. With the key switch in the “ON” position, use a multimeter to check for voltage on the vehicle (VE) harness side: From X-9122 pin K01 X-9122 pin K03 X-9122 pin K05

To chassis ground chassis ground chassis ground

Value There should be 12.0 V . There should be 12.0 V . There should be 12.0 V .

A. If the voltage is present on all of the checks, leave connector X-9122 disconnected and continue with Step 4. B. If the voltage is not present for one or more of the checks, refer to the appropriate vehicle service manual and electrical schematics to locate and restore supply power to the ECU A-9000. 4. Check the ECU A-9000 grounding. With the key switch in the “OFF” position, use a multimeter to check for continuity on the vehicle (VE) harness side:

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From X-9122 pin K02 X-9122 pin K04 X-9122 pin K06

To chassis ground chassis ground chassis ground

Value There should be continuity. There should be continuity. There should be continuity.

A. If there is continuity on all of the checks, leave connector X-9122 disconnected and continue with Step 5. B. If there is no continuity for one or more of the checks, refer to the appropriate vehicle service manual and electrical schematics to locate and restore the grounding circuit to the ECU A-9000. 5. Determine the condition of the ECU A-9000 CAN circuit. With the key switch in the “OFF” position, use a multimeter to measure the resistance of the CAN connection on the vehicle (VE) harness side: From X-9122 pin K24 X-9122 pin K24 X-9122 pin K25

To X-9122 pin K25 chassis ground chassis ground

Value There should be 120 Ω. There should not be continuity There should not be continuity

Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU A-9000: From X-9122 pin K24

To X-9122 pin K25

Value There should be 120 Ω.

A. If the measured resistances are correct and neither conductor is grounded, check the ECU A-9000 for the appropriate software and re-flash, if necessary. B. If the measured resistances are not correct or one or both of the conductors is grounded, refer to the appropriate vehicle service manual and electrical schematics to locate and restore the termination resistance to the CAN circuit. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3180-CAN communication error between vehicle controller to ECU WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on two or more separate Controller Area Networks (CAN). Proper configuration and monitoring of these twisted pair configured networks is also a function of the ECU A-9000. CAN Node A Bus is the main vehicle interface bus. The ECU A-9000 provides a CAN termination resistor for the CAN Node A Bus, internal to the ECU A-9000. The ECU A-9000 receives and responds to proprietary information like low and high idle or intermediate speed set points and parameters or feedback. If the ECU A-9000 does not receive the message every 0.050 s, this fault will occur. Cause: ECU A-9000 has sensed a timeout of required vehicle controller data provided on CAN Node A. Possible failure modes: 1. Faulty vehicle system, related CAN fault. 2. Faulty supply voltage or ground, missing. 3. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit. 4. Faulty ECU A-9000, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check for other vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If other vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that this fault is also resolved. B. If other vehicle CAN faults do not exist, continue with Step 3. 3. Check the ECU A-9000 supply voltage. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9122. To energize the main relay K-9102, which provides power to the ECU A-9000, place a jumper wire between the vehicle harness (VE) side of connector X-9122 pin K28 and chassis ground. Use a multimeter to check for voltage on the vehicle (VE) harness side: From X-9122 pin K01 X-9122 pin K03 X-9122 pin K05

To chassis ground chassis ground chassis ground

Value There should be 12.0 V . There should be 12.0 V . There should be 12.0 V .

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4. Check the ECU A-9000 grounding. Use a multimeter to check for continuity on the vehicle (VE) harness side: From X-9122 pin K02 X-9122 pin K04 X-9122 pin K06

To chassis ground chassis ground chassis ground

Value There should be continuity. There should be continuity. There should be continuity.

To X-9122 pin K25 chassis ground chassis ground

Value There should be 120 Ω. There should not be continuity There should not be continuity

Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU A-9000: From X-9122 pin K24

To X-9122 pin K25

Value There should be 120 Ω.

A. If the measured resistances are correct and neither conductor is grounded, check the ECU A-9000 for the appropriate software and re-flash, if necessary. B. If the measured resistances are not correct or one or both of the conductors is grounded, refer to the appropriate vehicle service manual and electrical schematics to locate and restore the termination resistance to the CAN circuit or replace the ECU A-9000. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3188-Open load error of injector in cylinder 1 WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the fuel injector number 1 Y-9001 circuit. If the ECU A-9000 determines that there is an open circuit condition in the fuel injector number 1 Y-9001 circuit, this fault will occur. Cause: The ECU A-9000 has detected an open circuit in the fuel injector number 1 Y-9001 circuit. Possible failure modes: 1. Faulty fuel injector number 1 Y-9001, internal failure. 2. Faulty fuel injector number 1 Y-9001 wiring, open circuit. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check fuel injector number 1 for an internal failure. Disconnect connector X-9030 from fuel injector number 1 Y-9001. Use a multimeter to perform the following resistance check on the fuel injector pins : From X-9030 pin 1

To X-9030 pin 2

Value There should be approximately 0.3 - 0.5 Ω.

A. If the specified range is not measured, the fuel injector has failed. Replace the fuel injector number 1 Y-9001. B. If the specified range is measured, leave connector X-9030 disconnected and continue to Step 3. 3. Check the fuel injector number 1 Y-9001 engine harness (EN) wiring for an open circuit. Disconnect connector X-9139 from the engine interface connector. With they key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side: From X-9139 pin A X-9139 pin B

To X-9030 pin 1 X-9030 pin 2

Value There should be continuity. There should be continuity.

A. If there is no continuity, there is an open circuit in the fuel injector number 1 Y-9001 engine harness (EN) wiring. Locate and repair the broken conductor. B. If there is continuity, leave connectors X-9030 and X-9139 disconnected and continue to Step 4. 4. Check the fuel injector number 1 Y-9001 vehicle harness (VE) wiring for an open circuit. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121.

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With they key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side: From X-9139 pin A X-9139 pin B

To X-9121 pin A16 X-9121 pin A32

Value There should be continuity. There should be continuity.

A. If there is no continuity, there is an open circuit in the fuel injector number 1 Y-9001 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the broken conductor. B. If there is continuity, check the ECU A-9000 for the appropriate service manual and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3192-Open load error of injector in cylinder 2 WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the fuel injector number 2 Y-9002 circuit. If the ECU A-9000 determines that there is an open circuit condition in the fuel injector number 2 Y-9002 circuit, this fault will occur. Cause: The ECU A-9000 has detected an open circuit in the fuel injector number 2 Y-9002 circuit. Possible failure modes: 1. Faulty fuel injector number 2 Y-9002, internal failure. 2. Faulty fuel injector number 2 Y-9002 wiring, open circuit. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check fuel injector number 2 for an internal failure. Disconnect connector X-9033 from fuel injector number 2 Y-9002. Use a multimeter to perform the following resistance check on the fuel injector pins : From X-9033 pin 1

To X-9033 pin 2

Value There should be approximately 0.3 - 0.5 Ω.

A. If the specified range is not measured, the fuel injector has failed. Replace the fuel injector number 2 Y-9002. B. If the specified range is measured, leave connector X-9033 disconnected and continue to Step 3. 3. Check the fuel injector number 2 Y-9002 engine harness (EN) wiring for an open circuit. Disconnect connector X-9139 from the engine interface connector. With they key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side: From X-9139 pin H X-9139 pin G

To X-9033 pin 1 X-9033 pin 2

Value There should be continuity. There should be continuity.

A. If there is no continuity, there is an open circuit in the fuel injector number 2 Y-9002 engine harness (EN) wiring. Locate and repair the broken conductor. B. If there is continuity, leave connectors X-9033 and X-9139 disconnected and continue to Step 4. 4. Check the fuel injector number 2 Y-9002 vehicle harness (VE) wiring for an open circuit. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121.

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With they key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side: From X-9139 pin H X-9139 pin G

To X-9121 pin A02 X-9121 pin A46

Value There should be continuity. There should be continuity.

A. If there is no continuity, there is an open circuit in the fuel injector number 2 Y-9002 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the broken conductor. B. If there is continuity, check the ECU A-9000 for the appropriate service manual and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3196-Open load error of injector in cylinder 3 WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the fuel injector number 3 Y-9003 circuit. If the ECU A-9000 determines that there is an open circuit condition in the fuel injector number 3 Y-9003 circuit, this fault will occur. Cause: The ECU A-9000 has detected an open circuit in the fuel injector number 3 Y-9003 circuit. Possible failure modes: 1. Faulty fuel injector number 3 Y-9003, internal failure. 2. Faulty fuel injector number 3 Y-9003 wiring, open circuit. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check fuel injector number 3 for an internal failure. Disconnect connector X-9031 from fuel injector number 3 Y-9003. Use a multimeter to perform the following resistance check on the fuel injector pins : From X-9031 pin 1

To X-9031 pin 2

Value There should be approximately 0.3 - 0.5 Ω.

A. If the specified range is not measured, the fuel injector has failed. Replace the fuel injector number 3 Y-9003. B. If the specified range is measured, leave connector X-9031 disconnected and continue to Step 3. 3. Check the fuel injector number 3 Y-9003 engine harness (EN) wiring for an open circuit. Disconnect connector X-9139 from the engine interface connector. With they key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side: From X-9139 pin D X-9139 pin C

To X-9031 pin 1 X-9031 pin 2

Value There should be continuity. There should be continuity.

A. If there is no continuity, there is an open circuit in the fuel injector number 3 Y-9003 engine harness (EN) wiring. Locate and repair the broken conductor. B. If there is continuity, leave connectors X-9031 and X-9139 disconnected and continue to Step 4. 4. Check the fuel injector number 3 Y-9003 vehicle harness (VE) wiring for an open circuit. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121.

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With they key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side: From X-9139 pin D X-9139 pin C

To X-9121 pin A01 X-9121 pin A31

Value There should be continuity. There should be continuity.

A. If there is no continuity, there is an open circuit in the fuel injector number 3 Y-9003 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the broken conductor. B. If there is continuity, check the ECU A-9000 for the appropriate service manual and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3200-Open load error of injector in cylinder 4 WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the fuel injector number 4 Y-9004 circuit. If the ECU A-9000 determines that there is an open circuit condition in the fuel injector number 4 Y-9004 circuit, this fault will occur. Cause: The ECU A-9000 has detected an open circuit in the fuel injector number 4 Y-9004 circuit. Possible failure modes: 1. Faulty fuel injector number 4 Y-9004, internal failure. 2. Faulty fuel injector number 4 Y-9004 wiring, open circuit. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check fuel injector number 4 for an internal failure. Disconnect connector X-9032 from fuel injector number 4 Y-9004. Use a multimeter to perform the following resistance check on the fuel injector pins : From X-9032 pin 1

To X-9032 pin 2

Value There should be approximately 0.3 - 0.5 Ω.

A. If the specified range is not measured, the fuel injector has failed. Replace the fuel injector number 4 Y-9004. B. If the specified range is measured, leave connector X-9032 disconnected and continue to Step 3. 3. Check the fuel injector number 4 Y-9004 engine harness (EN) wiring for an open circuit. Disconnect connector X-9139 from the engine interface connector. With they key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side: From X-9139 pin E X-9139 pin F

To X-9032 pin 1 X-9032 pin 2

Value There should be continuity. There should be continuity.

A. If there is no continuity, there is an open circuit in the fuel injector number 4 Y-9004 engine harness (EN) wiring. Locate and repair the broken conductor. B. If there is continuity, leave connectors X-9032 and X-9139 disconnected and continue to Step 4. 4. Check the fuel injector number 4 Y-9004 vehicle harness (VE) wiring for an open circuit. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121.

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With they key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side: From X-9139 pin E X-9139 pin F

To X-9121 pin A17 X-9121 pin A48

Value There should be continuity. There should be continuity.

A. If there is no continuity, there is an open circuit in the fuel injector number 4 Y-9004 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the broken conductor. B. If there is continuity, check the ECU A-9000 for the appropriate service manual and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3210-Injection bank 1 short circuit failure (all injectors of the same bank can be affected) WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the fuel injector harness for a short circuit condition. If the ECU A-9000 detects a short circuit pattern in the fuel injector harness of both bank 1 fuel injections, this fault will occur. The bank 1 fuel injectors are fuel injector number 1 Y-9001 and fuel injector number 4 Y-9004. Cause: The ECU A-9000 has detected a a short circuit pattern between both bank 1 fuel injectors. Possible failure modes: 1. Faulty fuel injector wiring, short circuit. 2. Fault ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Use the Electronic Service Tool (EST) to check if the following related faults are active: 3063 - Short circuit error of injector in cylinder 1 3083 - Short circuit error of injector in cylinder 4 A. If any of the related faults are active, diagnose them first and then return to this fault, 3210 - Injection bank 1 short circuit failure (all injectors of the same bank can be affected). B. If none of the related faults are active, continue to Step 3. 3. Check the fuel injector harness (INJ) for a short circuit condition. Disconnect the vehicle harness (VE) from the engine interface connector X-9139. With the key in the OFF position, use a multimeter to perform the following continuity check on the fuel injector harness (INJ) side : From X-9139 X-9139 X-9139 X-9139

pin pin pin pin

A A B B

To X-9139 X-9139 X-9139 X-9139

pin pin pin pin

E F E F

Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit condition in the fuel injector number 4 Y-9004 fuel injector harness (INJ) wiring. Locate and repair the shorted conductor. B. If there is no continuity, leave the engine interface connector X-9139 disconnected and continue to Step 4. 4. Check the fuel injector number 4 Y-9004 vehicle harness (VE) for a short circuit condition. With the key in the OFF position, use a multimeter to perform the following continuity check from the vehicle harness (VE) side : 47683911 27/02/2015

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From X-9139 X-9139 X-9139 X-9139

pin pin pin pin

A A B B

To X-9139 X-9139 X-9139 X-9139

pin pin pin pin

E F E F

Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit condition in the fuel injector number 4 Y-9004 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, Check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3218-Injection bank 2 short circuit failure (all injectors of the same bank can be affected) WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the fuel injector harness for a short circuit condition. If the ECU A-9000 detects a short circuit pattern in the fuel injector harness of both bank 2 fuel injections, this fault will occur. The bank 2 fuel injectors are fuel injector number 2 Y-9002 and fuel injector number 3 Y-9003. Cause: The ECU A-9000 has detected a a short circuit pattern between both bank 2 fuel injectors. Possible failure modes: 1. Faulty bank fuel injector wiring, short circuit. 2. Fault ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Use the Electronic Service Tool (EST) to check if the following related faults are active: 3071 - Short circuit error of injector in cylinder 3 3079 - Short circuit error of injector in cylinder 2 A. If any of the related faults are active, diagnose them first and then return to this fault, 3218 - Injection bank 2 short circuit failure (all injectors of the same bank can be affected). B. If none of the related faults are active, continue to Step 3. 3. Check the fuel injector harness (INJ) for a short circuit condition. Disconnect the vehicle harness (VE) from the engine interface at connector X-9139. With the key in the OFF position, use a multimeter to perform the following continuity check on the injector harness (INJ) side : From X-9139 X-9139 X-9139 X-9139

pin pin pin pin

D D C C

To X-9139 X-9139 X-9139 X-9139

pin pin pin pin

H G H G

Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit condition in the fuel injector harness (INJ) wiring. Locate and repair the shorted conductor. B. If there is no continuity, leave the engine interface connector X-9139 disconnected and continue to Step 4. 4. Check the fuel injector vehicle harness (VE) for a short circuit condition. With the key in the OFF position, use a multimeter to perform the following continuity check from the vehicle harness (VE) side : 47683911 27/02/2015

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From X-9139 X-9139 X-9139 X-9139

pin pin pin pin

D D C C

To X-9139 X-9139 X-9139 X-9139

pin pin pin pin

H G H G

Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit condition in the fuel injector vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, Check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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Electrical systems - FAULT CODES

3230-ECU internal failure - Injector CY33x component C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors diagnostic checks on the fuel injection power stages. This diagnostic procedure uses pattern detection to identify specific errors and can trigger the appropriate reaction. If the ECU A-9000 detects a specific combination of errors in the injection power stages, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3235-Exceeded the number of injections for a given engine speed C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The ECU A-9000 monitors the requested number of fuel injections and the current capability of the injection system fulfilling that request. If the ECU A-9000 determines that the requested number of injections is greater than the current capability of the fuel injection system for the current engine speed, this fault will occur. Cause: The ECU A-9000 has determined that the requested number of fuel injections is greater than the capability of the fuel injection system based on engine speed. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3236-Number of injections is limited by system WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The ECU A-9000 monitors the requested number of fuel injections and the current capability of the fuel injection system to fulfill that request. If the ECU A-9000 determines that the number of requested fuel injections is greater than the current capability of the fuel injection system, this fault will occur. For more information regarding the troubleshooting of the fuel system, refer to the engine service manual Fuel injection system - Troubleshooting (10.218). Cause: The ECU A-9000 has determined that the number of requested fuel injections is greater than the current capability of the fuel injection system to fulfill that request. Possible failure modes: 1.

Faulty fuel back-flow, excessive.

Faulty high pressure pump, worn or ageing.

Faulty fuel metering unit, unable to open.

Faulty fuel temperature, too high.

Faulty fuel injectors, worn or internal leakage.

Faulty fuel filters, clogged.

Faulty charge gear pump, low efficiency.

Faulty Pressure Relief Valve (PRV), leakage.

Faulty rail pressure sensor B-9004, drifted signal or leakage.

10. Faulty fuel injection system, leaking or blocked lines. 11. Faulty ECU A-9000, software.

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3237-Number of desired injections exceeds threshold WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the requested number of fuel injections. If the ECU A-9000 determines that the number of requested injections is greater than the current capability of the fuel injection system, this fault will occur, Cause: The ECU A-9000 has determined that the number of requested fuel injections has exceeded the current capability of the fuel injection system. Possible failure modes: 1. Faulty battery, low voltage. 2. Faulty ECU A-9000 power supply. 3. Faulty ECU A-9000, software. Solution: 1. Check battery voltage. Load test the battery. There should be approximately 12.0 V. A. If the battery passes the load test, continue to Step 2. B. If the battery fails the load test, the battery has failed. Replace the battery. 2. Check the ECU A-9000 power supply wiring. Disconnect connector X-9122 from the ECU A-9000. With the key in the ON position, use a multimeter to perform the following voltage check. From X-9122 pin K03

To Chassis ground

X-9122 pin K05

Chassis ground

X-9122 pin K01

Chassis ground

Value There should be approximately 12.0 V. There should be approximately 12.0 V. There should be approximately 12.0 V.

A. If there is approximately 12.0 V, leave the connector disconnected and continue to Step 3. B. If there is not approximately 12.0 V, there is a fault in the ECU A-9000 power supply wiring. Locate and repair the failed conductor. 3. Check the ECU A-9000 ground supply wiring. With the key in the OFF position, use a multimeter to perform the following continuity check. From X-9122 pin K02 X-9122 pin K04 X-9122 pin K06

To Chassis ground Chassis ground Chassis ground

Value There should be continuity. There should be continuity. There should be continuity.

A. If there is no continuity, there is a fault in the ECU A-9000 ground supply wiring. Locate and repair the failed conductor. B. If there is continuity, continue to Step 4. 47683911 27/02/2015

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4. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern. Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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Electrical systems - FAULT CODES

3238-ECU internal failure C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 performs a diagnostic check of the sensor supplies by monitoring the sensor supplies communication. If the ECU A-9000 detects a communication error during this diagnostic check, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3239-ECU internal failure - EEPROM read error C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 has detected an error during the last EEPROM write operation. The hardware encapsulation of the ECU A-9000 checks each data block of the EEPROM and sets a status flag depending on if an error is found or not found. These flags are processed every 20 milliseconds by the Diagnostic System Management (DSM) and if the value is out of range, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3240-ECU internal failure - EEPROM write error C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

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Electrical systems - FAULT CODES

3241-ECU internal failure - EEPROM write/read error C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

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Electrical systems - FAULT CODES

3242-ECU internal failure - Software resets in DSM 0 C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: If this fault is active, the Engine Control Unit (ECU) A-9000 has detected an error that has led to a software reset. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3243-ECU internal failure - Software resets in DSM 1 C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 will perform a software reset if a software failure is detected. If this fault is active, a software failure has been reported and a software reset has occurred. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3244-ECU internal failure - Software resets in DSM 2 C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

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Electrical systems - FAULT CODES

3245-ECU internal failure - Query/response communication errors C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors the communication between the ECU A-9000 processor and the power stage controller over the SPI bus. If there is an error in the communication, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3252-ECU internal failure - SPI communication error C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

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Electrical systems - FAULT CODES

3253-ECU internal failure - Voltage ratio in ADC monitoring C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors the Analog Digital Converter (ADC) for plausibility by providing a test voltage to be converted. If the converted voltage is out of range, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3255-ECU internal failure - ADC test C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors the Analog Digital Converter (ADC) plausibility by performing a fixed input voltage test. If the voltage during the test is out of range, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3256-ECU internal failure - NTP error in ADC monitoring C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors the Analog Digital Converter (ADC) plausibility by running a No-load Test Pulse operation (NTP). If the ECU A-9000 detects an error during this operation, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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3258-Starter relay high side driver circuit shorted to battery WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 controls the starter control relay K-9104 using a low side and high side driver. If the ECU A-9000 detects a short circuit to battery in the high side driver circuit, this fault will occur. Cause: The ECU A-9000 has detected a short circuit to battery in the starter control relay K-9104 high side driver circuit. Possible failure modes: 1. Faulty starter control relay K-9104 wiring, short to a voltage source. 2. Faulty starter control relay K-9104, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the starter control relay K-9104 coil for an internal failure. Remove the starter control relay K-9104. Use a multimeter to measure the relay coil resistance on the starter control relay K-9104 pins : From X-9120 pin 85

To X-9120 pin 86

Value There should be approximately 70 130 Ω.

To Chassis ground

Value There should be no voltage.

With the key in the ON position, use a multimeter to perform the following voltage check for short to a voltage source on the vehicle harness (VE) side : From X-9120 pin 85

To Chassis ground

Value There should be no voltage.

A. If there is voltage, there is a short to a voltage source in the starter control relay K-9104 wiring in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no voltage, continue to Step 4. 47683911 27/02/2015

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4. Check the starter control relay K-9104 high side driver vehicle harness (VE) wiring for a short circuit. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122. With the key in the OFF position, use a multimeter to perform the following continuity check for short circuit on the vehicle harness (VE) side : From X-9122 pin K53

To All pins in connector X-9122

Value There should be no continuity.

A. If there is continuity, there is a short circuit in the starter control relay K-9104 wiring in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, check the ECU A-9000 for the appropriate service manual and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 01 - Power distribution and starting (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3259-Starter relay high side driver circuit shorted to ground WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 controls the starter control relay K-9104 using a low side and high side driver. If the ECU A-9000 detects a short circuit to ground in the high side driver circuit, this fault will occur. Cause: The ECU A-9000 has detected a short circuit to ground in the starter control relay K-9104 high side driver circuit. Possible failure modes: 1. Faulty starter control relay K-9104 wiring, short to ground. 2. Faulty starter control relay K-9104, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the starter control relay K-9104 coil for an internal failure. Remove the starter control relay K-9104. Use a multimeter to measure the relay coil resistance on the starter control relay K-9104 pins : From X-9120 pin 85

To X-9120 pin 86

Value There should be approximately 70 130 Ω.

To Chassis ground X-9120 pin 86

Value There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short to ground in the starter control relay K-9104 wiring in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, continue to Step 4. 4. Check the starter control relay K-9104 high side driver vehicle harness (VE) wiring for a short circuit. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122.

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With the key in the OFF position, use a multimeter to perform the following continuity check for a short to ground on the vehicle harness (VE) side : From X-9122 pin K53

To All pins in connector X-9122

Value There should be no continuity.

A. If there is continuity, there is a short to ground in the starter control relay K-9104 wiring in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, check the ECU A-9000 for the appropriate service manual and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 01 - Power distribution and starting (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3260-Starter relay low side driver circuit open failure WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 controls the starter control relay K-9104 using a low side and high side driver. If the ECU A-9000 detects an open circuit in the high side driver circuit, this fault will occur. Cause: The ECU A-9000 has detected an open circuit in the starter control relay K-9104 high side driver circuit. Possible failure modes: 1. Faulty starter control relay K-9104 wiring, open circuit. 2. Faulty starter control relay K-9104, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 4. 2. Check the starter control relay K-9104 coil for an internal failure. Remove the starter control relay K-9104. Use a multimeter to measure the relay coil resistance on the starter control relay K-9104 pins : From X-9120 pin 85

To X-9120 pin 86

Value There should be approximately 70 130 Ω.

A. If there is approximately 70 - 130 Ω, leave the starter control relay K-9104 disconnected and continue to Step 3. B. If there is not approximately 70 - 130 Ω, the relay has failed. Replace the starter control relay K-9104. 3. Check the starter control relay K-9104 vehicle harness (VE) wiring for an open circuit. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122. With the key in the OFF position, use a multimeter to perform the following continuity check for an open circuit on the vehicle harness (VE) side : From To Value X-9120 pin 85 X-9122 pin K53 There should be continuity. X-9120 pin 86 X-9122 pin K27 There should be continuity. NOTE: Wiggle the harness during the check to promote an intermittent electrical connection. A. If there is no continuity, there is an open circuit in the starter control relay K-9104 wiring in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the broken conductor. B. If there is continuity, check the ECU A-9000 for the appropriate service manual and re-flash, if necessary.

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4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 01 - Power distribution and starting (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3261-Starter relay low side driver circuit shorted to battery WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 controls the starter control relay K-9104 using a low side and high side driver. If the ECU A-9000 detects a short circuit to battery in the low side driver circuit, this fault will occur. Cause: The ECU A-9000 has detected a short circuit to battery in the starter control relay K-9104 low side driver circuit. Possible failure modes: 1. Faulty starter control relay K-9104 wiring, short to a voltage source. 2. Faulty starter control relay K-9104, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the starter control relay K-9104 coil for an internal failure. Remove the starter control relay K-9104. Use a multimeter to measure the relay coil resistance on the starter control relay K-9104 pins : From X-9120 pin 85

To X-9120 pin 86

Value There should be approximately 70 130 Ω.

To Chassis ground

Value There should be no voltage.

With the key in the ON position, use a multimeter to perform the following voltage check for a short to a voltage source on the vehicle harness (VE) side : From X-9120 pin 86

To Chassis ground

Value There should be no voltage.

A. If there is voltage, there is a short to a voltage source in the starter control relay K-9104 low side driver wiring in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor.

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B. If there is no voltage, leave the starter control relay K-9104 disconnected and continue to Step 4. 4. Check the starter control relay K-9104 low side driver vehicle harness (VE) wiring for a short circuit. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9120 pin 86 X-9122 pin K27

To X-9120 pin 85 All pins in connector X-9122

Value There should be no continuity. There should be no continuity.

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3262-Starter relay low side driver circuit shorted to ground WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 controls the starter control relay K-9104 using a low side and high side driver. If the ECU A-9000 detects a short circuit to ground in the low side driver circuit, this fault will occur. Cause: The ECU A-9000 has detected a short circuit to ground in the starter control relay K-9104 low side driver circuit. Possible failure modes: 1. Faulty starter control relay K-9104 wiring, short to ground. 2. Faulty starter control relay K-9104, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 4. 2. Check the starter control relay K-9104 coil internal resistance. Remove the starter control relay K-9104. Using a multimeter, to measure the resistance on the starter control relay K-9104 pins : From X-9120 pin 85

To X-9120 pin 86

Value There should be approximately 70 130 Ω.

A. If there is approximately 70 - 130 Ω, leave the relay disconnected and continue to Step 3. B. If there is not approximately 70 - 130 Ω, the relay starter control relay K-9104 has failed. Replace the starter control relay K-9104. 3. Check the starter control relay K-9104 low side driver vehicle harness (VE) wiring for a short circuit. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9120 pin 86

To Chassis ground

Value There should be no continuity.

Disconnect the ECU A-9000 connector X-9122. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9122 pin K27

To All pins in connector X-9122

Value There should be no continuity.

A. If there is continuity, there is a short circuit in the starter control relay K-9104 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. 47683911 27/02/2015

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B. If there is no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 01 - Power distribution and starting (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3265-Fuel injection requested during overrun C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000, during after run, monitors fuel injector actuation time by calculating the demanded fuel injection quantity of actual injection and actual fuel pressure. If the ECU A-9000 determines that energizing time is greater than engine speed, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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3266-ECU internal failure - Calculated engine speed C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors engine speed in multiple software levels. If the ECU A-9000 determines that there is plausibility error in the engine speed monitoring, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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3283-ECU 5 volt sensor supply 2 out of range WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 provides three independent five volt sensor supplies. The ECU A-9000 monitors each sensor supply voltage to ensure they operate within a given range. If the ECU A-9000 determines that the voltage for sensor supply 2 is out of range, this fault will occur. The ECU A-9000 pin numbers associated with sensor supply 2 are K12, K13, K14, K15, and K16.

Cause: The ECU A-9000 has determined that the sensor supply 2 voltage is out of range. Possible failure modes: 1. Faulty battery voltage. 2. Faulty ECU A-9000 supply voltage. 3. Faulty ECU A-9000 sensor supply 2 pins. 4. Faulty ECU A-9000 connector X-9121, corrosion or damage. 5. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check the battery voltage. Charge the battery, then, perform a load test on the battery. A. If the battery passes the load test, continue to Step 3. B. If the battery fails the load test, the battery has failed. Replace the battery. 3. Check the ECU A-9000 supply voltage. Disconnect the ECU A-9000 connector X-9122. Place a jumper wire between X-9122 pin K28 and chassis ground. This will energize the main relay K-9102. With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From X-9122 pin K03 X-9122 pin K05 X-9122 pin K01

To X-9122 pin K02 X-9122 pin K04 X-9122 pin K06

Value There should be approximately 12 V. There should be approximately 12 V. There should be approximately 12 V.

A. If there is approximately 12 V, leave connector X-9122 disconnected and continue to Step 4.

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B. If there is not approximately 12 V, there is a failure in the ECU A-9000 supply wiring. Use the appropriate service manual, if necessary, to locate and repair the failed conductor. 4. Check the following pins listed below on the ECU A-9000 and in connector X-9122. Pin X-9122 pin K12 X-9122 pin K13 X-9122 pin K14 X-9122 pin K15 X-9122 pin K16

Physical condition The pin and connector should be free of corrosion damage. The pin and connector should be free of corrosion damage. The pin and connector should be free of corrosion damage. The pin and connector should be free of corrosion damage. The pin and connector should be free of corrosion damage.

or or or or or

A. If a pin or connector shows signs of corrosion or damage, repair as necessary. B. If a pin or connector shows no signs of corrosion or damage, continue to Step 5. 5. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3285-ECU 5 volt sensor supply 3 out of range WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 provides three independent five volt sensor supplies. The ECU A-9000 monitors each sensor supply voltage to ensure they operate within a given range. If the ECU A-9000 determines that the voltage for sensor supply 3 is out of range, this fault will occur. The ECU A-9000 pin numbers associated with sensor supply 3 are K17, K18 and A29.

Cause: The ECU A-9000 has determined that the sensor supply 3 voltage is out of range. Possible failure modes: 1. Faulty battery voltage. 2. Faulty ECU A-9000, supply voltage. 3. Faulty ECU A-9000 sensor supply 3 pins. 4. Faulty ECU A-9000 connector X-9122 or X-9121, corrosion or damage. 5. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check the battery voltage. Charge the battery, then, perform a load test on the battery. A. If the battery passes the load test, continue to Step 3. B. If the battery fails the load test, the battery has failed. Replace the battery. 3. Check the ECU A-9000 supply voltage. Disconnect the ECU A-9000 connector X-9122. Place a jumper wire between X-9122 pin K28 and chassis ground. This will energize the main relay K-9102. With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From X-9122 pin K03 X-9122 pin K05 X-9122 pin K01

To X-9122 pin K02 X-9122 pin K04 X-9122 pin K06

Value There should be approximately 12 V. There should be approximately 12 V. There should be approximately 12 V.

A. If there is approximately 12 V, leave connector X-9122 disconnected and continue to Step 4.

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B. If there is not approximately 12 V, there is a failure in the ECU A-9000 supply wiring. Use the appropriate service manual, if necessary, to locate and repair the failed conductor. 4. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. Check the following pins listed below on the ECU A-9000 and in connectors X-9122 and X-9121. Pin X-9122 pin K17 X-9122 pin K18 X-9121 pin A29

A. If a pin or connector shows signs of corrosion or damage, repair as necessary. B. If a pin or connector shows no signs of corrosion or damage, continue to Step 5. 5. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, Then, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, Then, erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04) Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3293-Fuel rail pressure has exceeded maximum positive deviation limits WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Common rail Relief valve - Configure - Reset ECU data (10.218), if necessary. NOTE: If the rail pressure sensor B-9004 is replaced, it is necessary to perform the Replacement of the Rail Pressure sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Common rail pressure sensor - Configure - Reset ECU data (Rail pressure sensor) (55.010), if necessary. Context: The Engine Control Unit (ECU) A-9000 monitors fuel rail pressure. If the measured rail pressure is lower than the desired pressure by 100 bar (1450 psi) depending on engine speed, this fault will occur. For more information regarding fuel system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218). Cause: The ECU A-9000 has determined that the measured rail pressure is 100 bar (1450 psi) lower than desired fuel pressure based on engine speed. Possible failure modes: 1.

Faulty fuel metering unit Y-9000, internal failure.

Faulty charge gear pump, low efficiency.

Faulty fuel filters, clogged.

Faulty low pressure fuel supply lines, clogged or damaged.

Faulty high pressure fuel supply lines, clogged or damaged.

Faulty Pressure Relief Valve (PRV), leakage.

Faulty high pressure fuel pump, low efficiency.

Faulty fuel injectors, worn, clogged or internal leakage.

Faulty rail pressure sensor B-9004, drifted or leaking.

10. Faulty ECU A-9000, software.

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3301-Fuel rail pressure has exceeded maximum negative deviation limits WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Common rail Relief valve - Configure - Reset ECU data (10.218), if necessary. NOTE: If the rail pressure sensor B-9004 is replaced, it is necessary to perform the Replacement of the Rail Pressure sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Common rail pressure sensor - Configure - Reset ECU data (Rail pressure sensor) (55.010), if necessary. Context: The Engine Control Unit (ECU) A-9000 monitors fuel rail pressure. If the ECU A-9000 determines that fuel pressure is higher than the desired fuel pressure, depending on engine speed, this fault will occur. For more information regarding fuel system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218). Cause: The ECU A-9000 has determined that the fuel rail pressure is higher than desired based on engine speed. Possible failure modes: 1. Faulty fuel metering unit Y-9000, stuck open. 2. Faulty fuel back-flow, clogged or damaged. 3. Faulty Pressure Relief Valve (PRV), stuck or blocked. 4. Faulty rail pressure sensor B-9004, drifted. 5. Faulty high pressure pump. 6. Faulty ECU A-9000, software.

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3305-Fuel rail pressure has dropped below the minimum limit WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Common rail Relief valve - Configure - Reset ECU data (10.218), if necessary. NOTE: If the rail pressure sensor B-9004 is replaced, it is necessary to perform the Replacement of the Rail Pressure sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Common rail pressure sensor - Configure - Reset ECU data (Rail pressure sensor) (55.010), if necessary. Context: The Engine Control Unit (ECU) A-9000 monitors fuel rail pressure using the rail pressure sensor B-9004. If the ECU A-9000 determines that the measured rail pressure is less than a dependent engine speed value, this fault will occur. Other active faults may have caused this fault to occur. For more information regarding fuel system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218). Cause: The ECU A-9000 has determined that the measured rail pressure is less than a dependent engine speed value. Possible failure modes: 1.

Faulty fuel filters, clogged.

Faulty low pressure fuel lines, clogged or damaged.

Faulty high pressure fuel lines, clogged or damaged.

Faulty electric fuel pump (if equipped).

Faulty charge gear pump, low efficiency.

Faulty high pressure pump, low efficiency or excessive leak-off.

Faulty fuel injectors, excessive or leaking internally.

Faulty Pressure Relief Valve (PRV), leaking or stuck open.

Faulty rail pressure sensor B-9004 or sensor leaking.

10. Faulty fuel metering unit Y-9000 11. Faulty ECU A-9000, software.

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3309-Fuel rail pressure has exceeded maximum limit WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Common rail Relief valve - Configure - Reset ECU data (10.218), if necessary. NOTE: If the rail pressure sensor B-9004 is replaced, it is necessary to perform the Replacement of the Rail Pressure sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Common rail pressure sensor - Configure - Reset ECU data (Rail pressure sensor) (55.010), if necessary. Context: The Engine Control Unit (ECU) A-9000 monitors fuel rail pressure using the rail pressure sensor B-9004. If the ECU A-9000 determines that the measured rail pressure is greater than desired by more than a dependent engine speed value, this fault will occur. For more information regarding fuel system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218). Cause: The ECU A-9000 has determined that the measured rail pressure is greater than desired by more than a dependent engine speed value. Possible failure modes: 1. Faulty fuel metering unit Y-9000, stuck open or internal failure. 2. Faulty fuel back-flow lines, blocked or damaged. 3. Faulty Pressure Relief Valve (PRV), stuck closed or mechanically unable to open. 4. Faulty high pressure pump, zero delivery throttle valve clogged. 5. Faulty rail pressure sensor B-9004, drifted signal. 6. Faulty ECU A-9000, software.

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3334-CAN communication failure between vehicle controller and ECU controller - TSC1_PE message WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on two separate Controller Area Networks (CAN). Proper configuration and monitoring of the two twisted pair configured networks is also a function of the ECU A-9000. CAN Node A Bus is the main vehicle interface bus. The ECU A-9000 provides a CAN termination resistor for the CAN Node A Bus, internal to the ECU A-9000. If the ECU A-9000 senses that CAN Node A Bus is not functioning properly, this fault will occur. Cause: ECU A-9000 has sensed a timeout of vehicle data provided on CAN Node A. Possible failure modes: 1. Faulty supply voltage or ground, missing. 2. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit. 3. Faulty ECU A-9000, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check for other vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If other vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that 3334 - CAN communication failure between vehicle controller and ECU controller - TSC1_PE message is also resolved. B. If other vehicle CAN faults do not exist, continue with Step 3. 3. Check the ECU A-9000 supply voltage. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9122. With the key switch in the “ON” position, use a multimeter to check for voltage on the vehicle (VE) harness side: From X-9122 pin K01 X-9122 pin K03 X-9122 pin K05

To chassis ground chassis ground chassis ground

Value There should be 12.0 V . There should be 12.0 V . There should be 12.0 V .

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From X-9122 pin K02 X-9122 pin K04 X-9122 pin K06

To chassis ground chassis ground chassis ground

Value There should be continuity. There should be continuity. There should be continuity.

To X-9122 pin K25 chassis ground chassis ground

Value There should be 120 Ω. There should not be continuity There should not be continuity

Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU A-9000: From X-9122 pin K24

To X-9122 pin K25

Value There should be 120 Ω.

A. If the measured resistances are correct and neither conductor is grounded, check the ECU A-9000 for the appropriate software and re-flash, if necessary. B. If the measured resistances are not correct or one or both of the conductors is grounded, refer to the appropriate vehicle service manual and electrical schematics to locate and restore the termination resistance to the CAN circuit. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3335-CAN-Receive-Frame Torque / Speed control from ABS / ASR to ECU through TSC1_PR Message active WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on two separate Controller Area Networks (CAN). Proper configuration and monitoring of the two twisted pair configured networks is also a function of the ECU A-9000. CAN Node A Bus is the main vehicle interface bus. The ECU A-9000 provides a CAN termination resistor for the CAN Node A Bus, internal to the ECU A-9000. If the ECU A-9000 senses that CAN Node A Bus is not functioning properly, this fault will occur. Cause: ECU A-9000 has sensed a timeout of vehicle data provided on CAN Node A. Possible failure modes: 1. Faulty supply voltage or ground, missing. 2. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit. 3. Faulty ECU A-9000, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check for other vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If other vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that 3335 - CAN-ReceiveFrame Torque / Speed control from ABS / ASR to ECU through TSC1_PR Message active is also resolved. B. If other vehicle CAN faults do not exist, continue with Step 3. 3. Check the ECU A-9000 supply voltage. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9122. With the key switch in the “ON” position, use a multimeter to check for voltage on the vehicle (VE) harness side: From X-9122 pin K01 X-9122 pin K03 X-9122 pin K05

To chassis ground chassis ground chassis ground

Value There should be 12.0 V . There should be 12.0 V . There should be 12.0 V .

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From X-9122 pin K02 X-9122 pin K04 X-9122 pin K06

To chassis ground chassis ground chassis ground

Value There should be continuity. There should be continuity. There should be continuity.

To X-9122 pin K25 chassis ground chassis ground

Value There should be 120 Ω. There should not be continuity There should not be continuity

Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU A-9000: From X-9122 pin K24

To X-9122 pin K25

Value There should be 120 Ω.

A. If the measured resistances are correct and neither conductor is grounded, check the ECU A-9000 for the appropriate software and re-flash, if necessary. B. If the measured resistances are not correct or one or both of the conductors is grounded, refer to the appropriate vehicle service manual and electrical schematics to locate and restore the termination resistance to the CAN circuit. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3338-CAN communication failure between vehicle controller and ECU controller - TSC1_VE message WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on two separate Controller Area Networks (CAN). Proper configuration and monitoring of the two twisted pair configured networks is also a function of the ECU A-9000. CAN Node A Bus is the main vehicle interface bus. The ECU A-9000 provides a CAN termination resistor for the CAN Node A Bus, internal to the ECU A-9000. If the ECU A-9000 senses that CAN Node A Bus is not functioning properly, this fault will occur. Cause: ECU A-9000 has sensed a timeout of required vehicle controller data provided on CAN Node A. Possible failure modes: 1. Faulty supply voltage or ground, missing. 2. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit. 3. Faulty ECU A-9000, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check for other vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If other vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that 3338 - CAN communication failure between vehicle controller and ECU controller - TSC1_VE message is also resolved. B. If other vehicle CAN faults do not exist, continue with Step 3. 3. Check the ECU A-9000 supply voltage. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9122. With the key switch in the “ON” position, use a multimeter to check for voltage on the vehicle (VE) harness side: From X-9122 pin K01 X-9122 pin K03 X-9122 pin K05

To chassis ground chassis ground chassis ground

Value There should be 12.0 V . There should be 12.0 V . There should be 12.0 V .

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From X-9122 pin K02 X-9122 pin K04 X-9122 pin K06

To chassis ground chassis ground chassis ground

Value There should be continuity. There should be continuity. There should be continuity.

To X-9122 pin K25 chassis ground chassis ground

Value There should be 120 Ω. There should not be continuity There should not be continuity

Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU A-9000: From X-9122 pin K24

To X-9122 pin K25

Value There should be 120 Ω.

A. If the measured resistances are correct and neither conductor is grounded, check the ECU A-9000 for the appropriate software and re-flash, if necessary. B. If the measured resistances are not correct or one or both of the conductors is grounded, refer to the appropriate vehicle service manual and electrical schematics to locate and restore the termination resistance to the CAN circuit. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3339-CAN communication failure between vehicle controller and ECU controller - TSC1_VE message WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on two separate Controller Area Networks (CAN). Proper configuration and monitoring of the two twisted pair configured networks is also a function of the ECU A-9000. CAN Node A Bus is the main vehicle interface bus. The ECU A-9000 provides a CAN termination resistor for the CAN Node A Bus, internal to the ECU A-9000. If the ECU A-9000 senses that CAN Node A Bus is not functioning properly, this fault will occur. Cause: ECU A-9000 has sensed a timeout of required vehicle controller data provided on CAN Node A. Possible failure modes: 1. Faulty supply voltage or ground, missing. 2. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit. 3. Faulty ECU A-9000, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check for other vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If other vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that 3339 - CAN communication failure between vehicle controller and ECU controller - TSC1_VE message is also resolved. B. If other vehicle CAN faults do not exist, continue with Step 3. 3. Check the ECU A-9000 supply voltage. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9122. With the key switch in the “ON” position, use a multimeter to check for voltage on the vehicle (VE) harness side: From X-9122 pin K01 X-9122 pin K03 X-9122 pin K05

To chassis ground chassis ground chassis ground

Value There should be 12.0 V . There should be 12.0 V . There should be 12.0 V .

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From X-9122 pin K02 X-9122 pin K04 X-9122 pin K06

To chassis ground chassis ground chassis ground

Value There should be continuity. There should be continuity. There should be continuity.

To X-9122 pin K25 chassis ground chassis ground

Value There should be 120 Ω. There should not be continuity There should not be continuity

Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU A-9000: From X-9122 pin K24

To X-9122 pin K25

Value There should be 120 Ω.

A. If the measured resistances are correct and neither conductor is grounded, check the ECU A-9000 for the appropriate software and re-flash, if necessary. B. If the measured resistances are not correct or one or both of the conductors is grounded, refer to the appropriate vehicle service manual and electrical schematics to locate and restore the termination resistance to the CAN circuit. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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Electrical systems - FAULT CODES

3350-Engine cranked for too long or key switch failure WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 is notified of a request for engine cranking at connector X-9122 pin K08. If the request for cranking signal exists for longer than 80.0 s the ECU A-9000 assumes a mechanical failure in the ignition key module or start relay or a short to a voltage source condition exists in the input circuit and this fault occurs. Cause: The engine cranking signal has exceeded the signal ON time established be the ECU A-9000. Possible failure modes: 1. Faulty vehicle cranking circuit component, key switch or crank / start relay. 2. Faulty cranking circuit wiring, shorted to a voltage source. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 4. 2. Check the cranking circuit wiring for a short to voltage source condition. Carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle harness (VE) side : From X-9122 pin K08

To chassis ground

Result There should be no voltage.

A. If there is voltage, Use the appropriate vehicle service manual, if necessary, to locate the voltage source. B. If there is no voltage, leave connector X-9122 disconnected and continue with Step 3. 3. Check the cranking circuit wiring for an ECU A-9000 sourced short to voltage condition. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9122 pin K08

To Result to all other pins in connector X-9122 There should be no continuity.

A. If there is continuity, there is a short to a voltage source condition in the vehicle harness (VE). Use the appropriate vehicle service manual, if necessary, to locate and repair the shorted conductors. B. If there is no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. 47683911 27/02/2015

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A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 01 - Power distribution and starting (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3358-CAN transmit error - EEC1 message (Electronic Engine Control 1 message - Torque, accelerator pedal, engine speed, and other signals) WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on two separate Controller Area Networks (CAN). Proper configuration and monitoring of the two twisted pair configured networks is also a function of the ECU A-9000. CAN Node A Bus is the main vehicle interface bus. The ECU A-9000 provides a CAN termination resistor for the CAN Node A Bus, internal to the ECU A-9000. If the ECU A-9000 senses that CAN Node A Bus is not functioning properly, this fault will occur. Cause: ECU A-9000 has sensed a timeout of required vehicle controller data provided on CAN Node A. Possible failure modes: 1. Faulty supply voltage or ground, missing. 2. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit. 3. Faulty ECU A-9000, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check for other vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If other vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that 3358 - CAN transmit error - EEC1 message (Electronic Engine Control 1 message - Torque, accelerator pedal, engine speed, and other signals) is also resolved. B. If other vehicle CAN faults do not exist, continue with Step 3. 3. Check the ECU A-9000 supply voltage. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9122. With the key switch in the “ON” position, use a multimeter to check for voltage on the vehicle (VE) harness side: From X-9122 pin K01 X-9122 pin K03 X-9122 pin K05

To chassis ground chassis ground chassis ground

Value There should be 12.0 V . There should be 12.0 V . There should be 12.0 V .

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With the key switch in the “OFF” position, use a multimeter to check for continuity on the vehicle (VE) harness side: From X-9122 pin K02 X-9122 pin K04 X-9122 pin K06

To chassis ground chassis ground chassis ground

Value There should be continuity. There should be continuity. There should be continuity.

To X-9122 pin K25 chassis ground chassis ground

Value There should be 120 Ω. There should not be continuity There should not be continuity

Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU A-9000: From X-9122 pin K24

To X-9122 pin K25

Value There should be 120 Ω.

A. If the measured resistances are correct and neither conductor is grounded, check the ECU A-9000 for the appropriate software and re-flash, if necessary. B. If the measured resistances are not correct or one or both of the conductors is grounded, refer to the appropriate vehicle service manual and electrical schematics to locate and restore the termination resistance to the CAN circuit. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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Electrical systems - FAULT CODES

3361-ECU internal failure - EEPROM erase error C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 has a functionality for reading and erasing values to a memory media (Flash or EEPROM). If the ECU A-9000 determines that this process can not be performed or successfully completed, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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3362-ECU internal failure - Fuel calibration C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 checks the map for the conversion from fuel quantity to torque for consistency. If there is an error during this conversion check, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3368-Torque limitation caused by performance limiter C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: This fault is for informational purposes only and may have been caused by another fault. The Engine Control Unit (ECU) A-9000 has detected higher level of NOx emissions than expected. If this fault occurs, a toque limitation of equal to or greater than 25 % will occur. Other active faults may have caused this fault to occur.

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3369-Torque limitation caused by smoke limitation C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: This fault is for informational purposes only and is active because there has been a torque limitation set by the Engine Control Unit (ECU) A-9000. The (ECU) A-9000 monitors air/fuel ratio. If the ECU A-9000 determines that the ratio is too lean, a torque limitation of 25 % will be active to prevent engine damage. Though no action is necessary due to this error, if the power reduction occurred due to an actual defect, the error triggering the torque limitation should also be in fault memory. Use the Electronic Service Tool (EST) to check for related faults. Diagnose the related faults first and then return to this fault, 3369 - Torque limitation caused by smoke limitation. Also, see the list below of possible mechanical failures that may have caused this fault. Refer to the engine service manual Fuel injection system - Poor quality (10.218) for more information on troubleshooting a lean air/fuel ratio condition. Cause: The ECU A-9000 has set a torque limitation due to a lean air/fuel ratio. Possible failure modes: 1.

Operating in extreme high altitudes, greater than an altitude of 1800 m (5906 ft).

Operating in low ambient pressure conditions, less than an ambient pressure of 0.78 bar (11.31 psi).

Faulty lambda sensor B-9123, drifted.

Faulty Exhaust Gas Recirculation (EGR) actuator, stuck or inoperative.

Faulty turbocharger wastegate Y-9008, sticking or stuck open.

Faulty turbocharger, low efficiency.

Faulty air induction, leakage or blockage.

Faulty intake manifold pressure sensor B-9001. At key ON there should be approximately the value of ambient pressure.

Faulty ECU A-9000, software.

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Electrical systems - FAULT CODES

3370-Strong torque limitation from engine protection active C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: This fault is for information purposes only and may have been caused by another fault. The Engine Control Unit (ECU) A-9000 has detected an active power reduction due to too high exhaust gas temperature, engine coolant temperature, engine oil temperature or fuel temperature. If this fault is active, an engine power or engine speed reduction of equal to or greater than 25 % of the desired torque will be active to protect the engine from damage. Though no action is necessary due to this error, if the power reduction occurred due to an actual defect, the error triggering the torque limitation should also be in fault memory. Use the Electronic Service Tool (EST) to check for related fault codes and diagnose them first, then check the status of this fault, 3370 - Strong torque limitation from engine protection active. Cause: This fault is an information only fault. It has been triggered by another fault. Solution: 1. Use the Electronic Service Tool (EST) to check for other faults that may have caused this fault to occur. A. If any related faults are active, diagnose them first, then return to this fault, 3370 - Strong torque limitation from engine protection active. B. If there are no related faults active, continue to Step 2. 2. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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3371-Strong torque limitation from injection system active C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: This fault is for information purposes only and may have been caused by another fault. The Engine Control Unit (ECU) A-9000 has detected an active power reduction due to higher than expected fuel temperature. If this fault is active, a power reduction of equal to or greater than 25 % of the desired torque will be active to protect the high pressure fuel pump from damage. Though no action is necessary due to this error, if the power reduction occurred due to an actual defect, the error triggering the torque limitation should also be in fault memory. Use the Electronic Service Tool (EST) to check for related fuel system faults and diagnose them first, then check the status of this fault, 3371 - Strong torque limitation from injection system active. For information regarding fuel system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218).

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3374-Injection quantity adjustment failure C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 uses an IMA code to correct fuel trim for each fuel injector equipped with the engine at every key ON. If the ECU A-9000 determines that this trim correction for fuel injector number 1 Y-9001 can not be performed, this fault will occur. For more information about how to configure injector IMA codes, refer to the engine service manual Fuel injectors - Configure - IMA codes (10.218). Cause: The ECU A-9000 has determined that the fuel injector number 1 Y-9001 fuel trim correction can not be performed. Solution: 1. Use the Electronic Service Tool (EST) ensure that the correct IMA code is programmed to fuel injector number 1 Y-9001. A. If the correct code is not programmed. Use the EST to program the correct code. B. If the correct code is programmed, continue to Step 2. NOTE: The IMA code may be under the paint on the fuel injector. 2. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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3390-Air Filter Restriction Switch Short To Ground WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The instrument cluster detects a signal to ground on X-C23 pin 11 indicating that the air filter restriction switch has been tripped. Cause: The instrument cluster detects a signal to ground indicating that the air filter restriction switch has been tripped. Possible failure modes: 1. Clogged air filter. 2. Signal wire short circuit to minus battery or chassis ground. 3. A faulty air filter restriction switch. 4. A faulty instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 3390 is recorded again. Go to step 2. 2. Inspect the engine air filter. Inspect the engine air filter. Replace the filter if needed. A. The filter is OK and does not need to be replaced. Go to step 3. B. The filter is in poor condition or is clogged. Replace the filter. Return to step 1 to confirm elimination of the fault. 3. Verify that the wiring and connectors are free of damage. Inspect the instrument cluster and the air filter restriction switch connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the instrument cluster to the air filter restriction switch. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 4. Test the air filter restriction circuit. Disconnect the signal wire from air filter restriction switch. Turn the ignition switch ON, engine OFF. Access the fault code screen on the Electronic Service Tool. The air filter restriction fault code should no longer be active. A. The fault code is no longer active. Go to step 4.

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B. Fault code 3390 is still active. Go to step 5. 5. Check air filter restriction switch. Remove the air filter restriction switch from the air filter housing. Measure the resistance across the switch. The resistance should be greater than 20,000 Ω. A. The resistance is greater than 20,000 Ω. Inspect the wiring around the sensor. Go to step 5. B. The resistance is less than 20,000 Ω. Temporarily replace the air filter restriction switch and retest. Return to step 1 to confirm elimination of fault. 6. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect instrument cluster connector X-C23. Measure the resistance between X-C23 pin 11 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 20,000 Ω. There is a short to chassis ground in the signal wire. Repair or replace the wire as required. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 Instrument Cluster (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 10 Cab to Chassis Interface (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 03 Ignition Charging System (55.100.DP-C.20.E.03) Wiring harnesses - Electrical schematic sheet 26 Instrument Cluster (55.100.DP-C.20.E.26) Wiring harnesses - Electrical schematic sheet 12 Cab to Chassis Interface (55.100.DP-C.20.E.12) Wiring harnesses - Electrical schematic sheet 03 Ignition Charging System (55.100.DP-C.20.E.03)

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3402-Maximum rail pressure exceeded WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

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3403-Starter relay low side ECU driver circuit over temperature WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 controls the starter control relay K-9104 using a low side and high side driver. If the ECU A-9000 detects an over temperature/current condition in the high side driver circuit, this fault will occur. Cause: The ECU A-9000 has detected an over temperature/current condition in the starter control relay K-9104 high side driver circuit. Possible failure modes: 1. Faulty starter control relay K-9104 wiring, short circuit. 2. Faulty starter control relay K-9104, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check the starter control relay K-9104 coil for an internal failure. Remove the starter control relay K-9104. Use a multimeter to measure the relay coil resistance on the starter control relay K-9104 pins : From X-9120 pin 85

To X-9120 pin 86

Value There should be approximately 70 130 Ω.

To X-9120 pin 86 Chassis ground

Value There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short to ground in the starter control relay K-9104 high side driver circuit in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, leave the starter control relay K-9104 disconnected and continue to Step 4. 4. Check the starter control relay K-9104 high side driver vehicle harness (VE) wiring for a short to a voltage source.

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With the key in the OFF position, use a multimeter to perform the following voltage check for a short to a voltage source on the vehicle harness (VE) side : From X-9120 pin 85

To Chassis ground

Value There should be no voltage.

With the key in the ON position, use a multimeter to perform the following voltage check for a short to a voltage source on the vehicle harness (VE) side : From X-9120 pin 85

To Chassis ground

Value There should be no voltage.

A. If there is voltage, there is a short to a voltage source in the starter control relay K-9104 high side driver circuit in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no voltage, continue to Step 5. 5. Check the starter control relay K-9104 high side driver vehicle harness (VE) wiring for a short to a voltage source. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122. With the key in the OFF position, use a multimeter to perform the following continuity check for a short to a voltage source on the vehicle harness (VE) side : From X-9122 pin K53

To All pins in connector X-9122

Value There should be no continuity.

A. If there is continuity, there is a short circuit in the starter control relay K-9104 high side driver circuit in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no voltage, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 01 - Power distribution and starting (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3405-Wastegate pressure modulator control circuit open WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the wastegate pressure modulator valve Y-9008 circuit. If the ECU A-9000 determines that there is an open load in the wastegate pressure modulator valve Y-9008 circuit, this fault will occur. Cause: The ECU A-9000 has detected an open load in the wastegate pressure modulator valve Y-9008 circuit. Possible failure modes: 1. Faulty wastegate pressure modulator valve Y-9008 wiring, open circuit. 2. Faulty wastegate pressure modulator valve Y-9008, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check the wastegate pressure modulator valve Y-9008 internal resistance. Disconnect the wastegate pressure modulator valve Y-9008 connector X-9038. Use a multimeter to perform the following resistance check on the wastegate pressure modulator valve Y-9008 pins : From

Value There should be between 21.8 24.2 Ω. NOTE: The provided value should be measured at a temperature of approximately 20 °C (68 °F). X-9038 pin 1

X-9038 pin 2

A. If there is between 21.8 - 24.2 Ω, leave connector X-9038 disconnected and continue to Step 3. B. If there is not between 21.8 - 24.2 Ω, the wastegate pressure modulator valve Y-9008 has failed internally. Replace the wastegate pressure modulator valve Y-9008. 3. Check the wastegate pressure modulator valve Y-9008 engine harness (EN) wiring for an open circuit. Disconnect the vehicle harness (VE) from the engine interface at connector X-9138. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From To Value X-9038 pin 1 X-9138 pin 28 There should be continuity. X-9038 pin 2 X-9138 pin 27 There should be continuity. NOTE: Wiggle the harness during the check to promote an intermittent electrical connection. A. If there is no continuity, there is an open circuit in the wastegate pressure modulator valve wiring in the engine harness (EN). Locate and repair the broken conductor.

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B. If there is continuity, leave connector X-9138 disconnected and continue to Step 4. 4. Check the wastegate pressure modulator valve Y-9008 vehicle harness (VE) wiring for an open circuit. With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness side : From

Value There should be approximately 12.0 V. NOTE: Wiggle the harness during the check to promote an intermittent electrical connection. X-9138 pin 28

Chassis ground

A. If there is no voltage, there is an open circuit in the wastegate pressure modulator valve wiring in the vehicle harness (VE). Use the appropriate service manual, if necessary to locate and repair the broken conductor. B. If there is approximately 12.0 V, leave connector X-9138 disconnected and continue to Step 5. 5. Check the wastegate pressure modulator valve Y-9008 vehicle harness (VE) wiring for an open circuit. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key in the OFF position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From To Value X-9138 pin 27 X-9121 pin A04 There should be continuity. NOTE: Wiggle the harness during the check to promote an intermittent electrical connection. A. If there is no continuity, there is an open circuit in the wastegate pressure modulator valve wiring in the vehicle harness (VE). Use the appropriate service manual, if necessary to locate and repair the broken conductor. B. If there is continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3406-Wastegate pressure modulator control circuit over temperature WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the wastegate pressure modulator valve Y-9008 circuit. If the ECU A-9000 determines that there is an over temperature/current condition in the wastegate pressure modulator valve Y-9008 circuit, this fault will occur. Cause: The ECU A-9000 has detected an over temperature/current condition in the wastegate pressure modulator valve Y-9008 circuit. Possible failure modes: 1. Faulty wastegate pressure modulator valve Y-9008 wiring, short to a voltage source. 2. Faulty wastegate pressure modulator valve Y-9008, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 7. 2. Check the wastegate pressure modulator valve Y-9008 internal resistance. Disconnect the wastegate pressure modulator valve Y-9008 connector X-9038. Use a multimeter to perform the following resistance check on the wastegate pressure modulator valve Y-9008 pins : From

Value There should be between 21.8 24.2 Ω. NOTE: The provided value should be measured at a temperature of approximately 20 °C (68 °F). X-9038 pin 1

X-9038 pin 2

To X-9038 pin 2

Value There should be no continuity.

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4. Check the wastegate pressure modulator valve Y-9008 wiring for a short to battery condition. With the key in the OFF position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-9038 pin 2

To Chassis ground

Value There should be no voltage.

A. If there is voltage, there is a short to battery in the wastegate pressure modulator valve wiring. Use the appropriate service manual, if necessary to locate and repair the shorted conductor. B. If there is no voltage, continue to Step 5. 5. Check the wastegate pressure modulator valve Y-9008 wiring for a short to a voltage source. Disconnect the vehicle harness (VE) from the engine interface at connector X-9138. With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-9038 pin 2

To Chassis ground

Value There should be no voltage.

A. If there is voltage, there is a short to a voltage source in the wastegate pressure modulator valve wiring in the engine harness (EN). Locate and repair the shorted conductor. B. If there is no voltage, continue to Step 6. 6. Check the wastegate pressure modulator valve Y-9008 wiring for a short to a voltage source. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From X-9138 pin 27

To Chassis ground

Value There should be no voltage.

A. If there is voltage, there is a short to a voltage source in the wastegate pressure modulator valve wiring in the vehicle harness (VE). Locate and repair the shorted conductor. B. If there is no voltage, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3409-Low oil pressure WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the oil pressure switch S-9016 for proper operation. The oil pressure switch S-9016 changes from its off to on state between 0.6 - 0.9 bar (8.7 - 13.0 psi). If the oil pressure switch S-9016 does actuate once the engine has been running for 6.0 s at greater than 500.0 RPM, this fault will occur. Cause: The ECU A-9000 has determined that the oil pressure switch S-9016 did not actuate. Possible failure modes: 1. Faulty oil level, too low. 2. Faulty oil pressure switch S-9016, failed internally. 3. Faulty oil pressure switch S-9016 circuit wiring, shorted to chassis ground. 4. Faulty oil pressure, too low or blockage. 5. Faulty ECU A-9000, hardware or software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 8. 2. Check oil level. Use the appropriate operator or service manual, if necessary, to determine if the lubrication system has the appropriate amount of oil. There should be at least the minimum acceptable level of oil. A. If there is at least the minimum acceptable level of oil, continue with Step 3. B. If there less than the minimum acceptable level of oil, use the appropriate operator or service manual, if necessary, to determine the type and quantity of oil required to re-fill the oil system. 3. Check the condition of the oil pressure switch S-9016. Disconnect the engine harness (EN) from the oil pressure switch S-9016 at connector X-9016. With the engine not running, use a multimeter to check for continuity on the component side : From X-9016 pin 1

To chassis ground

Result There should be continuity.

Start the engine and allow it to run at greater than 500 RPM for at least 6.0 s. While the engine is running at greater than 500 RPM, use a multimeter to check for continuity on the component side : From X-9016 pin 1

To chassis ground

Result There should be no continuity.

A. If the specified values are measured, leave connector X-9016 disconnected and continue with Step 4.

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B. If the oil pressure switch S-9016 did not change state, leave connector X-9016 disconnected and continue with Step 7. 4. Check the oil pressure switch S-9016 circuit for a short to ground condition. With the key switch in the OFF position, use a multimeter to check for continuity on the engine harness (EN) side : From X-9016 pin 1

To chassis ground

Result There should be no continuity.

A. If there is continuity, leave connector X-9016 disconnected and continue with Step 5. B. If there is no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Locate the short to ground condition. Carefully disconnect the vehicle harness (VE) from the engine interface connector X-9138. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9138 pin 3

To chassis ground

Result There should be no continuity.

A. If there is continuity, leave connector X-9138 disconnected and continue with Step 6. B. If there is no continuity, the short to a ground condition is in the engine harness (EN) between connector X-9016 pin 1 and connector X-9138 pin 3, wire EN-9105. Locate and repair the grounded conductor. 6. Locate the short to ground condition. Carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9121 pin A06

To chassis ground

Result There should be no continuity.

A. If there is continuity, the short to chassis ground condition is in the vehicle harness (VE) between connector X-9121 pin A06 and connector X-9138 pin 3, wire VE-9105. Use the appropriate service manual, if necessary, to locate and repair the grounded conductor. B. If there is no continuity, the ECU A-9000 has failed internally, replace the ECU A-9000. 7. Check lubrication system for blockage. Refer to the engine service manual, Engine lubrication system - Test (10.304), if necessary, to determine if the lubrication system has the appropriate amount of oil pressure. Between 0.6 - 0.9 bar (8.7 - 13.0 psi) is required to actuate the oil pressure switch S-9016. There should be at least the minimum acceptable level of oil pressure. A. If there is adequate oil pressure, the oil pressure switch S-9016 has failed internally replace the switch. B. If there less than the minimum acceptable level of oil pressure, use the appropriate service manual, if necessary, to locate and restore oil pressure to the lubrication system. 8. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

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3410-Throttle valve actuator will not open to commanded position WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: Once repaired, this fault may take up to up to 10 min of operation to reset. Context: The Engine Control Unit (ECU) A-9000 monitors the Throttle Valve Actuator (TVA) Z-9001. The TVA Z-9001 provides the ECU A-9000 with a feedback using a position sensor. If the ECU A-9000 determines that there is a positive deviation between the required and measured position, this fault will occur. If this fault is active, the ECU A-9000 will command the TVA Z-9001 to open and close at a fast rate in order to attempt to “unblock “ the actuator. This fault is not caused by a wiring failure. It is likely caused by an obstruction to the throttle valve flap or excessive carbon build up on the throttle valve seat. For more information regarding TVA Z-9001 inspection, refer to the engine service manual Throttle Valve Actuator (TVA) - Inspect (55.014). Cause: The ECU A-9000 has detected a positive deviation between the required and measured position of the TVA Z-9001. The desired throttle valve position can not be reached. Possible failure modes: 1. Faulty throttle valve actuator Z-9001, sticking or blocked. 2. Faulty throttle valve actuator Z-9001, internal failure. 3. Faulty ECU A-9000, software.

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3411-Throttle valve actuator will not close to commanded position WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: Once repaired, this fault may take up to up to 10 min of operation to reset. Context: The Engine Control Unit (ECU) A-9000 monitors the Throttle Valve Actuator (TVA) Z-9001. The TVA Z-9001 provides the ECU A-9000 with a feedback using a position sensor. If the ECU A-9000 determines that there is a negative deviation between the required and measured position, this fault will occur. If this fault is active, the ECU A-9000 will command the TVA Z-9001 to open and close at a fast rate in order to attempt to “unblock “ the actuator. This fault is not caused by a wiring failure. It is likely caused by an obstruction to the throttle valve flap or excessive carbon build up on the throttle valve seat. Cause: The ECU A-9000 has detected a negative deviation between the required and measured position of the TVA Z-9001. The desired throttle valve position can not be reached. For more information regarding TVA Z-9001 inspection, refer to the engine service manual Throttle Valve Actuator (TVA) - Inspect (55.014). Possible failure modes: 1. Faulty throttle valve actuator Z-9001, sticking or blocked. 2. Faulty throttle valve actuator Z-9001, internal failure. 3. Faulty ECU A-9000, software.

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3414-Glow plug 1 control circuit shorted to ground WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: For information regarding the functional operation of the glow plug control module Z-9101, refer to the engine service manual Glow plug system Glow plug control module - Overview - Glow plug control module (55.202). The Engine Control Unit (ECU) A-9000 requests operation of the glow plug control module Z-9101 via a Pulse Width Modulated (PWM) control circuit and monitors the status of possible electrical defects via a diagnostic feedback signal from the glow plug control module Z-9101. If the ECU A-9000 is notified of a short circuit condition in the glow plug 1 R-9001 circuit, this fault will occur. Cause: The glow plug control module Z-9101 has communicated to the ECU A-9000, via a diagnostic connection, that a short circuit condition exists in the glow plug 1 R-9001 circuit. Possible failure modes: 1. Faulty glow plug 1 R-9001, internal failure. 2. Faulty glow plug 1 R-9001 control circuit wiring, shorted to ground. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 7. 2. Check the glow plug for a short to ground condition. Disconnect the engine harness (EN) from glow plug 1 R-9001 at connector X-9034. Use a multimeter to check on the component for a grounded (shorted) condition : From X-9034 pin 1

To chassis ground

Result There should be 0.2 - 5.0 Ω.

A. If there is greater than 0.2 Ω, leave connector X-9034 disconnected and continue with Step 3. B. If there is less than 0.2 Ω, the glow plug 1 R-9001 has failed internally, replace the glow plug. 3. Check the glow plug 1 R-9001 control circuit for a short to ground condition. With the key switch in the OFF position, use a multimeter to check for continuity on the engine harness (EN) side : From X-9034 pin 1

To chassis ground

Result There should be no continuity.

A. If there is continuity, continue with Step 4. B. If there is no continuity, continue with Step 6. 4. Locate the short to ground condition. Carefully disconnect the vehicle harness (VE) from the engine interface connector X-9138. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : 47683911 27/02/2015

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From X-9138 pin 61

To chassis ground

Result There should be no continuity.

A. If there is continuity, leave connector X-9138 disconnected and continue with Step 5. B. If there is no continuity, the short to a ground condition is in the engine harness (EN) between connector X-9034 pin 1 and connector X-9138 pin 61, wire EN-9058. Locate and repair the grounded conductor. 5. Locate the short to ground condition. Carefully disconnect the vehicle harness (VE) from the glow plug control module Z-9101 at connector X-9113. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9113 pin 2

To chassis ground

Result There should be no continuity.

A. If there is continuity, the short to chassis ground condition is in the vehicle harness (VE) between connector X-9113 pin 2 and connector X-9138 pin 61, wire VE-9058. Use the appropriate service manual, if necessary, to locate and repair the grounded conductor. B. If there is no continuity, continue with Step 6. 6. Replace the glow plug control module Z-9101, then use EST to check to see that this fault has been resolved. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3415-Glow plug 3 control circuit shorted to ground WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: For information regarding the functional operation of the glow plug control module Z-9101, refer to the engine service manual Glow plug system Glow plug control module - Overview - Glow plug control module (55.202). The Engine Control Unit (ECU) A-9000 requests operation of the glow plug control module Z-9101 via a Pulse Width Modulated (PWM) control circuit and monitors the status of possible electrical defects via a diagnostic feedback signal from the glow plug control module Z-9101. If the ECU A-9000 is notified of a short circuit condition in the glow plug 3 R-9003 circuit, this fault will occur. Cause: The glow plug control module Z-9101 has communicated to the ECU A-9000, via a diagnostic connection, that a short circuit condition exists in the glow plug 3 R-9003 circuit. Possible failure modes: 1. Faulty glow plug 3 R-9003, internal failure. 2. Faulty glow plug 3 R-9003 control circuit wiring, shorted to ground. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 7. 2. Check the glow plug for a short to ground condition. Disconnect the engine harness (EN) from glow plug 3 R-9003 at connector X-9036. Use a multimeter to check on the component for a grounded (shorted) condition : From X-9036 pin 1

To chassis ground

Result There should be 0.2 - 5.0 Ω.

A. If there is greater than 0.2 Ω, leave connector X-9036 disconnected and continue with Step 3. B. If there is less than 0.2 Ω, the glow plug 3 R-9003 has failed internally, replace the glow plug. 3. Check the glow plug 3 R-9003 control circuit for a short to ground condition. With the key switch in the OFF position, use a multimeter to check for continuity on the engine harness (EN) side : From X-9036 pin 1

To chassis ground

Result There should be no continuity.

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From X-9138 pin 58

To chassis ground

Result There should be no continuity.

A. If there is continuity, leave connector X-9138 disconnected and continue with Step 5. B. If there is no continuity, the short to a ground condition is in the engine harness (EN) between connector X-9036 pin 1 and connector X-9138 pin 58 , wire EN-9060. Locate and repair the grounded conductor. 5. Locate the short to ground condition. Carefully disconnect the vehicle harness (VE) from the glow plug control module Z-9101 at connector X-9113. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9113 pin 1

To chassis ground

Result There should be no continuity.

A. If there is continuity, the short to chassis ground condition is in the vehicle harness (VE) between connector X-9113 pin 1 and connector X-9138 pin 58, wire VE-9060. Use the appropriate service manual, if necessary, to locate and repair the grounded conductor. B. If there is no continuity, continue with Step 6. 6. Replace the glow plug control module Z-9101, then use EST to check to see that this fault has been resolved. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3416-Glow plug 4 control circuit shorted to ground WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: For information regarding the functional operation of the glow plug control module Z-9101, refer to the engine service manual Glow plug system Glow plug control module - Overview - Glow plug control module (55.202). The Engine Control Unit (ECU) A-9000 requests operation of the glow plug control module Z-9101 via a Pulse Width Modulated (PWM) control circuit and monitors the status of possible electrical defects via a diagnostic feedback signal from the glow plug control module Z-9101. If the ECU A-9000 is notified of a short circuit condition in the glow plug 4 R-9004 circuit, this fault will occur. Cause: The glow plug control module Z-9101 has communicated to the ECU A-9000, via a diagnostic connection, that a short circuit condition exists in the glow plug 4 R-9004 circuit. Possible failure modes: 1. Faulty glow plug 4 R-9004, internal failure. 2. Faulty glow plug 4 R-9004 control circuit wiring, shorted to ground. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 7. 2. Check the glow plug for a short to ground condition. Disconnect the engine harness (EN) from glow plug 4 R-9004 at connector X-9037. Use a multimeter to check on the component for a grounded (shorted) condition : From X-9037 pin 1

To chassis ground

Result There should be 0.2 - 5.0 Ω.

A. If there is greater than 0.2 Ω, leave connector X-9037 disconnected and continue with Step 3. B. If there is less than 0.2 Ω, the glow plug 4 R-9004 has failed internally, replace the glow plug. 3. Check the glow plug 4 R-9004 control circuit for a short to ground condition. With the key switch in the OFF position, use a multimeter to check for continuity on the engine harness (EN) side : From X-9037 pin 1

To chassis ground

Result There should be no continuity.

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From X-9138 pin 57

To chassis ground

Result There should be no continuity.

A. If there is continuity, leave connector X-9138 disconnected and continue with Step 5. B. If there is no continuity, the short to a ground condition is in the engine harness (EN) between connector X-9037 pin 1 and connector X-9138 pin 57 , wire EN-9061. Locate and repair the grounded conductor. 5. Locate the short to ground condition. Carefully disconnect the vehicle harness (VE) from the glow plug control module Z-9101 at connector X-9113. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9113 pin 6

To chassis ground

Result There should be no continuity.

A. If there is continuity, the short to chassis ground condition is in the vehicle harness (VE) between connector X-9113 pin 6 and connector X-9138 pin 57, wire VE-9061. Use the appropriate service manual, if necessary, to locate and repair the grounded conductor. B. If there is no continuity, continue with Step 6. 6. Replace the glow plug control module Z-9101, then use EST to check to see that this fault has been resolved. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3417-Glow plug 2 control circuit shorted to ground WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: For information regarding the functional operation of the glow plug control module Z-9101, refer to the engine service manual Glow plug system Glow plug control module - Overview - Glow plug control module (55.202). The Engine Control Unit (ECU) A-9000 requests operation of the glow plug control module Z-9101 via a Pulse Width Modulated (PWM) control circuit and monitors the status of possible electrical defects via a diagnostic feedback signal from the glow plug control module Z-9101. If the ECU A-9000 is notified of a short circuit condition in the glow plug 2 R-9002 circuit, this fault will occur. Cause: The glow plug control module Z-9101 has communicated to the ECU A-9000, via a diagnostic connection, that a short circuit condition exists in the glow plug 2 R-9002 circuit. Possible failure modes: 1. Faulty glow plug 2 R-9002, internal failure. 2. Faulty glow plug 2 R-9002 control circuit wiring, shorted to ground. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 7. 2. Check the glow plug for a short to ground condition. Disconnect the engine harness (EN) from glow plug 2 R-9002 at connector X-9035. Use a multimeter to check on the component for a grounded (shorted) condition : From X-9035 pin 1

To chassis ground

Result There should be 0.2 - 5.0 Ω.

A. If there is greater than 0.2 Ω, leave connector X-9035 disconnected and continue with Step 3. B. If there is less than 0.2 Ω, the glow plug 2 R-9002 has failed internally, replace the glow plug. 3. Check the glow plug 2 R-9002 control circuit for a short to ground condition. With the key switch in the OFF position, use a multimeter to check for continuity on the engine harness (EN) side : From X-9035 pin 1

To chassis ground

Result There should be no continuity.

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From X-9138 pin 60

To chassis ground

Result There should be no continuity.

A. If there is continuity, leave connector X-9138 disconnected and continue with Step 5. B. If there is no continuity, the short to a ground condition is in the engine harness (EN) between connector X-9035 pin 1 and connector X-9138 pin 60 , wire EN-9059. Locate and repair the grounded conductor. 5. Locate the short to ground condition. Carefully disconnect the vehicle harness (VE) from the glow plug control module Z-9101 at connector X-9113. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9113 pin 7

To chassis ground

Result There should be no continuity.

A. If there is continuity, the short to chassis ground condition is in the vehicle harness (VE) between connector X-9113 pin 7 and connector X-9138 pin 60, wire VE-9059. Use the appropriate service manual, if necessary, to locate and repair the grounded conductor. B. If there is no continuity, continue with Step 6. 6. Replace the glow plug control module Z-9101, then use EST to check to see that this fault has been resolved. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3418-Wastegate pressure modulator control circuit shorted to battery WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the wastegate pressure modulator valve Y-9008 circuit. If the ECU A-9000 determines that there is a short to a voltage source in the wastegate pressure modulator valve Y-9008 circuit, this fault will occur. Cause: The ECU A-9000 has detected a short to a voltage source in the wastegate pressure modulator valve Y-9008 circuit. Possible failure modes: 1. Faulty wastegate pressure modulator valve Y-9008 wiring, short to a voltage source. 2. Faulty wastegate pressure modulator valve Y-9008, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 7. 2. Check the wastegate pressure modulator valve Y-9008 internal resistance. Disconnect the wastegate pressure modulator valve Y-9008 connector X-9038. Use a multimeter to perform the following resistance check on the wastegate pressure modulator valve Y-9008 pins : From

Value There should be between 21.8 24.2 Ω. NOTE: The provided value should be measured at a temperature of approximately 20 °C (68 °F). X-9038 pin 1

X-9038 pin 2

To X-9038 pin 2

Value There should be no continuity.

A. If there is continuity, there is a short circuit in the wastegate pressure modulator valve wiring. Use the appropriate service manual, if necessary to locate and repair the shorted conductor. B. If there is no continuity, continue to Step 4. 4. Check the wastegate pressure modulator valve Y-9008 wiring for a short to battery condition. 47683911 27/02/2015

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With the key in the OFF position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-9038 pin 2

To Chassis ground

Value There should be no voltage.

To Chassis ground

Value There should be no voltage.

To Chassis ground

Value There should be no voltage.

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3419-Wastegate pressure modulator control circuit shorted to ground WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the wastegate pressure modulator valve Y-9008 circuit. If the ECU A-9000 determines that there is a short to ground in the wastegate pressure modulator valve Y-9008 circuit, this fault will occur. Cause: The ECU A-9000 has detected a short to ground in the wastegate pressure modulator valve Y-9008 circuit. Possible failure modes: 1. Faulty wastegate pressure modulator valve Y-9008 wiring, short to ground. 2. Faulty wastegate pressure modulator valve Y-9008, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the wastegate pressure modulator valve Y-9008 internal resistance. Disconnect the wastegate pressure modulator valve Y-9008 connector X-9038. Use a multimeter to perform the following resistance check on the wastegate pressure modulator valve Y-9008 pins : From

Value There should be between 21.8 24.2 Ω. NOTE: The provided value should be measured at a temperature of approximately 20 °C (68 °F). X-9038 pin 1

X-9038 pin 2

To Chassis ground All pins in connector X-9138

Value There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit in the wastegate pressure modulator valve engine harness (EN) wiring. Locate and repair the shorted conductor. 47683911 27/02/2015

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B. If there is no continuity, leave connector X-9138 disconnected and continue to Step 4. 4. Check the wastegate pressure modulator valve Y-9008 vehicle harness (VE) wiring. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side of the connectors from : From X-9138 pin 27 X-9138 pin 27

To Chassis ground All pins in connector X-9139

Value There should be no continuity. There should be no continuity.

A. If there is continuity, there is an short circuit in the wastegate pressure modulator valve vehicle harness (VE) wiring. Use the appropriate service manual, if necessary to locate and repair the shorted conductor. B. If there is no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3425-Turbocharger boost pressure is higher than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors boost pressure using the intake manifold pressure sensor B-9001. If the ECU A-9000 determines that boost pressure is higher than expected, this fault will occur. For more information regarding the troubleshooting of an over-boost condition, refer to the engine service manual Turbocharger Boost Troubleshooting (10.250). Cause: The ECU A-9000 has determined that boost pressure is higher than expected. Possible failure modes: 1. Faulty wastegate pressure modulator valve Y-9008, if applicable. 2. Faulty wastegate, sticking or broken linkage. 3. Faulty intake manifold pressure sensor B-9001, signal drifted. 4. Faulty ECU A-9000, software.

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Electrical systems - FAULT CODES

3430-EGR Failure - Moderate Inducement C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors the efficiency of the Exhaust Gas Recirculation (EGR) valve Z-9000. If the ECU A-9000 detects an efficiency failure, inducement will be triggered and this fault will occur. This fault indicates a least severe inducement level. Other active faults may have caused this fault to occur.

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Electrical systems - FAULT CODES

3431-EGR Failure - Severe Inducement C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors the efficiency of the Exhaust Gas Recirculation (EGR) valve Z-9000. If the ECU A-9000 detects an efficiency failure, inducement will be triggered and this fault will occur. This fault indicates a most severe inducement level. Other active faults may have caused this fault to occur.

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Electrical systems - FAULT CODES

3432-EGR Failure - Mild Inducement C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors the efficiency of the Exhaust Gas Recirculation (EGR) valve Z-9000. If the ECU A-9000 detects an efficiency failure, an inducement warning will be triggered and this fault will occur. Other active faults may have caused this fault to occur.

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Electrical systems - FAULT CODES

3433-DPF - Moderate Inducement C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) monitors the Particulate Matter (PM) catalytic converter efficiency. If the ECU A-9000 detects an failure of efficiency, inducement will be triggered and this fault will occur. Other active faults may have caused this fault to occur. This fault indicates the least severe level of inducement.

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Electrical systems - FAULT CODES

3434-DPF - Severe Inducement C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

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Electrical systems - FAULT CODES

3435-DPF - Mild Inducement C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) monitors the Particulate Matter (PM) catalytic converter efficiency. If the ECU A-9000 detects an failure of efficiency, an inducement warning will be triggered and this fault will occur. Other active faults may have caused this fault to occur.

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3436-Inducement system is locked due to 3 detections in 40 hours. The system must be reset using the dealer service tool screen "Engine Restart Counter Reset" NOTE: Since this fault is part of the inducement strategy and has resulted in an inducement lock condition, it may be necessary to perform the Engine Restart Counter Reset / Unlock Inducement configuration and the SCR Fault Repair Verification Test with the Electronic Service Tool (EST) before you return the machine to service. Refer to Selective Catalytic Reduction (SCR) exhaust treatment - Configure - Engine restart counter reset (10.500) and Selective Catalytic Reduction (SCR) exhaust treatment - Service instruction - SCR fault repair verification test (10.500) , if necessary. If the machine is still locked in final inducement after following the above procedures, you must use the Easy Engine software provided with the Electronic Service Tool (EST) to clear all faults. Context: This failure path is only for information. One or more of the inducement blocks has been detected as active at least three times in the last 40 h by the Engine Control Unit (ECU) A-9000 which has caused the inducement system to lock. The failure causing the inducement must be located, resolved and reset prior to reset of this fault. The Electronic Service Tool (EST) is required to release inducement.

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Electrical systems - FAULT CODES

3517-Ambient temperature sensor voltage is higher than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the intake air temperature sensor B-9113. If the ECU A-9000 determines that the intake air temperature sensor B-9113 signal circuit voltage is greater than 4.93 V, this fault will occur. Once this fault occurs, the intake air temperature value is frozen by the ECU A-9000 at the last valid value for a preliminary failure or jumps to a fixed replacement value of 29.96 °C (85.93 °F) if the failure is validated. Cause: The intake air temperature sensor B-9113 signal circuit voltage is greater than 4.93 V. Possible failure modes: 1. Faulty intake air temperature sensor B-9113 wiring, short to a voltage source. 2. Faulty intake air temperature sensor B-9113, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check the intake air temperature sensor B-9113 wiring for a short circuit to battery. Disconnect the vehicle harness from the intake air temperature sensor B-9113 at connector X-9117. With the key in the OFF position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From X-9117 pin 1

To Chassis ground

Value There should be no voltage.

With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From X-9117 pin 1

To Chassis ground

Value There should be less than 5.5 V

A. If the specified values are measured, leave connector X-9117 disconnected and continue to Step 3. B. If the specified values are not measured, there is a short circuit to battery in the intake temperature sensor B-9113 signal circuit in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. 3. Check the intake air temperature sensor B-9113 wiring for an open circuit condition. Disconnect the vehicle harness from the ECU A-9000 at connector X-9122. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9117 pin 1 X-9117 pin 2

To X-9122 pin K19 X-9122 pin K20 47683911 27/02/2015

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Value There should be continuity. There should be continuity.

Electrical systems - FAULT CODES

A. If there is continuity, leave connectors X-9117 and X-9122 disconnected and continue to Step 4. B. If there is no continuity, there is an open circuit condition in the intake temperature sensor B-9113 signal circuit vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the broken conductor. 4. Check the intake air temperature sensor B-9113 wiring for a short circuit condition. With the key in the OFF position, use a multimeter to perform the following continuity check at the vehicle harness (VE) side of the connector from : From X-9122 pin K19 X-9122 pin K20

To All pins in connector X-9122 All pins in connector X-9122

Value There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short to ground condition in the intake temperature sensor B-9113 signal circuit vehicle harness (VE).Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, leave connector X-9117 disconnected and continue to Step 5. 5. Replace the intake temperature sensor B-9113. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 03 - Exhaust system and Controller Area Network (CAN) bus (55.100.DP-C.20.E.03) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3518-Ambient temperature sensor voltage is lower than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the intake air temperature sensor B-9113. If the ECU A-9000 determines that the intake air temperature sensor B-9113 signal circuit voltage is less than 198.00 mV, this fault will occur. Once this fault occurs, the intake air temperature value is frozen by the ECU A-9000 at the last valid value for a preliminary failure or jumps to a fixed replacement value of 29.96 °C (85.93 °F) if the failure is validated. Cause: The intake air temperature sensor B-9113 signal circuit voltage is less than 198.00 mV. Possible failure modes: 1. Faulty intake air temperature sensor B-9113 wiring, short to ground condition. 2. Faulty intake air temperature sensor B-9113, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the intake air temperature sensor B-9113 vehicle harness (VE) wiring for a short to ground condition. Disconnect the vehicle harness (VE) from the intake air temperature sensor B-9113 at connector X-9117. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9117 pin 1 X-9117 pin 1

To X-9117 pin 2 Chassis ground

Value There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short to ground condition in the air temperature sensor B-9113 signal circuit vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, leave connector X-9117 disconnected and continue to Step 3. 3. Check the intake air temperature sensor B-9113 vehicle harness (VE) wiring for a short to ground condition. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9122 pin K19 X-9122 pin K19

To Chassis ground All pins in connector X-9122

Value There should be no continuity. There should be no continuity.

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B. If there is no continuity, leave connector X-9117 disconnected and continue to Step 4. 4. Replace the intake temperature sensor B-9113. Use the Electronic Service Tool (EST) to check the status of this fault, 3518 - Ambient temperature sensor voltage is lower than expected . A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 03 - Exhaust system and Controller Area Network (CAN) bus (55.100.DP-C.20.E.03) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3616-Torque limitation caused by turbo charger protection C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: This fault is for information purposes only and may have been caused by another fault. The Engine Control Unit (ECU) A-9000 has detected an active power reduction due to turbocharger protection. This fault may have been caused by a detection of high altitude or extreme working conditions for a period greater than 120.00 s. If this fault occurs, a power reduction or engine speed reduction of equal to or greater than 25 % of the desired torque will be active in order to protect the turbocharger from a potential overspeed condition. If the power reduction occurred due to actual defect, the failure triggering the torque limitation should also be in the failure memory. Use the Electronic Service Tool (EST) to check for related fault codes and diagnose them first, then check the status of this fault, 3616 - Torque limitation caused by turbo charger protection.

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3650-Battery voltage is higher than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the battery voltage. If the ECU A-9000 detects a voltage higher than expected, this fault will occur. Cause: The ECU A-9000 has detected a battery voltage of greater than 28.8 V. Possible failure modes: 1. Faulty alternator, failed regulator. 2. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 3. 2. Start the engine and raise the Revolutions Per Minute (RPM) to approximately 1500 RPM for 1.00 min. Lower the RPM to idle speed and check the battery voltage with the engine running. With the engine running, use a multimeter to perform the following voltage check on the battery posts : From Battery +

To Battery -

Value 14.8 - 16.2 V

A. If the voltage is high, out of range (normal engine running operating range is approximately 14.8 - 16.2 V, the alternator has failed. Replace the alternator. B. If the voltage is within range (normal engine running operating range is approximately 14.8 - 16.2 V, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 3. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3651-Battery voltage is lower than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the battery voltage. If the ECU A-9000 detects a voltage lower than expected, this fault will occur. Cause: The ECU A-9000 has detected a battery voltage of less than 8.3 V. Possible failure modes: 1. Faulty battery. 2. Faulty alternator, failed regulator. 3. Engine started in extreme cold conditions. 4. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Charge the battery and perform a battery load test. A. If the pass battery does not pass the load test, replace the battery. B. If the battery passes the load test, continue to Step 3. 3. Start the engine and raise the Revolutions Per Minute (RPM) to about 1500 RPM for 1.00 min. Lower the RPM to idle speed and check the battery voltage with the engine running. With the engine running, use a multimeter to perform the following voltage check on the battery posts : From Battery +

To Battery -

Value 14.8 - 16.2 V

A. If the voltage is low, out of range (normal engine running operating range is approximately 14.8 - 16.2 V, the alternator has failed. Replace the alternator. B. If the voltage is within range (normal engine running operating range is approximately 14.8 - 16.2 V, continue to Step 4. 4. Check the ECU A-9000 voltage supply wiring. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122. Place a jumper wire between X-9122 pin K28 and chassis ground. This will energize the main relay K-9102. With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From X-9122 pin K01 X-9122 pin K03 X-9122 pin K05

To Chassis ground Chassis ground Chassis ground 47683911 27/02/2015

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Value There should be approximately 12 V. There should be approximately 12 V. There should be approximately 12 V.

Electrical systems - FAULT CODES

A. If there is less than approximately 12 V, continue to Step 5. B. If there is approximately 12 V, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Check the ECU A-9000 voltage supply wiring for a short circuit to ground. With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From X-9122 pin K01 X-9122 pin K03 X-9122 pin K05

To Chassis ground Chassis ground Chassis ground

Value There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit to ground condition in the ECU A-9000 voltage supply wiring. Locate and repair the shorted conductor. B. If there is no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3652-CAN A Bus off passive failure WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on two separate Controller Area Networks (CAN). Proper configuration and monitoring of the two twisted pair configured networks is also a function of the ECU A-9000. CAN Node A Bus is the main vehicle interface bus. The ECU A-9000 provides a CAN termination resistor for the CAN Node A Bus, internal to the ECU A-9000. If the ECU A-9000 senses that CAN Node A Bus is not functioning properly, this fault will occur. Cause: ECU A-9000 has sensed a “Bus Off” state to be present at the CAN Node A. Possible failure modes: 1. Faulty supply voltage or ground, missing. 2. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit. 3. Faulty ECU A-9000, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check for other vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If other vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that 3652 - CAN A Bus off passive failure is also resolved. B. If other vehicle CAN faults do not exist, continue with Step 3. 3. Check the ECU A-9000 supply voltage. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9122. To energize the Main relay K-9102, place a jumper wire between the vehicle harness (VE) side of connector X-9122 pin K28 and chassis ground. Use a multimeter to check for voltage on the vehicle (VE) harness side: From X-9122 pin K01 X-9122 pin K03 X-9122 pin K05

To chassis ground chassis ground chassis ground

Value There should be 12.0 V . There should be 12.0 V . There should be 12.0 V .

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Electrical systems - FAULT CODES

From X-9122 pin K02 X-9122 pin K04 X-9122 pin K06

To chassis ground chassis ground chassis ground

Value There should be continuity. There should be continuity. There should be continuity.

A. If there is continuity on all of the checks, leave connector X-9122 disconnected and continue with Step 5. B. If there is no continuity for one or more of the checks, see the appropriate vehicle service manual and electrical schematics, if necessary, to locate and restore the ground circuits to the ECU A-9000. 5. Determine the condition of the ECU A-9000 CAN circuit. With the key switch in the “OFF” position, use a multimeter to measure the resistance of the CAN connection on the vehicle (VE) harness side: From X-9122 pin K24 X-9122 pin K24 X-9122 pin K25

To X-9122 pin K25 chassis ground chassis ground

Value There should be 120 Ω. There should not be continuity There should not be continuity

Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU A-9000: From X-9122 pin K24

To X-9122 pin K25

Value There should be 120 Ω.

A. If the measured resistances are correct and neither conductor is grounded, check the ECU A-9000 for the appropriate software and re-flash, if necessary. B. If the measured resistances are not correct or one or both of the conductors is grounded, refer to the appropriate vehicle service manual and electrical schematics, if necessary, to locate and restore the termination resistance to the CAN circuit. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3655-Torque limitation active C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: This fault is for informational purposes only and may have been caused by another fault. The Engine Control Unit (ECU) A-9000 has detected one or more torque reductions. Though there are no actions necessary for this fault alone, if the power reduction occurred due to actual defect, the failure triggering the torque limitation should also be in the failure memory. Use the Electronic Service Tool (EST) to check for related faults and diagnose them first, then check the status of this fault, 3655 - Torque limitation active.

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Electrical systems - FAULT CODES

3656-Torque limitation caused by particulate filter C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: This fault has set due to a performance limitation to protect the particulate filter from high pressure. If there was a power reduction greater than 25 % or an engine speed limitation greater than 25 % due to particulate filter protection for more than 120.00 s a fault code was stored. This fault code is for information only and does not require any further action. That there was an active performance limitation due to the particulate filter protection against too high pressure, which was not caused by a failure, but an extreme working condition. If other fault codes are present that could influence the particulate filter high pressure, those faults could pinpoint an actual failure. Follow the troubleshooting procedure for the other fault.

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3657-CAN Bus Received frames : Timeout Error of CAN-Receive-Frame CM1BC WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on two separate Controller Area Networks (CAN). Proper configuration and monitoring of the two twisted pair configured networks is also a function of the ECU A-9000. CAN Node A Bus is the main vehicle interface bus. The ECU A-9000 provides a CAN termination resistor for the CAN Node A Bus, internal to the ECU A-9000. If the ECU A-9000 senses that CAN Node A Bus is not functioning properly, this fault will occur. Cause: ECU A-9000 has sensed a timeout of required vehicle controller data provided on CAN Node A. Possible failure modes: 1. Faulty supply voltage or ground, missing. 2. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit. 3. Faulty ECU A-9000, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check for other vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If other vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that 3657 - CAN Bus Received frames : Timeout Error of CAN-Receive-Frame CM1BC is also resolved. B. If other vehicle CAN faults do not exist, continue with Step 3. 3. Check the ECU A-9000 supply voltage. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9122. With the key switch in the “ON” position, use a multimeter to check for voltage on the vehicle (VE) harness side: From X-9122 pin K01 X-9122 pin K03 X-9122 pin K05

To chassis ground chassis ground chassis ground

Value There should be 12.0 V . There should be 12.0 V . There should be 12.0 V .

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From X-9122 pin K02 X-9122 pin K04 X-9122 pin K06

To chassis ground chassis ground chassis ground

Value There should be continuity. There should be continuity. There should be continuity.

To X-9122 pin K25 chassis ground chassis ground

Value There should be 120 Ω. There should not be continuity There should not be continuity

Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU A-9000: From X-9122 pin K24

To X-9122 pin K25

Value There should be 120 Ω.

A. If the measured resistances are correct and neither conductor is grounded, check the ECU A-9000 for the appropriate software and re-flash, if necessary. B. If the measured resistances are not correct or one or both of the conductors is grounded, refer to the appropriate vehicle service manual and electrical schematics to locate and restore the termination resistance to the CAN circuit. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3665-EGR valve will not open to commanded position C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

NOTE: Because the Engine Control Unit (ECU) A-9000 stores historical data relevant to the operation of the EGR valve Z-9000, it is necessary to perform the Replacement of the Exhaust GAs Recirculation Valve (EGR) – Reset ECU Data with the Electronic Service Tool (EST), if the EGR valve Z-9000 is replaced. Refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU data (EGR valve) (10.501), if necessary. Context: The Engine Control Unit (ECU) A-9000 controls the position of the EGR valve Z-9000 with an H-bridge Pulse Width Modulated (PWM) circuit. The ECU A-9000 also monitors the position of the EGR valve Z-9000 by monitoring the potentiometer feedback voltage. If the ECU A-9000 determines that the feedback position signal is 12 % greater than it should be for the commanded position for a period of time longer than that established by the ECU A-9000, this fault will occur. For information regarding the functional operation of the Exhaust Gas Recirculation (EGR) valve Z-9000 refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Overview (10.501). Cause: The ECU A-9000 has determined that the positive deviation between the required and measured position of the EGR valve Z-9000 has been exceeded. Possible failure modes: 1. Faulty EGR valve Z-9000, valve sticks, clean or replace, as required. 2. Faulty EGR valve Z-9000 position sensor, internal failure.

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3666-EGR valve will not close to commanded position C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

NOTE: Because the Engine Control Unit (ECU) A-9000 stores historical data relevant to the operation of the Exhaust Gas Recirculation (EGR) valve Z-9000, it is necessary to perform the “Replacement of the Exhaust Gas Recirculation Valve (EGR) – Reset ECU Data” with the Electronic Service Tool (EST), if the EGR valve Z-9000 is replaced. Refer to the engine service manual for Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU data (EGR valve) (10.501), if necessary. Context: The ECU A-9000 controls the position of the EGR valve Z-9000 with an H-bridge Pulse Width Modulated (PWM) circuit. The ECU A-9000 also monitors the position of the EGR valve Z-9000 by monitoring the potentiometer feedback voltage. If the ECU A-9000 determines that the feedback position signal is 12 % less than it should be for the commanded position for a period of time longer than that established by the ECU A-9000, this fault will occur. For information regarding the functional operation of the Exhaust Gas Recirculation (EGR) valve Z-9000 refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Overview (10.501). Cause: The ECU A-9000 has determined that the negative deviation between the required and measured position of the EGR valve Z-9000 has been exceeded. Possible failure modes: 1. Faulty EGR valve Z-9000, valve sticks, clean or replace, as required. 2. Faulty EGR valve Z-9000 position sensor, internal failure.

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3667-EGR valve control circuit open WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Exhaust Gas Recirculation (EGR) valve Z-9000 is replaced, it is necessary to perform the “Replacement of the Exhaust Gas Recirculation Valve (EGR) – Reset ECU Data” with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Exhaust Gas Recirculation (EGR) valve Configure - Reset ECU data (EGR valve) (10.501), if necessary. Context: The Engine Control Unit (ECU) A-9000 internally monitors the operation of the H-bridge Pulse Width Modulated (PWM) control circuit for the Exhaust Gas Recirculation (EGR) valve Z-9000 actuator for electrical defects. If the ECU A-9000 detects no current flow when EGR valve Z-9000 actuation is requested, this fault will occur. For information regarding the functional operation of the EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Overview (10.501). For more information regarding the technical specifications of the EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve actuator - Technical Data (55.989). Cause: The ECU A-9000 is sensing an open circuit condition in the EGR valve Z-9000 control circuit. Possible failure modes: 1. Faulty EGR valve Z-9000 actuator motor, failed internally. 2. Faulty EGR valve Z-9000 circuit wiring, open conductor. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the condition of the EGR valve Z-9000 actuator motor. Disconnect the engine harness (EN) from the EGR valve Z-9000 at connector X-9010. Use a multimeter to measure the resistance, on the EGR valve Z-9000 actuator motor: From X-9010 pin 1

To X-9010 pin 5

Value There should be between 1.7 - 3.2 Ω

A. If the specified value is measured, leave connector X-9010 disconnected and continue with Step 3. B. If the measured resistance is infinite, the EGR valve Z-9000 actuator motor has failed internally, replace the EGR valve Z-9000. Then use the EST, see Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU data (EGR valve) (10.501) if necessary, to perform the Replacement of the Exhaust Gas Recirculation Valve (EGR) – Reset ECU Data. 3. Check the engine harness (EN) for an open circuit condition. Carefully disconnect the vehicle harness (VE) from the engine interface at connector X-9138. Use a multimeter to check for continuity in the engine harness (EN) :

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From X-9010 pin 1 X-9010 pin 5

To X-9138 pin 29 X-9138 pin 30

Result There should be continuity. There should be continuity.

A. If there is continuity on both tests, leave connector X-9138 disconnected and continue with Step 4. B. If there is no continuity on either or both of the checks, there is an open circuit condition in the engine harness (EN) between connector X-9010 pin 1 and/or X-9010 pin 5 and connector X-9138 pin 29 and/or X-9138 pin 30, wire EN-9095 and/or EN-9096. Locate and repair the broken conductor. 4. Check the vehicle harness (VE) for an open circuit condition. Carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. Use a multimeter to check for continuity in the vehicle harness (VE) : From X-9121 pin A50 X-9121 pin A35

To X-9138 pin 29 X-9138 pin 30

Result There should be continuity. There should be continuity.

A. If there is no continuity on either or both of the checks, there is an open circuit condition in the vehicle harness (VE) between connector X-9121 pin A50 and/or X-9121 pin A35 and connector X-9138 pin 29 and/or X-9138 pin 30, wire VE-9095 and/or VE-9096. Use the appropriate service manual, if necessary, to locate and repair the broken conductor. B. If there is continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3668-EGR valve control circuit over current WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Exhaust Gas Recirculation (EGR) valve Z-9000 is replaced, it is necessary to perform the Replacement of the Exhaust Gas Recirculation Valve (EGR) – Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual, Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU data (EGR valve) (10.501), if necessary. Context: The Engine Control Unit (ECU) A-9000 internally monitors the operation of the H-bridge Pulse Width Modulated (PWM) control circuit for the Exhaust Gas Recirculation (EGR) valve Z-9000 actuator for electrical defects. If the ECU A-9000 detects excessive current flow when EGR valve Z-9000 actuation is requested, this fault will occur. For information regarding the functional operation of the EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Overview (10.501). For more information regarding the technical specifications of the EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve actuator - Technical Data (55.989). Cause: The ECU A-9000 is sensing a short circuit condition in the EGR valve Z-9000 control circuit. Possible failure modes: 1. Faulty EGR valve Z-9000 actuator motor, failed internally. 2. Faulty EGR valve Z-9000 circuit wiring, short circuit. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the condition of the EGR valve Z-9000 actuator motor. Disconnect the engine harness (EN) from the EGR valve Z-9000 at connector X-9010. Use a multimeter to measure the resistance, on the EGR valve Z-9000 actuator motor: From X-9010 pin 1 X-9010 pin 1 X-9010 pin 5

To X-9010 pin 5 chassis ground chassis ground

Value There should be between 1.7 - 3.2 Ω There should be no continuity. There should be no continuity.

A. If the specified values are measured, leave connector X-9010 disconnected and continue with Step 3. B. If the measured resistance is zero Ω or there is continuity to ground, the EGR valve Z-9000 actuator motor has failed internally, replace the EGR valve Z-9000. Then use the EST, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU data (EGR valve) (10.501) if necessary, to perform the Replacement of the Exhaust Gas Recirculation Valve (EGR) – Reset ECU Data. 3. Check the EGR valve Z-9000 actuator motor circuit for a short circuit condition. Use a multimeter to check for continuity on the engine harness (EN) side :

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From X-9010 pin 1 X-9010 pin 1 X-9010 pin 5

To X-9010 pin 5 chassis ground chassis ground

Result There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is continuity on any of the tests, continue with Step 4. B. If there is no continuity on any of the checks, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Determine the location of the short circuit condition. Disconnect the vehicle harness (VE) from the interface connector X-9138. Then carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. Use a multimeter to check for continuity in the vehicle harness (VE) : From X-9121 pin A50 X-9121 pin A50 X-9121 pin A35

To X-9121 pin A35 chassis ground chassis ground

Result There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is continuity on any of the checks, there is a short circuit condition in the vehicle harness (VE) between connector X-9121 pin A50 and X-9121 pin A35 or a short to ground condition between connector X-9121 pin A50 and X-9138 pin 29 or X-9121 pin A35 and X-9138 pin 30. Use the appropriate service manual, if necessary, to locate and repair the damaged conductors or grounded conductor. B. If there is no continuity on any of the checks, there is a short circuit condition in the engine harness (EN) between connector X-9010 pin 1 and X-9010 pin 5 or a short to ground condition between connector X-9010 pin 1 and X-9138 pin 29 or X-9010 pin 5 and X-9138 pin 30. Locate and repair the damaged conductors or grounded conductor. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3669-EGR valve control circuit high side shorted to battery WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 internally monitors the operation of the H-bridge Pulse Width Modulated (PWM) control circuit for the Exhaust Gas Recirculation (EGR) valve Z-9000 actuator for electrical defects. If the ECU A-9000 detects a short circuit of the circuit wiring to an external source, this fault will occur. For information regarding the functional operation of the EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Overview (10.501). For more information regarding the technical specifications of the EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve actuator - Technical Data (55.989). Cause: The ECU A-9000 is sensing a short to a voltage source condition in the EGR valve Z-9000 motor actuator control circuit. Possible failure modes: 1. Faulty EGR valve Z-9000 circuit wiring, shorted to voltage source. 2. Faulty ECU A-9000, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the EGR valve Z-9000 motor actuator control circuit for a short to voltage source condition. Carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. Disconnect the engine harness (EN) from the EGR valve Z-9000 at connector X-9010. With the key switch in the ON position, use a multimeter to check for voltage on the engine harness (EN) side : From X-9010 pin 1 X-9010 pin 5

To chassis ground chassis ground

Result There should be no voltage. There should be no voltage.

A. If there is voltage on either or both tests, leave connector X-9121 and connector X-9010 disconnected and continue with Step 3. B. If there is no voltage on either of the checks, leave connector X-9121 and connector X-9010 disconnected and continue with Step 4. 3. Locate the short to voltage source condition. Carefully disconnect the vehicle harness (VE) from the engine interface connector X-9138. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle harness (VE) side : From X-9138 pin 29 X-9138 pin 30

To chassis ground chassis ground

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Result There should be no voltage. There should be no voltage.

Electrical systems - FAULT CODES

A. If there is no voltage on either of the checks, the short to a voltage source condition is in the engine harness (EN) between connector X-9010 pin 1 or X-9010 pin 5 and connector X-9138 pin 29 or X-9138 pin 30. Locate and repair the damaged conductors. B. If there is voltage on either or both tests, the short to a voltage source condition is in the vehicle harness (VE) between connector X-9121 pin A50 or X-9121 pin A35 and connector X-9138 pin 29 or X-9138 pin 30. Use the appropriate service manual, if necessary, to locate and repair the damaged conductors. 4. Check the EGR valve Z-9000 motor actuator control circuit for a short to another circuit condition. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9121 pin A50 X-9121 pin A35

To Result to all other pins in connector X-9121 There should be no continuity. to all other pins in connector X-9121 There should be no continuity.

A. If there is continuity on any of the tests, there is a short to another circuit condition in the vehicle harness (VE) between connector X-9121 pin A50 and/or X-9121 pin A35, and another circuit. Use the appropriate service manual, if necessary, to locate and repair the damaged conductors. B. If there is no continuity on any of the checks, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3670-EGR valve control circuit low side shorted to battery WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

To chassis ground chassis ground

Result There should be no voltage. There should be no voltage.

To chassis ground chassis ground

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Result There should be no voltage. There should be no voltage.

Electrical systems - FAULT CODES

To Result to all other pins in connector X-9121 There should be no continuity. to all other pins in connector X-9121 There should be no continuity.

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3671-EGR valve control circuit high side shorted to ground WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Exhaust Gas Recirculation (EGR) valve Z-9000 is replaced, it is necessary to perform the Replacement of the Exhaust Gas Recirculation Valve (EGR) – Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU data (EGR valve) (10.501), if necessary. Context: The Engine Control Unit (ECU) A-9000 internally monitors the operation of the H-bridge Pulse Width Modulated (PWM) control circuit for the Exhaust Gas Recirculation (EGR) valve Z-9000 actuator for electrical defects. If the ECU A-9000 detects a short circuit of the circuit wiring to chassis ground, this fault will occur. For information regarding the functional operation of the EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Overview (10.501). For more information regarding the technical specifications of the EGR valve Z-9000, service manual Exhaust Gas Recirculation (EGR) valve actuator - Technical Data (55.989). Cause: The ECU A-9000 is sensing a short to chassis ground condition in the EGR valve Z-9000 motor actuator control circuit. Possible failure modes: 1. Faulty EGR valve Z-9000 motor, failed internally. 2. Faulty EGR valve Z-9000 circuit wiring, short to ground. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check the EGR valve Z-9000 motor actuator for a short to ground condition. Disconnect the engine harness (EN) from the EGR valve Z-9000 at connector X-9010. Use a multimeter to check on the component for a grounded condition : From X-9010 pin 1

To chassis ground

Result There should be no continuity.

A. If there is no continuity, leave connector X-9010 disconnected and continue with Step 3. B. If there is continuity, the EGR valve Z-9000 motor has failed internally, replace the EGR valve Z-9000. Then use the EST, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU data (EGR valve) (10.501) if necessary, to perform the Replacement of the Exhaust Gas Recirculation Valve (EGR) – Reset ECU Data. 3. Check the EGR valve Z-9000 motor actuator control circuit for a short to ground condition. With the key switch in the OFF position, use a multimeter to check for continuity on the engine harness (EN) side : From X-9010 pin 1

To chassis ground

A. If there is continuity, continue with Step 4. 47683911 27/02/2015

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Result There should be no continuity.

Electrical systems - FAULT CODES

B. If there is no continuity, continue with Step 5. 4. Locate the short to ground condition. Carefully disconnect the vehicle harness (VE) from the engine interface connector X-9138. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9138 pin 29

To chassis ground

Result There should be no continuity.

A. If there is continuity, leave connector X-9138 disconnected and continue with Step 5. B. If there is no continuity, the short to a ground condition is in the engine harness (EN) between connector X-9010 pin 1 and connector X-9138 pin 29, wire EN-9095. Locate and repair the grounded conductor. 5. Locate the short to ground condition. Carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9121 pin A50

To chassis ground

Result There should be no continuity.

A. If there is continuity, the short to chassis ground condition is in the vehicle harness (VE) between connector X-9121 pin A50 and connector X-9138 pin 29, wire VE-9095. Use the appropriate service manual, if necessary, to locate and repair the grounded conductor. B. If there is no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3672-EGR valve control circuit low side shorted to ground WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Exhaust Gas Recirculation (EGR) valve Z-9000 is replaced, it is necessary to perform the Replacement of the Exhaust Gas Recirculation Valve (EGR) – Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU data (EGR valve) (10.501), if necessary. Context: The Engine Control Unit (ECU) A-9000 internally monitors the operation of the H-bridge Pulse Width Modulated (PWM) control circuit for the Exhaust Gas Recirculation (EGR) valve Z-9000 actuator for electrical defects. If the ECU A-9000 detects a short circuit of the circuit wiring to chassis ground, this fault will occur. For information regarding the functional operation of the EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Overview (10.501). For more information regarding the technical specifications of the EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve actuator - Technical Data (55.989). Cause: The ECU A-9000 is sensing a short to chassis ground condition in the EGR valve Z-9000 motor actuator control circuit. Possible failure modes: 1. Faulty EGR valve Z-9000 motor, failed internally. 2. Faulty EGR valve Z-9000 circuit wiring, shorted to chassis ground. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check the EGR valve Z-9000 motor actuator for a short to ground condition. Disconnect the engine harness (EN) from the EGR valve Z-9000 at connector X-9010. Use a multimeter to check on the component for a grounded condition : From X-9010 pin 5

To chassis ground

Result There should be no continuity.

A. If there is no continuity, leave connector X-9010 disconnected and continue with Step 3. B. If there is continuity, the EGR valve Z-9000 motor has failed internally, replace the EGR valve Z-9000. Then use the EST, refer to th eengine service manual Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU data (EGR valve) (10.501) if necessary, to perform the Replacement of the Exhaust Gas Recirculation Valve (EGR) – Reset ECU Data. 3. Check the EGR valve Z-9000 motor actuator control circuit for a short to ground condition. With the key switch in the OFF position, use a multimeter to check for continuity on the engine harness (EN) side : From X-9010 pin 5

To chassis ground

A. If there is continuity, continue with Step 4. 47683911 27/02/2015

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Result There should be no continuity.

Electrical systems - FAULT CODES

To chassis ground

Result There should be no continuity.

A. If there is continuity, leave connector X-9138 disconnected and continue with Step 5. B. If there is no continuity, the short to a ground condition is in the engine harness (EN) between connector X-9010 pin 5 and connector X-9138 pin 30, wire EN-9096. Locate and repair the grounded conductor. 5. Locate the short to ground condition. Carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9121 pin A35

To chassis ground

Result There should be no continuity.

A. If there is continuity, the short to chassis ground condition is in the vehicle harness (VE) between connector X-9121 pin A35 and connector X-9138 pin 30, wire VE-9096. Use the appropriate service manual, if necessary, to locate and repair the grounded conductor. B. If there is no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3673-EGR valve control circuit over load WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Exhaust Gas Recirculation (EGR) valve Z-9000 is replaced, it is necessary to perform the Replacement of the Exhaust Gas Recirculation Valve (EGR) – Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU data (EGR valve) (10.501), if necessary. Context: The Engine Control Unit (ECU) A-9000 internally monitors the operation of the H-bridge Pulse Width Modulated (PWM) control circuit for the Exhaust Gas Recirculation (EGR) valve Z-9000 actuator for electrical defects. If the ECU A-9000 detects a short circuit of the circuit wiring to an external source or to chassis ground, this fault will occur. For information regarding the functional operation of the EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Overview (10.501). For more information regarding the technical specifications of the EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve actuator Technical Data (55.989). Cause: The ECU A-9000 is sensing a short to a voltage source or a short to chassis ground condition in the EGR valve Z-9000 motor actuator control circuit. Possible failure modes: 1. Faulty EGR valve Z-9000 motor, failed internally. 2. Faulty EGR valve Z-9000 motor actuator circuit wiring, grounded or shorted to voltage source. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 9. 2. Check the EGR valve Z-9000 motor for a shorted or grounded condition. Disconnect the engine harness (EN) from the EGR valve Z-9000 at connector X-9010. Use a multimeter to perform the following resistance and continuity checks on the component side of connector X-9010 : From X-9010 pin 1 X-9010 pin 1 X-9010 pin 5

To X-9010 pin 5 chassis ground chassis ground

Result There should be between 1.7 - 3.2 Ω There should be no continuity. There should be no continuity.

A. If the specified values are measured, leave connector X-9010 disconnected and continue with Step 3. B. If the specified values are not measured, the EGR valve Z-9000 motor has failed internally, replace the EGR valve Z-9000. Then use the EST, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU data (EGR valve) (10.501) if necessary, to perform the Replacement of the Exhaust Gas Recirculation Valve (EGR) – Reset ECU Data. 3. Check the EGR valve Z-9000 motor actuator control circuit for a short to ground condition. With the key switch in the OFF position, use a multimeter to check for continuity on the engine harness (EN) side : 47683911 27/02/2015

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From X-9010 pin 1 X-9010 pin 5

To chassis ground chassis ground

Result There should be no continuity. There should be no continuity.

A. If there is continuity on either check, continue with Step 4. B. If there is no continuity on both checks, leave connector X-9010 disconnected and continue with Step 6. 4. Locate the short to ground condition. Carefully disconnect the vehicle harness (VE) from the engine interface connector X-9138. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9138 pin 29 X-9138 pin 30

To chassis ground chassis ground

Result There should be no continuity. There should be no continuity.

A. If there is continuity on either check, leave connector X-9138 disconnected and continue with Step 5. B. If there is no continuity on both checks, the short to a ground condition is in the engine harness (EN) between connector X-9010 pin 1 or X-9010 pin 5 and connector X-9138 pin 29 or X-9138 pin 30, wire EN-9095 or EN-9096. Locate and repair the grounded conductor. 5. Locate the short to ground condition. Carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9121 pin A50 X-9121 pin A35

To chassis ground chassis ground

Result There should be no continuity. There should be no continuity.

A. If there is continuity on either check, the short to chassis ground condition is in the vehicle harness (VE) between connector X-9121 pin A50 or X-9121 pin A35 and connector X-9138 pin 29 or X-9138 pin 30, wire VE-9095 or VE-9096. Use the appropriate service manual, if necessary, to locate and repair the grounded conductor. B. If there is no continuity on both checks, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Check the EGR valve Z-9000 motor actuator control circuit for a short to a voltage source condition. Carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key switch in the ON position, use a multimeter to check for voltage on the engine harness (EN) side : From X-9010 pin 1 X-9010 pin 5

To chassis ground chassis ground

Result There should be no voltage. There should be no voltage.

A. If there is voltage on either or both tests, leave connectors X-9010 and X-9121 disconnected and continue with Step 7. B. If there is no voltage on either of the checks, leave connectors X-9010 and X-9121 disconnected and continue with Step 8. 7. Locate the short to a voltage source condition. Carefully disconnect the vehicle harness (VE) from the engine interface connector X-9138. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle harness (VE) side :

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From X-9138 pin 29 X-9138 pin 30

To chassis ground chassis ground

Result There should be no voltage. There should be no voltage.

A. If there is no voltage on either of the checks, the short to a voltage source condition is in the engine harness (EN) between connector X-9010 pin 1 or X-9010 pin 5 and connector X-9138 pin 29 or X-9138 pin 30, wire EN-9095 or EN-9096. Locate and repair the damaged conductors. B. If there is voltage on either or both of the checks, the short to a voltage source condition is in the vehicle harness (VE) between connector X-9138 pin 29 and/or X-9138 pin 30 and connector X-9121 pin A50 and/or connector X-9121 pin A35, wire VE-9095 or VE-9096. Use the appropriate service manual, if necessary, to locate and repair the damaged conductors. 8. Check the EGR valve Z-9000 motor actuator control circuit for a short to another circuit condition. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9121 pin A50 X-9121 pin A35

To Result to all other pins in connector X-9121 There should be no continuity. to all other pins in connector X-9121 There should be no continuity.

A. If there is continuity on any of the tests, there is a short to another circuit condition in the vehicle harness (VE) between connector X-9121 pin A50 and/or X-9121 pin A35, wire VE-9095 and/or VE-9096, and another circuit. Use the appropriate service manual, if necessary, to locate and repair the damaged conductors. B. If there is no continuity on any of the checks, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 9. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3674-EGR valve control circuit supply voltage too low WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 internally monitors the operation of the H-bridge Pulse Width Modulated (PWM) control circuit for the Exhaust Gas Recirculation (EGR) valve Z-9000 motor actuator for electrical defects. If the ECU A-9000 senses too low an output driver supply voltage, this fault will occur. For information regarding the functional operation of the EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve Overview (10.501). For more information regarding the technical specifications of the EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve actuator - Technical Data (55.989). Cause: The ECU A-9000 is sensing too high a system voltage fluctuation. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continues with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 4. 2. Check for related faults. Use the EST to check for faults relative to low battery or control system voltage level. A. If low voltage level faults are present, resolve those faults. Then determine if this fault has also been resolved. B. If no low voltage level faults are present, continue with Step 3. 3. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation.

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3675-EGR valve is blocked in closed position C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: For information regarding the functional operation of the EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Overview (10.501). For more information regarding the technical specifications of the EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve actuator - Technical Data (55.989).

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3676-EGR valve position sensor voltage is higher than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Exhaust Gas Recirculation (EGR) valve Z-9000 is replaced, it is necessary to perform the Replacement of the Exhaust Gas Recirculation Valve (EGR) – Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU data (EGR valve) (10.501), if necessary. Context: The Engine Control Unit (ECU) A-9000 monitors the electrical signal provided by the Exhaust Gas Recirculation (EGR) valve Z-9000 position feedback potentiometer. If the signal level becomes greater than 4.86 V the ECU A-9000 provides a replacement value and this fault will occur. For information regarding the functional operation of the EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Overview (10.501). For more information regarding the technical specifications of the EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve actuator - Technical Data (55.989). Cause: The ECU A-9000 is sensing the EGR valve Z-9000 position signal is greater than 4.86 V. Possible failure modes: 1. Faulty EGR valve Z-9000, failed internally. 2. Faulty EGR valve Z-9000 position sensor circuit wiring, shorted to a high source. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check the EGR valve Z-9000 potentiometer signal circuit for a short to voltage source condition. Disconnect the engine harness (EN) from the EGR valve Z-9000 at connector X-9010. With the key switch in the ON position, use a multimeter to check for voltage on the engine harness (EN) side : From X-9010 pin 2

To chassis ground

Result There should be less than 4.86 V.

A. If there is greater than 4.86 V, leave connector X-9010 disconnected and continue with Step 3. B. If there is less than 4.86 V, leave connector X-9010 disconnected and continue with Step 5. 3. Locate the short to voltage source condition. Carefully disconnect the vehicle harness (VE) from the engine interface connector X-9138. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle harness (VE) side : From X-9138 pin 34

To chassis ground

Result There should be less than 4.86 V.

A. If there is less than 4.86 V, the short to a voltage source condition is in the engine harness (EN) between connector X-9010 pin 2 and connector X-9138 pin 34. Locate and repair the damaged conductors.

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B. If there is greater than 4.86 V, leave connector X-9138 disconnected and continue with Step 4. 4. Locate the short to voltage source condition. Carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle harness (VE) side : From X-9121 pin A39

To chassis ground

Result There should be no voltage.

A. If there is voltage, there is a short to a voltage source condition in the vehicle harness (VE) between connector X-9121 pin A39 and connector X-9138 pin 34. Use the appropriate service manual, if necessary, to locate and repair the damaged conductors. B. If there is no voltage, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Replace the EGR valve Z-9000. Then use the EST, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Configure Reset ECU data (EGR valve) (10.501) if necessary, to perform the Replacement of the Exhaust Gas Recirculation Valve (EGR) – Reset ECU Data. Then check to see that the fault is resolved. A. If the fault is resolved, return the vehicle to operation. B. If the fault is not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3677-EGR valve position sensor voltage is lower than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Exhaust Gas Recirculation (EGR) valve Z-9000 is replaced, it is necessary to perform the Replacement of the Exhaust Gas Recirculation Valve (EGR) – Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU data (EGR valve) (10.501), if necessary. Context: The Engine Control Unit (ECU) A-9000 monitors the electrical signal provided by the Exhaust Gas Recirculation (EGR) valve Z-9000 position feedback potentiometer. If the signal level becomes less than 0.225 V the ECU A-9000 provides a replacement value and this fault will occur. For information regarding the functional operation of the EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Overview (10.501). For more information regarding the technical specifications of the EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve actuator - Technical Data (55.989). Cause: The ECU A-9000 is sensing the EGR valve Z-9000 position signal is less than 0.225 V. Possible failure modes: 1. Faulty EGR valve Z-9000, failed internally. 2. Faulty EGR valve Z-9000 position sensor circuit wiring, shorted to ground. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check the EGR valve Z-9000 potentiometer for a short to ground condition. Disconnect the engine harness (EN) from the EGR valve Z-9000 at connector X-9010. Use a multimeter to check for continuity on the EGR valve Z-9000 potentiometer side : From X-9010 pin 2 X-9010 pin 2

To chassis ground X-9010 pin 4

Result There should be no continuity. There should be no continuity.

A. If there is continuity, the EGR valve Z-9000 has failed internally, replace the EGR valve Z-9000. Then use the EST, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU data (EGR valve) (10.501) if necessary, to perform the Replacement of the Exhaust Gas Recirculation Valve (EGR) – Reset ECU Data. B. If there is no continuity, leave connector X-9010 disconnected and continue with Step 3. 3. Check the EGR valve Z-9000 potentiometer signal circuit for a short to ground condition. With the key switch in the OFF position, use a multimeter to check for continuity on the engine harness (EN) side : From X-9010 pin 2

To chassis ground

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Result There should be no continuity.

Electrical systems - FAULT CODES

A. If there is continuity, leave connector X-9010 disconnected and continue with Step 4. B. If there is no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Locate the short to ground condition. Carefully disconnect the vehicle harness (VE) from the engine interface connector X-9138. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9138 pin 34

To chassis ground

Result There should be no continuity.

A. If there is no continuity, the short to ground condition is in the engine harness (EN) between connector X-9010 pin 2 and connector X-9138 pin 34. Locate and repair the damage to the conductor. B. If there is continuity, leave connector X-9138 disconnected and continue with Step 5. 5. Locate the short to ground condition. Carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9121 pin A39

To chassis ground

Result There should be no continuity.

A. If there is continuity, there is a short to ground condition in the vehicle harness (VE) between connector X-9121 pin A39 and connector X-9138 pin 34. Use the appropriate service manual, if necessary, to locate and repair the damage to the conductor. B. If there is no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3680-Engine speed limitation via fuel injection cut off is active C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 will perform an injection cut-off to limit the engine speed to a controllable range, if needed. Implausible signals from certain parameters such as accelerator pedal signal, fuel injection parameters or engine speed can cause an injection cut-off. If torque or injection quantity are not plausible and engine speed is greater than 1200 RPM, this fault will occur. Other active faults may have caused this fault to occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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3684-Exhaust manifold temperature too high C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors the exhaust manifold temperature sensor B-9018. If the ECU A-9000 detects an exhaust manifold temperature greater than 950 °C (1742 °F), this fault will occur. For more information regarding the exhaust manifold temperature sensor B-9018, refer to the engine service manual Exhaust manifold temperature sensor - Overview (55.014). For more information regarding the technical specifications of the exhaust manifold temperature sensor B-9018, refer to the engine service manual Exhaust manifold temperature sensor Technical Data (55.014). Cause: The ECU A-9000 has detected a temperature greater than 950 °C (1742 °F) from the exhaust manifold temperature sensor B-9018. Possible failure modes: 1. Faulty exhaust manifold temperature sensor B-9018, drifted signal. 2. Faulty ECU A-9000, software.

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3688-Water in fuel sensor or sensor circuit failure WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: This fault code is for the Water in Fuel switch with black connector housing. Context: The water in fuel switch provides a diagnostic self-test signal (less than 3.9 V for 2.5 s +/- 20%) at key-ON. If the Engine Control Unit (ECU) does not sense the diagnostic self-test signal, this fault will occur and there will be no monitoring of water content in the fuel supply. Cause: The ECU has not received an acceptable water in fuel switch S-9102 self-test signal. Possible failure modes: 1. Faulty water in fuel switch circuit wiring, damaged. 2. Faulty water in fuel switch, internal failure. 3. Faulty ECU, software. Solution: 1. Verify this fault code is still present and in an active state. Use the Easy Engine software provided on the Electronic Service Tool (EST) to check the fault status. A. If the fault is still present and active, continue with step 2. B. If the fault is no longer present or is in an inactive state, continue with step 7. 2. Use the EST to check the status of the related fault 3146 - Water detected in fuel - Shorted to high source. A. If fault 3146 - Water detected in fuel - Shorted to high source is active, resolve fault 3146 - Water detected in fuel - Shorted to high source, then return to this fault, 3688 - Water in fuel sensor or sensor circuit failure. B. If fault 3146 - Water detected in fuel - Shorted to high source is not active, continue with step 3. 3. Check the water in fuel switch for the initial self-test voltage pulse. Carefully back probe the water in fuel switch at connector X-011. With the help of an assistant, use a multimeter to perform the following test at Key-ON: From

Value There should be less than 3.9 V for 2.5 s +/- 20%. NOTE: The signal line should switch to battery voltage after the self-test period. X-011 pin 1

Chassis ground

A. If the self-test is successful, continue with step 4. B. If the self-test is not successful, the water in fuel switch has failed internally. Replace the switch and retest. 4. Check for open, short and grounded circuit conditions in the water in fuel switch circuit. Disconnect the water in fuel switch at connector X-011. Disconnect the ECU connector X-012. With the key switch in the OFF position, use a multimeter to perform the following test :

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From X-011 pin 1 X-011 pin 2 X-011 pin 3

Value There should be continuity. There should be continuity. There should be continuity.

Value There should be no continuity. There should be no continuity. There should be no continuity.

Value There should be no continuity. There should be no continuity.

X-012 pin 30 Chassis ground X-012 pin 54

Then use the multimeter to perform the following test : From X-011 pin 1 X-011 pin 1 X-011 pin 2

X-011 pin 2 X-011 pin 3 X-011 pin 3

Then use the multimeter to perform the following test : From X-011 pin 1 X-011 pin 3

Chassis ground Chassis ground

A. If the results are not as expected for any of the wiring tests listed above, there is an open, short or grounded circuit condition in the wiring. Repair or replace the harness as required. B. If the results are as expected in all of the wiring tests listed above, then the wiring is okay. Leave connectors X-012 and X-011 disconnected and continue with step 5. 5. Check for key switch voltage supply to the water in fuel switch. With the key switch in an ON position, use a multimeter to perform the following test : From X-011 pin 3 X-011 pin 1

To Chassis ground Chassis ground

Value There should be key switch voltage. There should be no key switch voltage.

A. If there is key switch voltage present in the first check and not present in the second check, continue with step 6. B. If key switch voltage is not present in the first check or present in the second check, then there is a problem in the wiring harness. Repair or replace the harness as required. 6. Replace the water in fuel switch, then check to see if this fault has been resolved. A. If the fault is resolved, return the machine to service. B. If the fault is not resolved, check the ECU for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3689-Glow Control Unit (GCU) data error WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: For information regarding the functional operation of the glow plug control module Z-9101, refer to the engine service manual Glow plug system Glow plug control module - Overview - Glow plug control module (55.202). The Engine Control Unit (ECU) A-9000 requests operation of the glow plug control module Z-9101 via a Pulse Width Modulated (PWM) control circuit and monitors the status of possible electrical defects via a diagnostic feedback signal from the glow plug control module Z-9101. If the ECU A-9000 determines the diagnostic data transmission is faulty, this fault will occur. Cause: The glow plug control module Z-9101 diagnostic connection with the ECU A-9000 is damaged or the data protocol is incorrect. Possible failure modes: 1. Faulty glow plug control module Z-9101 diagnostic circuit wiring, open, shorted or grounded circuit. 2. Faulty glow plug control module Z-9101, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 4. 2. Check for damaged diagnostic circuit wiring. Carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9122 pin K22 X-9122 pin K22

To chassis ground all other pins in connector X-9122

Result There should be no continuity. There should be no continuity.

Carefully disconnect the vehicle harness (VE) from the glow plug control module Z-9101 at connector X-9113. Place a jumper wire between connector X-9113 pin 3 and chassis ground. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9122 pin K22

To chassis ground

Result There should be continuity.

A. If there is continuity from connector X-9122 pin K22 to ground or any other pin in connector X-9122 or there is no continuity from X-9122 pin K22 to connector X-9113 pin 3, there is a short to ground or another circuit or an open circuit condition is in the vehicle harness (VE) between connector X-9113 pin 3 and connector X-9122 pin K22, wire VE-9073. Use the appropriate service manual, if necessary, to locate and repair the damage in the circuit. B. If there is no continuity from connector X-9122 pin K22 to ground or any other pin in connector X-9122 and there is continuity from X-9122 pin K22 to connector X-9113 pin 3, continue with Step 3.

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3. Replace the glow plug control module Z-9101, then use EST to check to see that this fault has been resolved. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3691-Glow plug control circuits open WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: For information regarding the functional operation of the glow plug control module Z-9101, refer to the engine service manual Glow plug system Glow plug control module - Overview - Glow plug control module (55.202). The Engine Control Unit (ECU) A-9000 requests operation of the glow plug control module Z-9101 via a Pulse Width Modulated (PWM) control circuit and monitors the status of possible electrical defects via a diagnostic feedback signal from the glow plug control module Z-9101. If the ECU A-9000 is notified of an open circuit condition in one or more of the glow plugs or glow plug circuits, this fault will occur. Cause: The glow plug control module Z-9101 has communicated to the ECU A-9000, via a diagnostic connection, that an open circuit condition exists in one or more of the glow plugs or glow plug circuits. Possible failure modes: 1. Faulty glow plug, internal failure. 2. Faulty glow plug control circuit wiring, open circuit. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check each of the glow plugs for an open circuit condition. Disconnect the engine harness (EN) from each of the glow plugs. Use a multimeter to check on the component for an open circuit condition : From X-9034 X-9035 X-9036 X-9037

pin pin pin pin

1 1 1 1

To chassis chassis chassis chassis

ground ground ground ground

Result There should be 0.2 - 5.0 Ω. There should be 0.2 - 5.0 Ω. There should be 0.2 - 5.0 Ω. There should be 0.2 - 5.0 Ω.

A. If there is a nominal amount of resistance measured on each of the glow plugs, leave all of the glow plugs disconnected and continue with Step 3. B. If there is infinite resistance measured on any of the glow plugs, that glow plug has failed internally, replace the faulted glow plug. 3. Check the glow plug control circuits for an open circuit condition. Carefully disconnect the vehicle harness (VE) from the engine interface connector X-9138. With the key switch in the OFF position, place a jumper wire from each of the glow plug connectors to chassis ground. Use a multimeter to check for continuity on the engine harness (EN) side :

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From X-9138 X-9138 X-9138 X-9138

pin pin pin pin

61 60 58 57

To chassis chassis chassis chassis

ground ground ground ground

Result There should be continuity. There should be continuity. There should be continuity. There should be continuity.

A. If there is continuity on all of the checks, leave the jumper wires in place, reconnect connector X-9138 and continue with Step 4. B. If there is no continuity on one or more of the checks, there is an open circuit condition in the engine (EN) harness between the engine interface connector X-9138 and the respective glow plug. Locate and repair the broken conductor. 4. Locate the open circuit condition. Carefully disconnect the vehicle harness (VE) from the glow plug control module Z-9101 at connector X-9113. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9113 X-9113 X-9113 X-9113

pin pin pin pin

2 7 1 6

To chassis chassis chassis chassis

ground ground ground ground

Result There should be continuity. There should be continuity. There should be continuity. There should be continuity.

A. If there is no continuity on one or more of the checks, the open circuit condition is in the vehicle harness (VE) between connector X-9113 pin 2 and connector X-9138 pin 61 and/or connector X-9113 pin 7 and connector X-9138 pin 60 and/or connector X-9113 pin 1 and X-9138 pin 58 and/or connector X-9113 pin 6 and connector X-9138 pin 57, wire VE-9058, VE-9059, VE-9060 and/or VE-9061. Use the appropriate service manual, if necessary, to locate and repair the broken conductor. B. If there is continuity on all of the checks, continue with Step 5. 5. Replace the glow plug control module Z-9101, then use EST to check to see that this fault has been resolved. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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Electrical systems - FAULT CODES

3692-Glow plug control circuits shorted WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: For information regarding the functional operation of the glow plug control module Z-9101, refer to the engine service manual Glow plug system Glow plug control module - Overview - Glow plug control module (55.202). The Engine Control Unit (ECU) A-9000 requests operation of the glow plug control module Z-9101 via a Pulse Width Modulated (PWM) control circuit and monitors the status of possible electrical defects via a diagnostic feedback signal from the glow plug control module Z-9101. If the ECU A-9000 is notified of a short circuit to ground, over current, condition in one or more of the glow plugs or glow plug circuits, this fault will occur. Cause: The glow plug control module Z-9101 has communicated to the ECU A-9000, via a diagnostic connection, that a short to ground circuit condition exists in one or more of the glow plugs or glow plug circuits. Possible failure modes: 1. Faulty glow plug, internal failure. 2. Faulty glow plug control circuit wiring, open circuit. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check each of the glow plugs for a short circuit condition. Disconnect the engine harness (EN) from each of the glow plugs. Use a multimeter to check on the component for a short to ground circuit condition : From X-9034 X-9035 X-9036 X-9037

pin pin pin pin

1 1 1 1

To chassis chassis chassis chassis

ground ground ground ground

Result There should be 0.2 - 5.0 Ω. There should be 0.2 - 5.0 Ω. There should be 0.2 - 5.0 Ω. There should be 0.2 - 5.0 Ω.

A. If there is a nominal amount of resistance measured on each of the glow plugs, leave all of the glow plugs disconnected and continue with Step 3. B. If there is less than 0.2 Ω resistance measured on any of the glow plugs, that glow plug has failed internally, replace the faulted glow plug. 3. Check the glow plug control circuits in the engine harness (EN) for a short to ground circuit condition. Carefully disconnect the vehicle harness (VE) from the engine interface connector X-9138. With the key switch in the OFF position, use a multimeter to check for continuity on the engine harness (EN) side : From X-9138 pin 61 X-9138 pin 60 X-9138 pin 58

To chassis ground chassis ground chassis ground 47683911 27/02/2015

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Result There should be no continuity. There should be no continuity. There should be no continuity.

Electrical systems - FAULT CODES

From X-9138 pin 57

To chassis ground

Result There should be no continuity.

A. If there is no continuity on all of the checks, leave connector X-9138 disconnected and continue with Step 4. B. If there is continuity on one or more of the checks, there is a short to ground circuit condition in the engine (EN) harness between the engine interface connector X-9138 and the respective glow plug. Locate and repair the damaged conductor. 4. Check the glow plug control circuits in the vehicle harness (VE) for a short to ground circuit condition. Carefully disconnect the vehicle harness (VE) from the glow plug control module Z-9101 at connector X-9113. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9113 X-9113 X-9113 X-9113

pin pin pin pin

2 7 1 6

To chassis chassis chassis chassis

ground ground ground ground

Result There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is continuity on one or more of the checks, there is a short circuit to ground condition in the vehicle harness (VE) between connector X-9113 pin 2 and connector X-9138 pin 61 and/or connector X-9113 pin 7 and connector X-9138 pin 60 and/or connector X-9113 pin 1 and X-9138 pin 58 and/or connector X-9113 pin 6 and connector X-9138 pin 57, wire VE-9058, VE-9059, VE-9060 and/or VE-9061. Use the appropriate service manual, if necessary, to locate and repair the grounded conductor. B. If there is no continuity on all of the checks, continue with Step 5. 5. Replace the glow plug control module Z-9101, then use EST to check to see that this fault has been resolved. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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Electrical systems - FAULT CODES

3693-Glow plug control circuits shorted to battery WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: For information regarding the functional operation of the glow plug control module Z-9101, refer to the engine service manual Glow plug system Glow plug control module - Overview - Glow plug control module (55.202). The Engine Control Unit (ECU) A-9000 requests operation of the glow plug control module Z-9101 via a Pulse Width Modulated (PWM) control circuit and monitors the status of possible electrical defects via a diagnostic feedback signal from the glow plug control module Z-9101. If the ECU A-9000 is notified of a short to a voltage source condition in one or more of the glow plug circuits, this fault will occur. Cause: The glow plug control module Z-9101 has communicated to the ECU A-9000, via a diagnostic connection, that a short circuit to a voltage source condition exists in one or more of the glow plug circuits. Possible failure modes: 1. Faulty glow plug control circuit wiring, shorted to a voltage source. 2. Faulty ECU A-9000, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check each of the glow plug circuits for a short to voltage source condition. Carefully disconnect the vehicle harness (VE) from the glow plug control module Z-9101 at connector X-9113. Disconnect the engine harness (EN) from each of the glow plugs. With the key switch in the ON position, use a multimeter to check for voltage on the engine harness (EN) side : From X-9034 X-9035 X-9036 X-9037

pin pin pin pin

1 1 1 1

To chassis chassis chassis chassis

ground ground ground ground

Result There should be no voltage. There should be no voltage. There should be no voltage. There should be no voltage.

A. If there is voltage measured on any of the checks, leave all of the connectors disconnected and continue with Step 3. B. If there is no voltage measured on any of the checks, continue with Step 4. 3. Locate the short to voltage source condition. Carefully disconnect the vehicle harness (VE) from the engine interface connector X-9138. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle harness (VE) side : From X-9138 pin 61 X-9138 pin 60 X-9138 pin 58

To chassis ground chassis ground chassis ground 47683911 27/02/2015

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Result There should be no voltage. There should be no voltage. There should be no voltage.

Electrical systems - FAULT CODES

From X-9138 pin 57

To chassis ground

Result There should be no voltage.

A. If there is no voltage on any of the checks, the short to voltage source condition is in the engine harness (EN) between connector X-9034 pin 1 and connector X-9138 pin 61 and/or connector X-9035 pin 1 and connector X-9138 pin 60 and/or connector X-9036 pin 1 and X-9138 pin 58 and/or connector X-9037 pin 1 and connector X-9138 pin 57, wire EN-9058, EN-9059, EN-9060 and/or EN-9061. Locate and repair the damaged conductors. B. If there is voltage on one or more of the checks, the short to a voltage source condition is in the vehicle harness (VE) between connector X-9113 pin 2 and connector X-9138 pin 61 and/or connector X-9113 pin 7 and connector X-9138 pin 60 and/or connector X-9113 pin 1 and X-9138 pin 58 and/or connector X-9113 pin 6 and connector X-9138 pin 57, wire VE-9058, VE-9059, VE-9060 and/or VE-9061. Use the appropriate service manual, if necessary, to locate and repair the damaged conductors. 4. Replace the glow plug control module Z-9101, then use EST to check to see that this fault has been resolved. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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Electrical systems - FAULT CODES

3694-Glow plug control circuits shorted to ground WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 requests operation of the glow plug control module Z-9101 via a Pulse Width Modulated (PWM) control circuit and monitors the status of possible electrical defects via a diagnostic feedback signal from the glow plug control module Z-9101. If the ECU A-9000 is notified of a short to ground condition in one or more of the glow plug circuits, this fault will occur. For information regarding the functional operation of the glow plug control module Z-9101 refer to the engine service manual, Glow plug system Glow plug control module - Overview Glow plug control module (55.202). Cause: The glow plug control module Z-9101 has communicated to the ECU A-9000, via a diagnostic connection, that a short to ground circuit condition exists in one or more of the glow plugs or glow plug circuits. Possible failure modes: 1. Faulty glow plug, internal failure. 2. Faulty glow plug control circuit wiring, shorted to ground. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check each of the glow plugs for a short circuit condition. Disconnect the engine harness (EN) from each of the glow plugs. Use a multimeter to check on the component for a short to ground circuit condition : From X-9034 X-9035 X-9036 X-9037

pin pin pin pin

1 1 1 1

To chassis chassis chassis chassis

ground ground ground ground

Result There should be 0.2 - 5.0 Ω. There should be 0.2 - 5.0 Ω. There should be 0.2 - 5.0 Ω. There should be 0.2 - 5.0 Ω.

To chassis ground chassis ground chassis ground 47683911 27/02/2015

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Result There should be no continuity. There should be no continuity. There should be no continuity.

Electrical systems - FAULT CODES

From X-9138 pin 57

To chassis ground

Result There should be no continuity.

A. If there is no continuity on all of the checks, leave connector X-9138 disconnected and continue with Step 4. B. If there is continuity on one or more of the checks, there is a short to ground circuit condition in the engine (EN) harness between the respective glow plug connector X-9034 pin 1 and the engine interface connector X-9138 pin 61 and/or connector X-9035 pin 1 and connector X-9138 pin 60 and/or connector X-9036 pin 1 and connector X-9138 pin 58 and/or connector X-9037 pin 1 and connector X-9138 pin 57, wire EN-9058 and/or EN-9059 and/or EN-9060 and/or EN-9061. Locate and repair the grounded conductor. 4. Check the glow plug control circuits in the vehicle harness (VE) for a short to ground circuit condition. Carefully disconnect the vehicle harness (VE) from the glow plug control module Z-9101 at connector X-9113. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9113 X-9113 X-9113 X-9113

pin pin pin pin

2 7 1 6

To chassis chassis chassis chassis

ground ground ground ground

Result There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

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Electrical systems - FAULT CODES

3699-ECU internal failure - EEPROM memory failure C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 calculates the correction values from the EEPROM. If the ECU A-9000 detects an error n the EEPROM block, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3703-The minimum rail pressure value necessary to allow fuel injection has not been reached WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Common rail Relief valve - Configure - Reset ECU data (10.218), if necessary. NOTE: If the rail pressure sensor B-9004 is replaced, it is necessary to perform the Replacement of the Rail Pressure sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Common rail pressure sensor - Configure - Reset ECU data (Rail pressure sensor) (55.010), if necessary. Context: The Engine Control Unit (ECU) A-9000 monitors fuel rail pressure. If the ECU A-9000 determines that fuel rail pressure is less than 130.0 bar (1885.0 psi) or below a limit value from an ECU A-9000 calculated curve, this fault will occur. Other active faults may have caused this fault to occur. For more information regarding fuel system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218). Cause: The ECU A-9000 has determined that fuel rail pressure is too low to continue engine operation. Possible failure modes: 1.

Faulty fuel metering unit Y-9000, stuck closed or internal failure.

Faulty high pressure pump, low efficiency.

Faulty charge gear pump, low efficiency.

Faulty fuel filters, clogged.

Faulty fuel lines, leakage or blockage.

Faulty electric fuel pump (if equipped).

Faulty fuel injectors, internal leakage or stuck open.

Faulty Pressure Relief Valve (PRV), leakage.

Faulty rail pressure sensor B-9004 drifted signal or leaking.

10. Faulty ECU A-9000, software.

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Electrical systems - FAULT CODES

3704-Missing adjustment value programming for injector in cylinder 2 C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 uses an IMA code to correct fuel trim for each fuel injector equipped with the engine at every key ON. If the ECU A-9000 determines that this trim correction for fuel injector number 2 Y-9002 can not be performed, this fault will occur. Cause: The ECU A-9000 has determined that the fuel injector number 2 Y-9002 fuel trim correction can not be performed. Solution: 1. Use the Electronic Service Tool (EST) ensure that the correct IMA code is programmed to fuel injector number 2 Y-9002. A. If the correct code is not programmed. Use the EST to program the correct code. B. If the correct code is programmed, continue to Step 2. NOTE: The IMA code may be under the paint on the fuel injector. NOTE: For more information regarding programming IMA codes, refer to the engine service manual Fuel injectors - Configure - IMA codes (10.218). 2. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3705-Missing adjustment value programming for injector in cylinder 3 C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 uses an IMA code to correct fuel trim for each fuel injector equipped with the engine at every key ON. If the ECU A-9000 determines that this trim correction for fuel injector number 3 Y-9003 can not be performed, this fault will occur. Cause: The ECU A-9000 has determined that the fuel injector number 3 Y-9003 fuel trim correction can not be performed. Solution: 1. Use the Electronic Service Tool (EST) ensure that the correct IMA code is programmed to fuel injector number 3 Y-9003. A. If the correct code is not programmed. Use the EST to program the correct code. B. If the correct code is programmed, continue to Step 2. NOTE: The IMA code may be under the paint on the fuel injector. NOTE: For more information regarding programming IMA codes, refer to the service manual Fuel injectors Configure - IMA codes (10.218). 2. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3706-Missing adjustment value programming for injector in cylinder 4 C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 uses an IMA code to correct fuel trim for each fuel injector equipped with the engine at every key ON. If the ECU A-9000 determines that this trim correction for fuel injector number 4 Y-9004 can not be performed, this fault will occur. For more information about how to configure injector IMA codes, refer to the engine service manual Fuel injectors - Configure - IMA codes (10.218). Cause: The ECU A-9000 has determined that the fuel injector number 4 Y-9004 fuel trim correction can not be performed. Solution: 1. Use the Electronic Service Tool (EST) ensure that the correct IMA code is programmed to fuel injector number 4 Y-9004. A. If the correct code is not programmed. Use the EST to program the correct code. B. If the correct code is programmed, continue to Step 2. NOTE: The IMA code may be under the paint on the fuel injector. 2. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3707-Lambda sensor nernst cell open circuit WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: For information regarding the functional operation of the Lambda sensor B-9123, refer to the engine service manual Lambda sensor - Overview (55.989). The Engine Control Unit (ECU) A-9000 has determined that the Lambda sensor B-9123 nernst signal is not present. The Lambda sensor B-9123 is the primary measurement device for ECU A-9000 fuel control, to determine if the engine is too rich or too lean. Cause: The ECU A-9000 is sensing an open circuit condition in the Lambda sensor B-9123 nernst signal circuit. Possible failure modes: 1. Faulty Lambda sensor B-9123 circuit wiring, open circuit. 2. Faulty Lambda sensor B-9123, failed internally. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 4. 2. Check the Lambda sensor B-9123 nernst signal circuit wiring for an open circuit condition. Disconnect the vehicle harness (VE) from the Lambda sensor B-9123 at connector X-9123. Carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122 and place a jumper wire between X-9122 pin K63 and chassis ground. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9123 pin 6

To chassis ground

Result There should be continuity.

A. If there is no continuity, there is an open circuit condition in the vehicle harness (VE) between connector X-9123 pin 6 and X-9122 pin K63, wire VE-9156. Use the appropriate vehicle service manual, if necessary, to locate and repair the broken conductor. B. If there is continuity, continue with Step 3. 3. Replace the Lambda sensor B-9123. Use EST to check to see that this fault has been resolved. A. If the fault has been resolved, return the machine to service. B. If this fault has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. 47683911 27/02/2015

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Electrical systems - FAULT CODES

Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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Electrical systems - FAULT CODES

3708-Lambda sensor pump current open circuit WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: The Engine Control Unit (ECU) A-9000 has determined that the Lambda sensor B-9123 pump current is not present. The Lambda sensor B-9123 is the primary measurement device for ECU A-9000 fuel control, to determine if the engine is too rich or too lean. For information regarding the functional operation of the Lambda sensor B-9123, refer to the engine service manual Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the lambda sensor B-9123, refer to the engine service manual Lambda sensor - Technical Data (55.989). Cause: The ECU A-9000 is sensing an open circuit condition in the Lambda sensor B-9123 pump current control circuit. Possible failure modes: 1. Faulty Lambda sensor B-9123 pump current control circuit wiring, open circuit. 2. Faulty Lambda sensor B-9123, failed internally. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 4. 2. Check the Lambda sensor B-9123 pump current control circuit wiring for an open circuit condition. Disconnect the vehicle harness (VE) from the Lambda sensor B-9123 at connector X-9123. Carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122 and place a jumper wire between X-9122 pin K64 and chassis ground. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9123 pin 1

To chassis ground

Result There should be continuity.

A. If there is no continuity, there is an open circuit condition in the vehicle harness (VE) between connector X-9123 pin 1 and X-9122 pin K64 , wire VE-9154. Use the appropriate vehicle service manual, if necessary, to locate and repair the broken conductor. B. If there is continuity, continue with Step 3. 3. Replace the Lambda sensor B-9123. Use the EST, refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989) if necessary, to perform the Replacement of the Lambda Sensor - Reset ECU Data. Use EST to check to see that this fault has been resolved. A. If the fault has been resolved, return the machine to service. 47683911 27/02/2015

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Electrical systems - FAULT CODES

B. If this fault has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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Electrical systems - FAULT CODES

3709-Lambda sensor virtual ground open circuit WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: For information regarding the functional operation of the Lambda sensor B-9123 refer to the engine service manual Lambda sensor - Overview (55.989). The Engine Control Unit (ECU) A-9000 has determined that the Lambda sensor B-9123 virtual ground circuit is open. The Lambda sensor B-9123 is the primary measurement device for ECU A-9000 fuel control, to determine if the engine is too rich or too lean. Cause: The ECU A-9000 is sensing an open circuit condition in the Lambda sensor B-9123 virtual ground circuit. Possible failure modes: 1. Faulty Lambda sensor B-9123 virtual ground circuit wiring, open circuit. 2. Faulty Lambda sensor B-9123, failed internally. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 4. 2. Check the Lambda sensor B-9123 virtual ground circuit wiring for an open circuit condition. Disconnect the vehicle harness (VE) from the Lambda sensor B-9123 at connector X-9123. Carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122 and place a jumper wire between X-9122 pin K85 and chassis ground. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9123 pin 2

To chassis ground

Result There should be continuity.

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4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3711-Lambda sensor heater power stage short circuit to battery WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: The Lambda sensor B-9123 has a heating element encased in ceramic that heats the sensor tip. Whenever the heater is operating, the heater low side driver power stage contained in the Engine Control Unit (ECU) A-9000 is monitored for a short circuit to battery condition. If a short circuit to a power source condition exists in the heater control circuit, this fault will occur. For information regarding the functional operation of the Lambda sensor B-9123, refer to the engine service manual Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the lambda sensor B-9123, refer to the engine service manual Lambda sensor - Technical Data (55.989). Cause: The Lambda sensor B-9123 low side driver heater control circuit is shorted to a voltage source. Possible failure modes: 1. Faulty Lambda sensor B-9123 heater control circuit wiring, shorted to a voltage source. 2. Faulty Lambda sensor B-9123, failed internally. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the Lambda sensor B-9123 heater control circuit wiring for a short to voltage source condition. Disconnect the vehicle harness (VE) from the Lambda sensor B-9123 at connector X-9123. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle harness (VE) side : From X-9123 pin 3

To chassis ground

Result There should be no voltage.

A. If there is voltage, leave connector X-9123 disconnected and continue with Step 3. B. If there is no voltage, continue with Step 4. 3. Locate the Lambda sensor B-9123 heater control circuit wiring short to voltage source condition. Carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9122 pin K07

To Result to all other pins in connector X-9122 There should be no continuity.

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B. If there is no continuity, the ECU A-9000 connector X-9122 is damaged or the ECU A-9000 has failed. Locate and repair the damage or replace the ECU A-9000. 4. Replace the Lambda sensor B-9123. Use the EST, refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989) if necessary, to perform the Replacement of the Lambda Sensor - Reset ECU Data. Use EST to check to see that this fault has been resolved. A. If the fault has been resolved, return the machine to service. B. If this fault has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3712-Lambda sensor heater power stage short circuit to ground WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: The Lambda sensor B-9123 has a heating element encased in ceramic that heats the sensor tip. Whenever the heater is operating, the heater low side driver power stage contained in the Engine Control Unit (ECU) A-9000 is monitored for a short circuit to ground condition. If a short to ground condition exists in the heater control circuit, this fault will occur. For information regarding the functional operation of the Lambda sensor B-9123, refer to the engine service manual Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the lambda sensor B-9123, refer to the engine service manual Lambda sensor - Technical Data (55.989). Cause: The Lambda sensor B-9123 low side driver heater control circuit is shorted to ground. Possible failure modes: 1. Faulty Lambda sensor B-9123 heater control circuit wiring, shorted to ground. 2. Faulty Lambda sensor B-9123, failed internally. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the Lambda sensor B-9123 heater control circuit wiring for a short to ground condition. Disconnect the vehicle harness (VE) from the Lambda sensor B-9123 at connector X-9123. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9123 pin 3

To chassis ground

Result There should be no continuity.

A. If there is continuity, continue with Step 3. B. If there is no continuity, continue with Step 4. 3. Locate the Lambda sensor B-9123 heater control circuit wiring short to ground condition. Carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9122 pin K07

To chassis ground

Result There should be no continuity.

A. If there is continuity, there is a short to ground condition in the vehicle harness (VE) between connector X-9123 pin 3 and X-9122 pin K07, wire VE-9200. Use the appropriate vehicle service manual, if necessary, to locate and repair the grounded conductor.

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3713-Lambda sensor heater power stage open circuit WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: The Lambda sensor B-9123 has a heating element encased in ceramic that heats the sensor tip. Whenever the heater is operating, the heater low side driver power stage contained in the Engine Control Unit (ECU) A-9000 is monitored for an open circuit condition. If an open circuit condition exists in the heater control circuit, this fault will occur. For information regarding the functional operation of the Lambda sensor B-9123, refer to the engine service manual Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the lambda sensor B-9123, refer to the engine service manual Lambda sensor - Technical Data (55.989). Cause: The Lambda sensor B-9123 low side driver heater control circuit is open. Possible failure modes: 1. Faulty Lambda sensor B-9123 heater control circuit wiring, open circuit. 2. Faulty Lambda sensor B-9123, failed internally. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 4. 2. Check the Lambda sensor B-9123 heater circuit wiring for an open circuit condition. Disconnect the vehicle harness (VE) from the Lambda sensor B-9123 at connector X-9123. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle harness (VE) side : From X-9123 pin 4

To chassis ground

Result There should be approximately 12.0 V.

Carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122 and place a jumper wire between X-9122 pin K07 and chassis ground. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9123 pin 3

To chassis ground

Result There should be continuity.

A. If there is no voltage or no continuity, there is an open circuit condition in the vehicle harness (VE) between connector X-9123 pin 4 and the vehicle switched battery source, wire VE-9081 or between connector X-9123 pin 3 and X-9122 pin K07, wire VE-9200. Use the appropriate vehicle service manual, if necessary, to locate and repair the broken conductor. B. If there is voltage and continuity, leave connector X-9123 disconnected and continue with Step 3. 3. Replace the Lambda sensor B-9123. 47683911 27/02/2015

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Use the EST, refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989) if necessary, to perform the Replacement of the Lambda Sensor - Reset ECU Data. Use EST to check to see that this fault has been resolved. A. If the fault has been resolved, return the machine to service. B. If this fault has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3714-Lambda sensor O2 calibrator too high error WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: The Engine Control Unit (ECU) A-9000 performs an electrical zero-offset calibration every 10 min of engine operation on the Lambda sensor B-9123 as long as the engine has been running for longer than 10 s after start, after-treatment regeneration is not active, the engine is in operating range one (speed between 300 - 1200 RPM and load between 2.00 - 11.00 mg per stroke), and the calibration is not inhibited due to a failure. The measured oxygen signal during calibration should be between - 0.200 - 0.200 V. If the oxygen signal, during this calibration, is out of range, higher than 0.200 V, this fault will occur. For more information regarding rich air/fuel ratio troubleshooting, refer to the engine service manual Fuel injection system - Poor quality (10.218). For more information regarding fuel system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218). For information regarding the functional operation of the Lambda sensor B-9123, refer to the engine service manual Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the lambda sensor B-9123, refer to the engine service manual Lambda sensor - Technical Data (55.989). Cause: The Lambda sensor B-9123 oxygen level signal, during calibration, to the ECU A-9000 is greater than 0.200 V. Possible failure modes: 1. Faulty injector, leaking. 2. Faulty Exhaust Gas Recirculation (EGR) Z-9000 valve, stuck closed. 3. Faulty Lambda sensor B-9123, contaminated. 4. Faulty ECU A-9000, software.

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3715-Lambda sensor O2 calibrator too low error WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: The Engine Control Unit (ECU) A-9000 performs an electrical zero-offset calibration every 10 min of engine operation on the Lambda sensor B-9123 as long as the engine has been running for longer than 10 s after start, after-treatment regeneration is not active, the engine is in operating range one (speed between 300 - 1200 RPM and load between 2.00 - 11.00 mg per stroke), and the calibration is not inhibited due to a failure. The measured oxygen signal during calibration should be between - 0.200 - 0.200 V. If the oxygen signal, during this calibration, is out of range, less than - 0.200 V, this fault will occur. For more information regarding lean air/fuel ratio troubleshooting, Refer to the engine service manual Fuel injection system - Poor quality (10.218). For more information regarding fuel system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218). For information regarding the functional operation of the Lambda sensor B-9123 refer to the engine service manual Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the lambda sensor B-9123, refer to the engine service manual Lambda sensor - Technical Data (55.989). Cause: The Lambda sensor B-9123 oxygen level signal, during calibration, to the ECU A-9000 is less than – 0.200 V. Possible failure modes: 1. Faulty fuel back-flow, excessive. 2. Faulty Exhaust Gas Recirculation (EGR) Z-9000 valve, stuck open. 3. Faulty Lambda sensor B-9123, contaminated. 4. Faulty ECU A-9000, software.

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3716-Lambda sensor O2 value above maximum threshold WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: The Engine Control Unit (ECU) A-9000 has detected a fault associated with the oxygen sensor. This fault is a result of an open circuit condition in the factory installed trim resistor circuit. For information regarding the functional operation of the Lambda sensor B-9123, refer to the engine service manual Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the lambda sensor B-9123, see Lambda sensor - Technical Data (55.989). Cause: The ECU A-9000 is sensing an open circuit condition in the Lambda sensor B-9123 trim resistor circuit. Possible failure modes: 1. Faulty Lambda sensor B-9123 circuit wiring, open circuit. 2. Faulty Lambda sensor B-9123, failed internally. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 4. 2. Check the Lambda sensor B-9123 trim resistor circuit wiring for an open circuit condition. Disconnect the vehicle harness (VE) from the Lambda sensor B-9123 at connector X-9123. Carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122 and place a jumper wire between X-9122 pin K86 and chassis ground. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9123 pin 5

To chassis ground

Result There should be continuity.

A. If there is no continuity, there is an open circuit condition in the vehicle harness (VE) between connector X-9123 pin 5 and X-9122 pin K86. Use the appropriate vehicle service manual, if necessary, to locate and repair the broken conductor. B. If there is continuity, continue with Step 3. 3. Replace the Lambda sensor B-9123. Use EST to check to see that this fault has been resolved. A. If the fault has been resolved, return the machine to service. B. If this fault has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary.

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4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3720-Lambda sensor heater battery voltage too low C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

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3721-ECU internal failure - SPI chip error configuration C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The SPI chip, which is internal to the ECU A-9000, controls the Lambda sensor B-9123 device for the measuring or the calibrating of the inner resistance for temperature evaluation, switches on and off the pump current to measure O2 content and monitors the hardware related to the open load and short circuit monitoring devices. The requests for these listed actions are made by software and result in a configuration of the initialization register, which is hardware controlled. The same configuration is calculated by software. If both configurations are not identical, the SPI is not plausible and this fault will occur. For information regarding the functional operation of the Lambda sensor B-9123, refer to the engine service manual Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the lambda sensor B-9123, refer to the engine service manual Lambda sensor - Technical Data (55.989). Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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3722-Lambda sensor estimated temperature higher than threshold WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual, Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: The Engine Control Unit (ECU) A-9000 monitors the internal resistance of the nernst cell to estimate the internal temperature of the Lambda sensor B-9123. If the ECU A-9000 calculates the internal temperature to be greater than 929.96 °C (1705.9 °F), this fault will occur. For information regarding the functional operation of the Lambda sensor B-9123 , refer to the engine service manual, Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the lambda sensor B-9123, refer to the engine service manual Lambda sensor - Technical Data (55.989). Cause: The ECU A-9000 calculated temperature, based on inner resistance, of the Lambda sensor B-9123 is greater than 929.96 °C (1705.9 °F). Possible failure modes: 1. Faulty Lambda sensor B-9123 nernst cell circuit wiring, shorted to ground. 2. Faulty Lambda sensor B-9123 connection, loose. 3. Faulty Lambda sensor B-9123, failed internally. 4. Faulty ECU A-9000, software. Solution: 1. Verify that the fault present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Visually inspect the Lambda sensor B-9123 for proper connection. A. If the Lambda sensor B-9123 is not properly connected or is loose, repair as necessary. B. If the Lambda sensor B-9123 is properly connected, continue to Step 3. 3. Check the Lambda sensor B-9123 nernst cell circuit wiring for a short to ground condition. Disconnect the vehicle harness (VE) from the Lambda sensor B-9123 at connector X-9123. With the key in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9123 pin 6

To chassis ground

Value There should be no continuity.

A. If there is continuity, there is a short to ground condition in the vehicle harness (VE) between connector X-9123 pin 6 and connector X-9122 pin K63, wire VE-9156. Use the appropriate vehicle service manual, if necessary, to locate and repair the grounded conductor. B. If there is no continuity, continue with Step 4. 4. Replace the Lambda sensor B-9123. Use EST to check to see that this fault has been resolved. 47683911 27/02/2015

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A. If the fault has been resolved, return the machine to service. B. If this fault has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3723-Lambda sensor estimated temperature lower than threshold WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual, Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: The Engine Control Unit (ECU) A-9000 monitors the internal resistance of the nernst cell to estimate the internal temperature of the Lambda sensor B-9123. If the ECU A-9000 calculates the internal temperature to be equal to or less than 719.96 °C (1327.9 °F), this fault will occur. For information regarding the functional operation of the Lambda sensor B-9123 refer to the engine service manual Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the lambda sensor B-9123, refer to the engine service manual Lambda sensor - Technical Data (55.989). Cause: The ECU A-9000 calculated temperature, based on inner resistance, of the Lambda sensor B-9123 is below or equal to 719.96 °C (1327.9 °F). Possible failure modes: 1. Faulty Lambda sensor B-9123 nernst cell or virtual ground circuit wiring, open circuit. 2. Faulty Lambda sensor B-9123, failed internally. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 4. 2. Check the Lambda sensor B-9123 nernst cell and virtual ground circuit wiring for an open circuit condition. Disconnect the vehicle harness (VE) from the Lambda sensor B-9123 at connector X-9123. Carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122 and place a jumper wire between X-9122 pin K85 and chassis ground. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9123 pin 2

To chassis ground

Result There should be continuity.

Move the connector X-9122 end of the jumper wire from connector X-9122 pin K85 to connector X-9122 pin K63. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9123 pin 6

To chassis ground

Result There should be continuity.

A. If there is no continuity on either of the checks, there is an open circuit condition in the vehicle harness (VE) between connector X-9123 pin 2 or connector X-9123 pin 6 and X-9122 pin K85 or connector X-9122 pin K63, wire VE-9155 or VE-9156. Use the appropriate vehicle service manual, if necessary, to locate and repair the broken conductor.

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B. If there is continuity on both checks, continue with Step 3. 3. Replace the Lambda sensor B-9123. Use EST to check to see that this fault has been resolved. A. If the fault has been resolved, return the machine to service. B. If this fault has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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Electrical systems - FAULT CODES

3724-Lambda sensor cell circuits short circuit to battery WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: The Engine Control Unit (ECU) A-9000 monitors the condition of the nernst cell, pump cell and virtual ground circuits. If the ECU A-9000 detects a short to a voltage source condition in any of the circuits or an open circuit condition in the virtual ground circuit, this fault will occur. For information regarding the functional operation of the Lambda sensor B-9123, refer to the engine service manual Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the lambda sensor B-9123, refer to the engine service manual Lambda sensor - Technical Data (55.989). Cause: The ECU A-9000 is sensing an open circuit condition in the Lambda sensor B-9123 virtual ground circuit or a short to a voltage source condition in the nernst cell, pump cell or virtual ground circuit. Possible failure modes: 1. Faulty Lambda sensor B-9123 nernst cell, pump cell, or virtual ground circuit wiring, shorted to voltage source. 2. Faulty Lambda sensor B-9123 virtual ground circuit wiring, open circuit. 3. Faulty Lambda sensor B-9123, failed internally. 4. Faulty ECU A-9000, software. Solution: 1. Verify that the fault present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the Lambda sensor B-9123 nernst cell, pump cell, and virtual ground circuit wiring for a short to voltage condition. Disconnect the vehicle harness (VE) from the Lambda sensor B-9123 at connector X-9123. Carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : X-9122 X-9122 X-9122 X-9122

pin pin pin pin

From K63 K64 K85 K86

To Result all the other pins in connector X-9122 There should be no continuity. all the other pins in connector X-9122 There should be no continuity. all the other pins in connector X-9122 There should be no continuity. all the other pins in connector X-9122 There should be no continuity.

With the key switch in the ON position, use a multimeter to check for voltage on the vehicle harness (VE) side : X-9122 X-9122 X-9122 X-9122

pin pin pin pin

From K63 K64 K85 K86

To chassis chassis chassis chassis

ground ground ground ground 47683911 27/02/2015

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Result There should be no voltage. There should be no voltage. There should be no voltage. There should be no voltage.

Electrical systems - FAULT CODES

A. If there is no continuity or voltage, leave connector X-9123 and connector X-9122 disconnected and continue with Step 3. B. If there is continuity or voltage, there is a short to another circuit condition is in the vehicle harness (VE). Use the appropriate vehicle service manual, if necessary, to locate and repair the damaged conductors. 3. Check the Lambda sensor B-9123 virtual ground circuit wiring for an open circuit condition. Carefully place a jumper wire between X-9122 pin K85 and chassis ground. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9123 pin 2

To chassis ground

Result There should be continuity.

A. If there is no continuity, there is an open circuit condition in the vehicle harness (VE) between connector X-9123 pin 2 and X-9122 pin K85, wire VE-9155. Use the appropriate vehicle service manual, if necessary, to locate and repair the broken conductor. B. If there is continuity, continue with Step 4. 4. Replace the Lambda sensor B-9123. Use the EST, refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989) if necessary, to perform the Replacement of the Lambda Sensor - Reset ECU Data. Use EST to check to see that this fault has been resolved. A. If the fault has been resolved, return the machine to service. B. If this fault has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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Electrical systems - FAULT CODES

3725-Lambda sensor cell circuits short circuit to ground WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: The Engine Control Unit (ECU) A-9000 monitors the condition of the Lambda sensor B-9123 nernst cell, pump cell and virtual ground circuits. If the ECU A-9000 detects a short to ground in any of the circuits, this fault will occur. For information regarding the functional operation of the Lambda sensor B-9123, refer to the engine service manual Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the lambda sensor B-9123, refer to the engine service manual Lambda sensor - Technical Data (55.989). Cause: The ECU A-9000 is sensing a short to ground condition in the Lambda sensor B-9123 nernst cell, pump cell or virtual ground circuit. Possible failure modes: 1. Faulty Lambda sensor B-9123 circuit wiring, shorted to ground. 2. Faulty Lambda sensor B-9123, failed internally. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 4. 2. Check the Lambda sensor B-9123 circuit wiring for a short to ground condition. Disconnect the vehicle harness (VE) from the Lambda sensor B-9123 at connector X-9123. Carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-9123 pin 1 X-9123 pin 2 X-9123 pin 6

To chassis ground chassis ground chassis ground

Result There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is continuity on any of the checks, there is a short to ground condition in the vehicle harness (VE) between connector X-9123 pin 1 or connector X-9123 pin 2 or connector X-9123 pin 6 and connector X-9122 pin K64 or connector X-9122 pin K85 or connector X-9122 pin K63, wire VE-9154 or VE-9155 or VE-9156. Use the appropriate vehicle service manual, if necessary, to locate and repair the damaged conductor. B. If there is no continuity on any of the checks, continue with Step 3. 3. Replace the Lambda sensor B-9123. Use the EST, refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989) if necessary, to perform the Replacement of the Lambda Sensor - Reset ECU Data.

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Electrical systems - FAULT CODES

Use EST to check to see that this fault has been resolved. A. If the fault has been resolved, return the machine to service. B. If this fault has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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Electrical systems - FAULT CODES

3727-Low oil viscosity C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

NOTE: If the engine oil/filter is replaced, it is necessary to perform the Replacement of the Engine Oil/Filter - Reset Change Reminder with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Engine oil system - Configure - Replacement of the Engine Oil/Filter - Reset Change Reminder (55.013), if necessary. Context: The ECU A-9000 monitors engine oil viscosity. If the ECU A-9000 determines that the engine oil viscosity is low, an oil change is necessary and this fault will occur. For more information on lubrication system troubleshooting, refer to the engine service manual Engine lubrication system - Troubleshooting (10.304).

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Electrical systems - FAULT CODES

3728-Too low oil viscosity C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

NOTE: If the engine oil/filter is replaced, it is necessary to perform the Replacement of the Engine Oil/Filter - Reset Change Reminder with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Engine oil system - Configure - Replacement of the Engine Oil/Filter - Reset Change Reminder (55.013), if necessary. Context: The ECU A-9000 monitors engine oil viscosity. If the ECU A-9000 determines that the engine oil viscosity is too low, an oil change is necessary and this fault will occur. For more information on lubrication system troubleshooting, refer to the engine service manual Engine lubrication system - Troubleshooting (10.304).

47683911 27/02/2015

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Electrical systems - FAULT CODES

3735-Fuel metering unit has an over-temperature error WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) monitors the fuel metering unit Y-9000 signal circuit for an over temperature/current condition. If the ECU A-9000 detects an over temperature/current condition in the fuel metering unit Y-9000 signal circuit, this fault will occur. Cause: The ECU A-9000 has detected an over temperature/current condition in the fuel metering unit Y-9000 signal circuit. Possible failure modes: 1. Faulty fuel metering unit Y-9000 wiring, short to a voltage source. 2. Faulty fuel metering unit Y-9000, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Test the fuel metering unit Y-9000 internal resistance. Disconnect the engine harness (EN) from the fuel metering unit Y-9000 at connector X-9007. Use a multimeter to measure the resistance on the fuel metering unit Y-9000 pins : From X-9007 pin 1

To X-9007 pin 2

Value There should be between 2.6 - 3.2 Ω at approximately 20.0 °C (68.0 °F).

To Chassis ground

Value There should be no voltage.

With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-9007 pin 2

To Chassis ground

Value There should be no voltage.

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Electrical systems - FAULT CODES

To All pins in connector X-9138.

Value There should be no continuity.

To All pins in connector X-9138. All pins in connector X-9121.

Value There should be no continuity. There should be no continuity.

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Electrical systems - FAULT CODES

3738-ECU internal failure - ROM error C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 runs a diagnostic fault check of the ROM memory. If any checksum errors in ROM-memory blocks are detected, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

47683911 27/02/2015

55.17 [55.DTC] / 404

Electrical systems - FAULT CODES

3739-ECU internal failure - Loss of synchronization to MM from CPU C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 performs a shut-off path test of the fuel injection power stages. Every time the key is turned ON, this test is performed to verify the correct functioning of the shut-off procedure. If an error is detected during the shut-off test, the fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

47683911 27/02/2015

55.17 [55.DTC] / 405

Electrical systems - FAULT CODES

3740-ECU internal failure - ECU shutdown test failure C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 performs a series of “shut-off path” tests which deactivates all power stages relevant to fuel injection if certain ECU A-9000 errors are detected. If an incorrect response to the power stage supply (CY320) is detected during this test, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

47683911 27/02/2015

55.17 [55.DTC] / 406

Electrical systems - FAULT CODES

3741-ECU internal failure - Wrong set response time C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 performs a series of “shut-off path” tests which deactivates all power stages relevant to fuel injection if certain ECU A-9000 errors are detected. If there is a time-out error during this test, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

47683911 27/02/2015

55.17 [55.DTC] / 407

Electrical systems - FAULT CODES

3742-ECU internal failure - SPI errors during MoCSOP execution C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 performs a series of “shut-off path” tests which deactivates all power stages relevant to fuel injection if certain ECU A-9000 errors are detected. If there is a faulty communication detected during this test, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

47683911 27/02/2015

55.17 [55.DTC] / 408

Electrical systems - FAULT CODES

3743-ECU internal failure - Undervoltage monitoring error C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 performs “shut-off paths” which deactivate all power stages relevant to fuel injection if certain ECU A-9000 errors are detected. If an under-voltage condition is detected during this test, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

47683911 27/02/2015

55.17 [55.DTC] / 409

Electrical systems - FAULT CODES

3744-ECU internal failure - Overvoltage monitoring error C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 performs “shut-off paths” which deactivate all power stages relevant to fuel injection if certain ECU A-9000 errors are detected. If an over-voltage condition is detected during this test, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

47683911 27/02/2015

55.17 [55.DTC] / 410

Electrical systems - FAULT CODES

3745-ECU internal failure - WDA is not working correctly C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 performs “shut-off paths” which deactivate all power stages relevant to fuel injection if certain ECU A-9000 errors are detected. If an implausible response in the power-stage feedback is detected during this test, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

47683911 27/02/2015

55.17 [55.DTC] / 411

Electrical systems - FAULT CODES

3746-ECU internal failure - Alarm task period error C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 performs “shut-off paths” which deactivate all power stages relevant to fuel injection if certain ECU A-9000 errors are detected. If an alarm task can not be set or reset after having detected a time-out error during this test, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

47683911 27/02/2015

55.17 [55.DTC] / 412

Electrical systems - FAULT CODES

3747-ECU internal failure - Positive test failed C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 performs “shut-off paths” which deactivate all power stages relevant to fuel injection if certain ECU A-9000 errors are detected. If the ECU A-9000 determines that the test has failed, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

47683911 27/02/2015

55.17 [55.DTC] / 413

Electrical systems - FAULT CODES

3748-ECU internal failure - Timeout in the shut off path test error C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 performs “shut-off paths” which deactivate all power stages relevant to fuel injection if certain ECU A-9000 errors are detected. If a time-out in the power-stage feedback is detected during this test, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

47683911 27/02/2015

55.17 [55.DTC] / 414

Electrical systems - FAULT CODES

3750-ECU internal failure - Fuel injection energizing time not plausible C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors fuel injector energizing time for plausibility. If the ECU A-9000 determines that this value is implausible for either pilot, main or post injection, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

47683911 27/02/2015

55.17 [55.DTC] / 415

Electrical systems - FAULT CODES

3751-ECU internal failure - Fuel injection energizing phase is not plausible C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors fuel injector energizing start time for plausibility. If the ECU A-9000 determines that this value is implausible for either pilot, main or post injection, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

47683911 27/02/2015

55.17 [55.DTC] / 416

Electrical systems - FAULT CODES

3752-Fuel injection correction has exceeded a minimum limit C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 checks the plausibility of the Zero Fuel Quantity Calibration (ZFC) energizing time. The ZFC is used to correct pilot injection quantity. If the ECU A-9000 determines the energizing time of the ZFC is implausible, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

47683911 27/02/2015

55.17 [55.DTC] / 417

Electrical systems - FAULT CODES

3753-ECU internal failure - Injection quality correction C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

47683911 27/02/2015

55.17 [55.DTC] / 418

Electrical systems - FAULT CODES

3754-ECU internal failure - SPI errors during MoCSOP execution C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors fuel pressure in the common rail. This monitoring is performed using two software levels of monitoring because fuel pressure monitoring is a critical functionality. If the ECU A-9000 sees an error in the level two monitoring but not in level one monitoring, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

47683911 27/02/2015

55.17 [55.DTC] / 419

Electrical systems - FAULT CODES

3755-ECU internal failure - Torque request comparison C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 performs a diagnostic comparison of requested engine torque to allowed engine torque. If the ECU A-9000 determines that requested engine torque is greater than maximum allowed torque, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

47683911 27/02/2015

55.17 [55.DTC] / 420

Electrical systems - FAULT CODES

3756-ECU internal failure - Post injection quality C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 performs a diagnostic fault check for post injection 2 by monitoring start angle and efficiency. If the ECU A-9000 determines that there is an error during this check, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

47683911 27/02/2015

55.17 [55.DTC] / 421

Electrical systems - FAULT CODES

3757-ECU internal failure - Post injection shut-off failure C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 performs a diagnostic fault check for post injection 2. If the ECU A-9000 determines that the post injection 2 quantity has exceeded the expected value, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

47683911 27/02/2015

55.17 [55.DTC] / 422

Electrical systems - FAULT CODES

3758-ECU internal failure - Post injection efficiency failure C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 performs a diagnostic fault check for post injection 3. If the ECU A-9000 determines that there is a post injection 3 plausibility error, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

47683911 27/02/2015

55.17 [55.DTC] / 423

Electrical systems - FAULT CODES

3759-ECU internal failure - Torque request due to fuel pressure exceeds maximum torque limit C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors “lead torque”, which is the input torque request that is calculated for determining fuel pressure. If the ECU A-9000 determines that “lead torque” is less than the limited maximal torque, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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55.17 [55.DTC] / 424

Electrical systems - FAULT CODES

3760-ECU internal failure - Torque request due to air control exceeds maximum torque limit C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

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Electrical systems - FAULT CODES

3761-ECU internal failure - Torque request exceeds maximum torque limit C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 calculates and monitors “inner torque”, torque produced by the engine. The ECU A-9000 compares “inner torque” to allowed “inner torque”. If the ECU A-9000 determines that “Inner torque” is greater than allowed “inner torque”, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

47683911 27/02/2015

55.17 [55.DTC] / 426

Electrical systems - FAULT CODES

3762-ECU 5 volt supply voltage is higher than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the ECU A-9000 internal 5 V supply. If the 5 V supply exceeds the maximal limit, this fault will occur. Cause: The ECU A-9000 has determined that the 5 V internal voltage supply is too high. Possible failure modes: 1. Faulty voltage supply. 2. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 3. 2. Check the ECU A-9000 supply voltage. Disconnect the ECU A-9000 connector X-9122. Place a jumper wire between X-9122 pin K28 and chassis ground. This will energize the main relay K-9102. With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From X-9122 pin K03 X-9122 pin K05 X-9122 pin K01

To X-9122 pin K02 X-9122 pin K04 X-9122 pin K06

Value There should be approximately 12 V. There should be approximately 12 V. There should be approximately 12 V.

A. If there is not approximately 12 V, there is a failure in the ECU A-9000 supply wiring. Use the appropriate service manual, if necessary, to locate and repair the failed conductor. B. If there is approximately 12 V, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 3. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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Electrical systems - FAULT CODES

3763-ECU 5 volt supply voltage is lower than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the ECU A-9000 internal 5 V supply. If the 5 V supply is below the minimal limit, this fault will occur. Cause: The ECU A-9000 has determined that the 5 V internal voltage supply is too low. Possible failure modes: 1. Faulty voltage supply. 2. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 3. 2. Check the ECU A-9000 supply voltage. Disconnect the ECU A-9000 connector X-9122. Place a jumper wire between X-9122 pin K28 and chassis ground. This will energize the main relay K-9102. With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From X-9122 pin K03 X-9122 pin K05 X-9122 pin K01

To X-9122 pin K02 X-9122 pin K04 X-9122 pin K06

Value There should be approximately 12 V. There should be approximately 12 V. There should be approximately 12 V.

47683911 27/02/2015

55.17 [55.DTC] / 428

Electrical systems - FAULT CODES

3764-ECU after run power interruption WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit A-9000 controls the main relay K-9102. The main relay K-9102 is powered on by the ECU A-9000 to achieve after-run. The main relay K-9102 is powered off once after-run is completed. If the ECU A-9000 determines that the main relay K-9102 has shut off before commanded, this fault will occur. Cause: The ECU A-9000 has determined that the main relay K-9102 has shut off before commanded to shut off. Possible failure modes: 1. Faulty main relay K-9102, wiring. 2. Faulty main relay K-9102, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 9. 2. Check the main relay K-9102 coil for an internal failure. Remove the main relay K-9102. Use a multimeter to measure the resistance on the main relay K-9102 pins : From X-9129 pin 85

To X-9129 pin 86

Value There should be approximately 70 130 Ω.

A. If there is approximately 70 - 130 Ω, leave the main relay K-9102 disconnected and continue to Step 3. B. If there is not approximately 70 - 130 Ω, the main relay K-9102 has failed. Replace the main relay K-9102. 3. Check the main relay K-9102 vehicle harness (VE) wiring for a short to a voltage source. With the key in the OFF position, use a multimeter to perform the following voltage check for a short to a voltage source on the vehicle harness (VE) side : From To Value X-9129 pin 85 There should be no voltage. Chassis ground NOTE: Wiggle the harness during the check to promote an intermittent electrical connection. With the key in the ON position, use a multimeter to perform the following voltage check for a short to a voltage source on the vehicle harness (VE) side : From To Value X-9129 pin 85 There should be no voltage. Chassis ground NOTE: Wiggle the harness during the check to promote an intermittent electrical connection. A. If there is voltage, there is a short to a voltage source in the main relay K-9102 wiring in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. 47683911 27/02/2015

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Electrical systems - FAULT CODES

B. If there is no voltage, leave the main relay K-9102 disconnected and continue to Step 4. 4. Check the main relay K-9102 vehicle harness (VE) wiring for a short to ground. With the key in the OFF position, use a multimeter to perform the following continuity check for a short to ground on the vehicle harness (VE) side : From To Value X-9129 pin 85 There should be no continuity. Chassis ground NOTE: Wiggle the harness during the check to promote an intermittent electrical connection. A. If there is continuity, there is a short to ground in the main relay K-9102 wiring in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the broken or damaged conductor. B. If there is no continuity, leave the main relay K-9102 disconnected and continue to Step 5. 5. Check the main relay K-9102 vehicle harness (VE) wiring for an open circuit. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122. With the key in the OFF position, use a multimeter to perform the following continuity check for an open circuit on the vehicle harness (VE) side : From To Value X-9129 pin 85 X-9122 pin K28 There should be continuity. NOTE: Wiggle the harness during the check to promote an intermittent electrical connection. A. If there is no continuity, there is an open circuit in the main relay K-9102 wiring in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the broken or damaged conductor. B. If there is continuity, leave the main relay K-9102 and connector X-9122 disconnected, then continue to Step 6. 6. Check the main relay K-9102 wiring for a short circuit condition. With the key in the OFF position, use a multimeter to perform the following continuity checks for a short circuit on the vehicle harness (VE) side : From To Value X-9129 pin 85 X-9129 pin 86 There should be no continuity. X-9122 pin K28 All pins in connector X-9122 There should be no continuity. NOTE: Wiggle the harness during the check to promote an intermittent electrical connection. A. If there is continuity, there is a short circuit in the main relay K-9102 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, leave the main relay K-9102 and connector X-9122 disconnected, then continue to Step 7. 7. Check the main relay K-9102 load-side wiring. With the key in the ON position, use a multimeter to perform the following voltage checks on the vehicle harness (VE) side : From

Value There should be approximately 12.0 V. X-9129 pin 30 There should be approximately Chassis ground 12.0 V. NOTE: Wiggle the harness during the check to promote an intermittent electrical connection. X-9129 pin 86

Chassis ground

A. If there is not approximately 12.0 V, there is a failure in the main relay K-9102 load-side wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is approximately 12.0 V, leave the main relay K-9102 and connector X-9122 disconnected, then continue to Step 8. 47683911 27/02/2015

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Electrical systems - FAULT CODES

8. Check the main relay K-9102 load-side wiring. With the key in the OFF position, use a multimeter to perform the following continuity checks on the vehicle harness (VE) side : From To Value X-9129 pin 87 X-9122 pin K01 There should be continuity. X-9129 pin 87 X-9122 pin K03 There should be continuity. X-9129 pin 87 X-9122 pin K05 There should be continuity. NOTE: Wiggle the harness during the check to promote an intermittent electrical connection. A. If there is no continuity, there is an open circuit in the main relay K-9102 load-side wiring or fuse. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor or open fuse. B. If there is continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 9. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 01 - Power distribution and starting (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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Electrical systems - FAULT CODES

3766-Diesel particulate filter pressure sensor: Fault check for the pressure sensor plausibility C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The exhaust differential pressure is measured between the intake and exhaust of the diesel particulate filter in the exhaust. This fault is a result of the differential pressure being inaccurate. The pressure value is above 2.5 kPa (0.4 psi). Check the differential pressure sensor hoses, and connections. If all the connections are good, and no damage is found. Replace the differential pressure sensor.

47683911 27/02/2015

55.17 [55.DTC] / 432

Electrical systems - FAULT CODES

3767-ECU internal failure - 'WDA active' reported due to errors in query/response communication C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors the communication between CJ945 (power stage chips) and CY320 (power stage voltage supplier). If the ABE wire between the CJ-945 and CY320 becomes active due to an unknown reason, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

47683911 27/02/2015

55.17 [55.DTC] / 433

Electrical systems - FAULT CODES

3768-ECU internal failure - 'ABE active' reported due to undervoltage detection C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors the communication between CJ945 (power stage chips) and CY320 (power stage voltage supplier). If the ABE wire between the CJ-945 and CY320 becomes active due to an undervoltage detection, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

47683911 27/02/2015

55.17 [55.DTC] / 434

Electrical systems - FAULT CODES

3769-ECU internal failure - 'ABE active' report due to overvoltage detection C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors the communication between CJ945 (power stage chips) and CY320 (power stage voltage supplier). If the ABE wire between the CJ-945 and CY320 becomes active due to an overvoltage detection, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

47683911 27/02/2015

55.17 [55.DTC] / 435

Electrical systems - FAULT CODES

3770-ECU internal failure - 'WDA/ABE active' reported C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors the communication between CJ945 (power stage chips) and CY320 (power stage voltage supplier). If there is an unexpected communication during this process, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

47683911 27/02/2015

55.17 [55.DTC] / 436

Electrical systems - FAULT CODES

3773-Turbocharger boost pressure is lower than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors boost pressure using the intake manifold pressure sensor B-9001. If the ECU A-9000 determines that boost pressure is lower than expected, this fault will occur. For more information regarding the troubleshooting of an under-boost condition, refer to the engine service manual Turbocharger Boost - Troubleshooting (10.250). Cause: The ECU A-9000 has determined that boost pressure is lower than expected. Possible failure modes: 1. Faulty intake plumbing, boost leakage. 2. Faulty air filter, clogged. 3. Faulty wastegate pressure modulator valve Y-9008, if applicable. 4. Faulty boost pressure accumulator, if applicable. 5. Faulty wastegate, sticking. 6. Faulty turbocharger, low efficiency. 7. Faulty intake manifold pressure sensor B-9001, drifted signal. 8. Faulty ECU A-9000, software.

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Electrical systems - FAULT CODES

3786-Diesel particulate filter signal range check is high C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The engine control unit (ECU) has detected the soot level in the DPF filter is exceeding the threshold limit, or the flow resistance is high. If this fault occurs, black smoke should be visible at the exhaust pipe. Check that the DPF filter is mounted properly and is not cracked. If the DPF filter is not mounted properly, refit the DPF filter correctly. If damaged is determined, replace the DPF filter. This fault will clear at the end of the next regeneration cycle.

47683911 27/02/2015

55.17 [55.DTC] / 438

Electrical systems - FAULT CODES

3787-Diesel particulate filter signal range check flow resistance of the particulate filter - very high C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The engine control unit (ECU) has detected the regeneration cycle did not complete in time. This could be a cause of exhaust restrictions, differential pressure sensor measuring wrong. Check the exhaust for any kind of restrictions. Check rear differential pressure sensor hose is not clogged. Perform the manual regeneration procedure.

47683911 27/02/2015

55.17 [55.DTC] / 439

Electrical systems - FAULT CODES

3789-Regeneration duration check exceeds maximum allowed duration C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

47683911 27/02/2015

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Electrical systems - FAULT CODES

3794-Intake manifold pressure sensor drifted high WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors boost pressure. Boost pressure is compared to environmental pressure by the ECU A-9000. If the ECU A-9000 determines that the difference between measured boost pressure and environmental pressure is greater than 0.1 bar (1.5 psi), this fault will occur. Cause: The ECU A-9000 has determined that boost pressure is greater than environmental pressure by 0.1 bar (1.5 psi). Possible failure modes: 1. Faulty intake manifold pressure sensor B-9001, internal failure. 2. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 4. 2. Use the Electronic Service Tool (EST) to check the status of following related faults: 3019 - Intake manifold pressure sensor voltage is higher than expected 3037 - Intake manifold pressure sensor voltage is lower than expected A. If any of the listed faults are active, diagnose them first and then return to this fault, 3794 - Intake manifold pressure sensor drifted high. B. If none of the listed faults are active, continue to Step 3. 3. Replace the intake manifold pressure sensor B-9001. Use the EST to verify the status of this fault, 3794 - Intake manifold pressure sensor drifted high. A. If the fault is no longer active, return the machine to service. B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation.

47683911 27/02/2015

55.17 [55.DTC] / 441

Electrical systems - FAULT CODES

3795-Intake manifold pressure sensor drifted low WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors boost pressure. Boost pressure is compared to environmental pressure by the ECU A-9000. If the ECU A-9000 determines that the boost pressure is less than environmental pressure by 0.1 bar (1.5 psi), this fault will occur. Cause: The ECU A-9000 has determined that boost pressure is less than environmental pressure by 0.1 bar (1.5 psi). Possible failure modes: 1. Faulty intake manifold pressure sensor B-9001, internal failure. 2. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 4. 2. Use the Electronic Service Tool (EST) to check the status of following related faults: 3019 - Intake manifold pressure sensor voltage is higher than expected 3037 - Intake manifold pressure sensor voltage is lower than expected A. If any of the listed faults are active, diagnose them first and then return to this fault, 3795 - Intake manifold pressure sensor drifted low. B. If none of the listed faults are active, continue to Step 3. 3. Replace the intake manifold pressure sensor B-9001. Use the EST to verify the status of this fault, 3795 - Intake manifold pressure sensor drifted low. A. If the fault is no longer active, return the machine to service. B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation.

47683911 27/02/2015

55.17 [55.DTC] / 442

Electrical systems - FAULT CODES

3796-Diesel particulate filter pressure sensor hose line error C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The engine control unit (ECU) has detected the filtered differential pressure signal is below 1.0 kPa (0.1 psi). This fault is a cause of a hose connection upstream from the diesel particulate filter not being attached, or is clogged. Check mounting of the hose lines, and check the hose line is free of clogs.

47683911 27/02/2015

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Electrical systems - FAULT CODES

3797-DPF differential pressure sensor is higher than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) monitors the differential pressure signal for electrical defects. Cause: The ECU has sensed the differential pressure sensor signal is greater than 6.5 V. Possible failure modes: 1. The differential pressure sensor has failed. 2. The differential pressure sensor circuit is shorted to a high source. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. A. If the fault is active, continue with Step 2. B. If the fault is not active, the fault may be intermittent. Continue with Step 6. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the differential pressure sensor connector. Verify that the wiring harness is free of damage, corrosion, abrasion and incorrect attachment. A. The connectors are secure and the wiring harness is free of damage. Continue with Step 3. B. The connectors or the wiring harness has damage. Repair or replace the wiring harness or connectors as required. 3. Check the signal circuit. Disconnect the wiring harness from the differential pressure sensor. Place a jumper wire between the wiring harness sensor connector pin 2 and pin 3. Place the key switch ON. Monitor the diagnostic screen for the fault code to change from “Shorted to high source” to “Shorted to low source”. A. If the fault code changed, remove the jumper wire. Continue with Step 4. B. If the fault code did not change, remove the jumper wire. Continue with Step 5. 4. Check the 5.0 V supply and ground reference circuit. Place the key switch ON. Use a multimeter to check for voltage from the wiring harness sensor connector pin 1 to pin 2. There should be approximately 4.5 - 5.5 V. A. If the voltage reading is not in range, continue with Step 5. B. If the voltage is in range, the sensor has failed. Replace the sensor. 5. Check the wiring harness for a short to high source. Place the key switch OFF. 47683911 27/02/2015

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Carefully disconnect the wiring harness from the ECU. Place the key switch ON. Use a multimeter to check to perform the following checks. From To Sensor wiring harness connector pin Chassis ground 1 Sensor wiring harness connector pin Chassis ground 2 Sensor wiring harness connector pin Chassis ground 3

Result There should be no voltage. There should be no voltage. There should be no voltage.

A. If the wiring harness test is good, verify the ECU for proper operation. B. If the wiring harness test fails, locate and repair the broken conductor. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation.

47683911 27/02/2015

55.17 [55.DTC] / 445

Electrical systems - FAULT CODES

3798-DPF differential pressure sensor is lower than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) monitors the differential pressure signal for electrical defects. Cause: The ECU has sensed the differential pressure sensor signal is less than 0.5 V. Possible failure modes: 1. The differential pressure sensor has failed. 2. The differential pressure sensor circuit is shorted to a low source. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. A. If the fault is active, continue with Step 2. B. If the fault is not active, the fault may be intermittent. Continue with Step 6. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the differential pressure sensor connector. Verify that the wiring harness is free of damage, corrosion, abrasion and incorrect attachment. A. The connectors are secure and the wiring harness is free of damage. Continue with Step 3. B. The connectors or the wiring harness has damage. Repair or replace the wiring harness or connectors as required. 3. Check the signal circuit. Disconnect the wiring harness from the differential pressure sensor. Place a jumper wire between the wiring harness sensor connector pin 1and pin 3. Place the key switch ON. Monitor the diagnostic screen for the fault code to change from “Shorted to low source” to “Shorted to high source”. A. If the fault code changed, remove the jumper wire. Continue with Step 4. B. If the fault code did not change, remove the jumper wire. Continue with Step 5. 4. Check the 5.0 V supply and ground reference circuit. Place the key switch ON. Use a multimeter to check for voltage from the wiring harness sensor connector pin 1 to pin 2. There should be approximately 4.5 - 5.5 V. A. If the voltage reading is not in range, continue with Step 5. B. If the voltage is in range, the sensor has failed. Replace the sensor. 5. Check the wiring harness for a short to low source. Place the key switch OFF. 47683911 27/02/2015

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Electrical systems - FAULT CODES

Carefully disconnect the wiring harness from the ECU. Use a multimeter to check to perform the following checks. From To Sensor wiring harness connector pin Chassis ground 1 Sensor wiring harness connector pin Chassis ground 2 Sensor wiring harness connector pin Chassis ground 3

Result There should be no continuity. There should be no continuity. There should be no continuity.

47683911 27/02/2015

55.17 [55.DTC] / 447

Electrical systems - FAULT CODES

3799-Fuel pressure relief valve is forced open, perform pressure shock C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: This fault is intended for information purposes only. Other active faults may have caused this fault to occur. The Engine Control Unit (ECU) A-9000, if necessary, will set the engine into limp home mode. This process is achieved in two steps by the ECU A-9000, a pressure increase and a pressure shock. The ECU A-9000 will execute step two by a fuel pressure shock. This is achieved by setting injection quantity to zero. If this fault is active, the ECU A-9000 has performed step two for achieving limp home mode, a fuel pressure shock. Cause: The ECU A-9000 has performed a fuel pressure shock to achieve limp home mode.

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3800-Quantity balance check if a successful PRV opening is ensured C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: This fault is intended for information purposes only. Other active faults may have caused this fault to occur. The Engine Control Unit (ECU) A-9000, monitors the fuel Pressure Relief Valve (PRV). To determine mechanical wear-out of the PRV, the ECU A-9000 will perform a fuel pressure increase and pressure shock, thus opening the PRV. Both steps are recorded in the ECU A-9000 failure memory.

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3801-Exhaust gas pressure sensor voltage is higher than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the exhaust gas absolute pressure sensor B-9005. If the ECU A-9000 detects a voltage greater than 4.74 V in the exhaust gas absolute pressure sensor B-9005 signal circuit, this fault will occur. The sensor value will be frozen at the last valid value for a preliminary failure or jump to a fixed replacement value of 0.500 bar (7.250 psi) if the failure is validated. Cause: The ECU A-9000 has detected a voltage greater than 4.74 V in the exhaust gas absolute pressure sensor B-9005 signal circuit. Possible failure modes: 1. Faulty exhaust gas absolute pressure sensor B-9005, wiring to internal failure. 2. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check the exhaust gas absolute pressure sensor B-9005 engine harness (EN) wiring. Disconnect connector X-9018 from the exhaust gas absolute pressure sensor B-9005. With the key in the ON position, use a multimeter to perform the following voltage check at the engine harness (EN) side of the connector from : From X-9018 pin 3

To Chassis ground

Value There should be no voltage.

A. If there is voltage, there is a short circuit in the exhaust gas absolute pressure sensor B-9005 signal circuit engine harness (EN) wiring. Locate and repair the shorted conductor. B. If there is no voltage, leave the connector disconnect and continue to Step 3. 3. Check the exhaust gas absolute pressure sensor B-9005 engine harness (EN) wiring. Disconnect the engine interface connector X-9138. With the key in the OFF position, use a multimeter to perform the following continuity check at the engine harness (EN) side of the connector from : From X-9138 pin 23

To All pins in connector X-9138

Value There should be no continuity.

A. If there is continuity, there is a short circuit in the exhaust gas absolute pressure sensor B-9005 signal circuit engine harness (EN) wiring. Locate and repair the shorted conductor. B. If there is no continuity, leave the connector disconnect and continue to Step 4. 4. Check the exhaust gas absolute pressure sensor B-9005 vehicle harness (VE) wiring. Disconnect the ECU A-9000 connector X-9122. 47683911 27/02/2015

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With the key in the OFF position, use a multimeter to perform the following continuity check at the vehicle harness (VE) side of the connector from : From X-9138 pin 23

To All pins in connector X-9138

Value There should be no continuity.

A. If there is continuity, there is a short circuit in the exhaust gas absolute pressure sensor B-9005 signal circuit vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, leave the connector disconnect and continue to Step 5. 5. Replace the exhaust gas absolute pressure sensor B-9005. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is no longer active, return the machine to service. B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3802-Exhaust gas pressure sensor voltage is lower than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the exhaust gas absolute pressure sensor B-9005. If the ECU A-9000 detects a voltage less than 427.00 mV in the exhaust gas absolute pressure sensor B-9005 signal circuit, this fault will occur. The sensor value will be frozen at the last valid value for a preliminary failure or jump to a fixed replacement value of 0.500 bar (7.250 psi) if the failure is validated. Cause: The ECU A-9000 has detected a voltage less than 427.00 mV in the exhaust gas absolute pressure sensor B-9005 signal circuit. Possible failure modes: 1. Faulty exhaust gas absolute pressure sensor B-9005, wiring to internal failure. 2. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check the exhaust gas absolute pressure sensor B-9005 engine harness (EN) wiring. Disconnect connector X-9018 from the exhaust gas absolute pressure sensor B-9005. With the key in the OFF position, use a multimeter to perform the following continuity check at the engine harness (EN) side of the connector from : From X-9018 pin 3

To X-9018 pin 2

Value There should be no continuity.

A. If there is continuity, there is a short circuit in the exhaust gas absolute pressure sensor B-9005 signal circuit engine harness (EN) wiring. Locate and repair the shorted conductor. B. If there is no continuity, leave the connector disconnect and continue to Step 3. 3. Check the exhaust gas absolute pressure sensor B-9005 engine harness (EN) wiring. Disconnect the engine interface connector X-9138. With the key in the OFF position, use a multimeter to perform the following continuity check at the engine harness (EN) side of the connector from : From X-9138 pin 23 X-9138 pin 23

To Chassis ground All pins in connector X-9138

Value There should be no continuity. There should be no continuity.

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Disconnect the ECU A-9000 connector X-9122. With the key in the OFF position, use a multimeter to perform the following continuity check at the vehicle harness (VE) side of the connector from : From X-9138 pin 23 X-9138 pin 23 X-9122 pin K57

To Chassis ground All pins in connector X-9138 All pins in connector X-9122

Value There should be no continuity. There should be no continuity. There should be no continuity.

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3803-ECU internal failure - Error on R2S2 module C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 has detected an error on the R2S2 module (low-level chip driver for the powerstage chips). Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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3808-High pressure pump fuel delivery quantity at low idle is too high WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors fuel rail pressure. If the ECU A-9000 determines that the requested fuel pressure is greater than the actual fuel pressure at idle, leakage is assumed and this fault will occur. Other active faults may have caused this fault to occur. Use the Electronic Service Tool (EST) to check for other active faults. Diagnose any active faults related to the fuel system first and then return to this fault. For more information regarding fuel system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218). Cause: The ECU A-9000 has determined that the requested fuel pressure is greater than the actual fuel pressure at idle. Possible failure modes: 1.

Faulty low pressure fuel system, clogged filter or leakage/blockage.

Faulty charge gear pump, low efficiency or line clogged/damaged.

Faulty electric fuel pump (if equipped).

Faulty fuel metering unit, unable to fully open.

Faulty high pressure pump, low efficiency.

Faulty fuel injectors, stuck open or internal leakage.

Faulty Pressure Relief Valve (PRV), leakage.

Faulty rail pressure sensor B-9004 drifted signal or leaking.

Faulty ECU A-9000, software.

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3810-Rail pressure raw value is intermittent WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the rail pressure sensor B-9004 is replaced, it is necessary to perform the Replacement of the Rail Pressure sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Common rail pressure sensor - Configure - Reset ECU data (Rail pressure sensor) (55.010), if necessary. Context: The Engine Control Unit (ECU) A-9000 monitors the rail pressure sensor B-9004 If the ECU A-9000 detects more than 5 pressure jumps of greater than 500 bar (7250 psi) and the time between the pressure jumps is less than 3.00 s, an intermittent connection is assumed and this fault will occur. Cause: The ECU A-9000 has detected an intermittent connection in the rail pressure sensor B-9004 signal circuit. Possible failure modes: 1. Faulty rail pressure sensor B-9004 wiring, intermittent electrical connection. 2. Faulty rail pressure sensor B-9004, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the rail pressure sensor B-9004 engine harness (EN) harness wiring for an open circuit condition. Disconnect the engine harness (EN) from the rail pressure sensor B-9004 at connector X-9026. Disconnect the vehicle harness (VE) from the engine interface at connector X-9138. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From To Value X-9026 pin 2 X-9138 pin 6 There should be continuity. NOTE: Wiggle the harness during the check to promote an intermittent electrical connection. A. If there is no continuity, there is an open circuit in the rail pressure sensor B-9004 wiring in the engine harness (EN). Locate and repair the broken conductor. B. If there is continuity, leave connectors X-9026 and X-9138 disconnected and continue to Step 3. 3. Check the rail pressure sensor B-9004 vehicle harness (VE) wiring for an open circuit condition. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From To Value X-9138 pin 6 X-9121 pin A41 There should be continuity. NOTE: Shake the harness during the check to promote an intermittent electrical connection. 47683911 27/02/2015

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A. If there is no continuity, there is an open circuit in the rail pressure sensor B-9004 wiring in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the broken conductor. B. If there is continuity, leave connector X-9026 disconnected and continue to Step 4. 4. Replace the rail pressure sensor B-9004. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is no longer active, return the machine to service. B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3811-ECU 5 volt sensor supply 1 out of range WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 provides three independent five volt sensor supplies. The ECU A-9000 monitors each sensor supply voltage to ensure they operate within a given range. If the ECU A-9000 determines that the voltage for sensor supply 1 is out of range, this fault will occur. The ECU A-9000 pin numbers associated with sensor supply 1 are A07, A08, A09, A10, A11, A12, and A13.

Cause: The ECU A-9000 has determined that the sensor supply 1 voltage is out of range. Possible failure modes: 1.

Faulty battery voltage.

Faulty ECU A-9000 supply voltage.

Faulty ECU A-9000 sensor supply 1 pins.

Faulty ECU A-9000 connector X-9121, corrosion or damage.

Faulty Throttle Valve Actuator (TVA) Z-9001, position sensor wiring or internal failure.

Faulty Exhaust Gas Recirculation (EGR) valve Z-9000, position sensor wiring or internal failure.

Faulty intake manifold pressure and temperature sensor B-9001, wiring or internal failure.

Faulty rail pressure sensor B-9004, wiring or internal failure.

Faulty exhaust manifold pressure sensor B-9005, wiring to internal failure.

10. Faulty camshaft speed sensor B-9017, wiring or internal failure. 11. Faulty ECU A-9000, software. Solution: 1.

Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 13.

Check the battery voltage. Charge the battery, then, perform a load test on the battery. A. If the battery passes the load test, continue to Step 3. B. If the battery fails the load test, the battery has failed. Replace the battery.

Disconnect the ECU A-9000 connector X-9121. Check the following pins listed below on the ECU A-9000 and in connector X-9121 . Pin X-9121 pin A07 X-9121 pin A08

Physical condition The pin and connector should be free of corrosion or damage. The pin and connector should be free of corrosion or damage. 47683911 27/02/2015

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Physical condition The pin and connector should be free of corrosion or damage. The pin and connector should be free of corrosion or damage. The pin and connector should be free of corrosion or damage. The pin and connector should be free of corrosion or damage. The pin and connector should be free of corrosion or damage.

X-9121 pin A09 X-9121 pin A10 X-9121 pin A11 X-9121 pin A12 X-9121 pin A13

A. If a pin or connector shows signs of corrosion or damage, repair as necessary. B. If a pin or connector shows no signs of corrosion or damage, re-connect the ECU A-9000 at connector X-9121 and continue to Step 4. 4.

Check the ECU A-9000 supply voltage. Disconnect the ECU A-9000 connector X-9122. Place a jumper wire between X-9122 pin K28 and chassis ground. This will energize the main relay K-9102. With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From X-9122 pin K03 X-9122 pin K05 X-9122 pin K01

To X-9122 pin K02 X-9122 pin K04 X-9122 pin K06

Value There should be approximately 12 V. There should be approximately 12 V. There should be approximately 12 V.

A. If there is approximately 12 V, remove the jumper wire and re-connect the ECU A-9000 at connector X-9122, then continue to Step 5. B. If there is not approximately 12 V, there is a failure in the ECU A-9000 supply wiring. Use the appropriate service manual, if necessary, to locate and repair the failed conductor. 5.

Disconnect each of the following connectors one at a time. Monitor the status of this fault, 3811 - ECU internal failure - Sensor 5 volt supply 1 during the check. The TVA Z-9001 connector X-9011. The EGR valve Z-9000 connector X-9010. The intake manifold pressure and temperature sensor B-9001 connector X-9003. The rail pressure sensor B-9004 connector X-9026. The exhaust manifold pressure sensor B-9005 connector X-9018. The camshaft speed sensor B-9017 connector X-9008. A. If the fault is no longer active after a component disconnection, the relevant component has failed. Replace the component. B. If the fault is still active after the component disconnections, leave all of the connectors disconnected and continue to Step 6.

Check the TVA Z-9001 voltage supply wiring. Disconnect the vehicle harness (VE) from the ECU A-9000 at connectors X-9122 and X-9121. With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side :

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From X-9011 pin 1

To Chassis ground

Value There should be no voltage.

Disconnect the vehicle harness (VE) from the engine interface at connector X-9138. With the key in the OFF position, use a multimeter to perform the following continuity checks on the engine harness (EN) side : From X-9011 pin 1 X-9011 pin 1 X-9011 pin 1 X-9011 pin 1 X-9138 pin 41

To Chassis ground X-9011 pin 3 X-9011 pin 2 X-9011 pin 6 All pins in connector X-9138

Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

With the key in the OFF position, use a multimeter to perform the following continuity checks on the vehicle harness (VE) side : From X-9138 pin 41 X-9121 pin A08

To All pins in connector X-9138 All pins in connector X-9121

Value There should be no continuity. There should be no continuity.

Check the EGR valve Z-9000 voltage supply wiring. With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-9010 pin 6

To Chassis ground

Value There should be no voltage.

pin pin pin pin pin

6 6 6 6 33

To Chassis ground X-9010 pin 4 X-9010 pin 5 X-9010 pin 1 All pins in connector X-9138

Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

With the key in the OFF position, use a multimeter to perform the following continuity checks on the vehicle harness (VE) side : From X-9138 pin 33 X-9121 pin A09

To All pins in connector X-9138 All pins in connector X-9121

Value There should be no continuity. There should be no continuity.

Check the intake manifold pressure and temperature sensor B-9001 voltage supply wiring.

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With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-9003 pin 3

To Chassis ground

Value There should be no voltage.

To Chassis ground X-9003 pin 1 All pins in connector X-9138

Value There should be no continuity. There should be no continuity. There should be no continuity.

With the key in the OFF position, use a multimeter to perform the following continuity checks on the vehicle harness (VE) side : From X-9138 pin 17 X-9121 pin A10

To All pins in connector X-9138 All pins in connector X-9121

Value There should be no continuity. There should be no continuity.

A. If the specified values are measured, re-connect the engine interface connector X-9138 and leave the ECU A-9000 connectors X-9121 and X-9122 disconnected. Then, continue to Step 9. B. If the specified values are not measured, there is a failure in the intake manifold pressure and temperature sensor B-9001 voltage supply wiring. Use the appropriate service manual, if necessary, to locate and repair the failed conductor. 9.

Check the rail pressure sensor B-9004 voltage supply wiring. With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-9026 pin 3

To Chassis ground

Value There should be no voltage.

To Chassis ground X-9026 pin 1 All pins in connector X-9138

Value There should be no continuity. There should be no continuity. There should be no continuity.

With the key in the OFF position, use a multimeter to perform the following continuity checks on the vehicle harness (VE) side : From X-9138 pin 7 X-9121 pin A11

To All pins in connector X-9138 All pins in connector X-9121

Value There should be no continuity. There should be no continuity.

A. If the specified values are measured, re-connect the engine interface connector X-9138 and leave the ECU A-9000 connectors X-9121 and X-9122 disconnected. Then, continue to Step 10. B. If the specified values are not measured, there is a failure in the rail pressure sensor B-9004 voltage supply wiring. Use the appropriate service manual, if necessary, to locate and repair the failed conductor. 10. Check the exhaust manifold pressure sensor B-9005 voltage supply wiring.

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With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-9018 pin 1

To Chassis ground

Value There should be no voltage.

To Chassis ground X-9018 pin 2 All pins in connector X-9138

Value There should be no continuity. There should be no continuity. There should be no continuity.

With the key in the OFF position, use a multimeter to perform the following continuity checks on the vehicle harness (VE) side : From X-9138 pin 21 X-9121 pin A12

To All pins in connector X-9138 All pins in connector X-9121

Value There should be no continuity. There should be no continuity.

A. If the specified values are measured, re-connect the engine interface connector X-9138 and leave the ECU A-9000 connectors X-9121 and X-9122 disconnected. Then, continue to Step 11. B. If the specified values are not measured, there is a failure in the rail pressure sensor B-9004 voltage supply wiring. Use the appropriate service manual, if necessary, to locate and repair the failed conductor. 11. Check the camshaft speed sensor B-9017 voltage supply wiring. With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-9008 pin 3

To Chassis ground

Value There should be no voltage.

To Chassis ground X-9008 pin 3 All pins in connector X-9138

Value There should be no continuity. There should be no continuity. There should be no continuity.

With the key in the OFF position, use a multimeter to perform the following continuity checks on the vehicle harness (VE) side : From X-9138 pin 8 X-9121 pin A13

To All pins in connector X-9138 All pins in connector X-9121

Value There should be no continuity. There should be no continuity.

A. If the specified values are measured, re-connect all of the connectors and continue to Step 12. B. If the specified values are not measured, there is a failure in the camshaft speed sensor B-9017 voltage supply wiring. Use the appropriate service manual, if necessary, to locate and repair the failed conductor. 12. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern. 47683911 27/02/2015

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13. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, Then, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, Then, erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04) Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3812-Physical range check high for ECU temperature sensor C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 has an internal temperature sensor. The ECU A-9000 monitors this sensor. If the ECU A-9000 determines that the temperature sensor value is too high, this fault will occur. Cause: The ECU A-9000 has determined that the internal ECU A-9000 temperature sensor value is too high. Possible failure modes: 1. Machine is operating in extreme environmental conditions. 2. Faulty ECU A-9000, software. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3813-Physical range check low for ECU temperature sensor C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 has an internal temperature sensor. The ECU A-9000 monitors this sensor. If the ECU A-9000 determines that the temperature sensor value is too low, this fault will occur. Cause: The ECU A-9000 has determined that the internal ECU A-9000 temperature sensor value is too low. Possible failure modes: 1. Machine is operating in extreme environmental conditions. 2. Faulty ECU A-9000, software. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3814-Engine Controller Internal Temperature Out Of Range (SPI Error - LM71) C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 has an internal temperature sensor. The ECU A-9000 monitors this sensor and if the ECU A-9000 determines that there is an internal SPI communication error, this fault will occur. Cause: The ECU A-9000 has detected an error in the internal ECU A-9000 temperature sensor communication. Possible failure modes: 1. Faulty ECU A-9000, software. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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3818-Throttle valve actuator control circuit open WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the throttle valve actuator Z-9001 output 1 and output 2 h-bridge circuits. If the ECU A-9000 detects a an open circuit in the throttle valve actuator Z-9001 output h-bridge circuits, this fault will occur. Cause: The ECU A-9000 has detected an open circuit in the throttle valve actuator Z-9001 output h-bridge circuits. Possible failure modes: 1. Faulty throttle valve actuator Z-9001 wiring, open circuit. 2. Faulty throttle valve actuator Z-9001, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the throttle valve actuator Z-9001 h-bridge engine harness (EN) wiring for an open circuit. Disconnect the throttle valve actuator Z-9001 connector X-9011. Disconnect the vehicle harness (VE) from the engine interface connector X-9138. With the key in the OFF position, use a multimeter to perform the following continuity check for an open circuit on the engine harness (EN) side : From X-9011 pin 6 X-9011 pin 2

To X-9138 pin 37 X-9138 pin 38

Value There should be continuity. There should be continuity.

A. If there is no continuity, there is an open circuit in the throttle valve actuator Z-9001 engine harness (EN) h-bridge circuit. Locate and repair the broken conductor. B. If there is continuity, leave connectors X-9011 and X-9138 disconnected and continue to Step 3. 3. Check the throttle valve actuator Z-9001 h-bridge vehicle harness (VE) wiring for an open circuit.. Disconnect the ECU A-9000 connector X-9121. With the key in the OFF position, use a multimeter to perform the following continuity check for an open circuit on the vehicle harness (VE) side : From X-9138 pin 37 X-9138 pin 38

To X-9121 pin A49 X-9121 pin A34

Value There should be continuity. There should be continuity.

A. If there is no continuity, there is an open circuit in the throttle valve actuator Z-9001 vehicle harness (VE) h-bridge circuit. Use the appropriate service manual, if necessary, to locate and repair the broken conductor.

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B. If there is continuity, leave connector X-9011 disconnected and continue to Step 4. 4. Replace the throttle valve actuator Z-9001. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is no longer active, return the machine to service. B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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Electrical systems - FAULT CODES

3819-Throttle valve actuator control circuit over current WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the throttle valve actuator Z-9001 output 1 and output 2 h-bridge circuits. If the ECU A-9000 detects an over temperature/current condition in the throttle valve actuator Z-9001 h-bridge circuit, this fault will occur. Cause: The ECU A-9000 has detected an over temperature/current condition in the throttle valve actuator Z-9001 h-bridge circuit. Possible failure modes: 1. Faulty throttle valve actuator Z-9001 wiring, short to ground condition. 2. Faulty throttle valve actuator Z-9001 wiring, short to high source condition. 3. Faulty throttle valve actuator Z-9001, internal failure. 4. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 7. 2. Check the throttle valve actuator Z-9001 h-bridge wiring for a short to battery condition. Disconnect the engine harness (EN) from the throttle valve actuator Z-9001 at connector X-9011. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-9011 pin 6 X-9011 pin 2

To Chassis ground Chassis ground

Value There should be no voltage. There should be no voltage.

A. If there is voltage, there is a short to battery in the throttle valve actuator Z-9001 h-bridge circuit. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no voltage, leave connectors X-9011 and X-9121 disconnected and continue to Step 3. 3. Check the throttle valve actuator Z-9001 h-bridge wiring for a short to ground condition. With the key in the OFF position, use a multimeter to perform the following continuity check for a short to ground on the engine harness (EN) side : From X-9011 pin 6 X-9011 pin 2

To Chassis ground Chassis ground

Value There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short to ground in the throttle valve actuator Z-9001 h-bridge circuit. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor.

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B. If there is no continuity, leave connectors X-9011 and X-9121 disconnected and continue to Step 4. 4. Check the throttle valve actuator Z-9001 engine harness (EN) wiring for a short circuit condition. Disconnect the vehicle harness (VE) from the engine interface connector X-9138. With the key in the OFF position, use a multimeter to perform the following continuity check for a short circuit on the engine harness (EN) side : From X-9011 pin 6 X-9011 pin 6 X-9011 pin 2 X-9138 pin 37 X-9138 pin 38

To X-9011 pin 2 X-9011 pin 1 X-9011 pin 1 All pins in connector X-9138 All pins in connector X-9138

Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit in the throttle valve actuator Z-9001 engine harness (EN) h-bridge circuit. Locate and repair the shorted conductor. B. If there is no continuity, leave connectors X-9138, X-9121, and X-9011 disconnected and continue to Step 5. 5. Check the throttle valve actuator Z-9001 vehicle harness (VE) h-bridge circuit for a short to high source condition. With the key in the OFF position, use a multimeter to perform the following continuity check for a short circuit on the vehicle harness (VE) side : X-9138 X-9138 X-9121 X-9121

pin pin pin pin

From 37 38 A49 A34

To All pins in connector X-9138 All pins in connector X-9138 All pins in connector X-9121 All pins in connector X-9121

Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short to high source in the throttle valve actuator Z-9001 vehicle harness (VE) h-bridge circuit. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, leave connector X-9011 disconnected and continue to Step 6. 6. Replace the throttle valve actuator Z-9001. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is no longer active, return the machine to service. B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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Electrical systems - FAULT CODES

3820-Throttle valve actuator control circuit over temperature WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

To Chassis ground Chassis ground

Value There should be no voltage. There should be no voltage.

To Chassis ground Chassis ground

Value There should be no continuity. There should be no continuity.

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To X-9011 pin 2 X-9011 pin 1 X-9011 pin 1 All pins in connector X-9138 All pins in connector X-9138

Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

pin pin pin pin

From 37 38 A49 A34

To All pins in connector X-9138 All pins in connector X-9138 All pins in connector X-9121 All pins in connector X-9121

Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

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3821-Throttle valve actuator control circuit high side shorted to battery WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the throttle valve actuator Z-9001 output 1 and output 2 h-bridge circuits. If the ECU A-9000 detects a short to high source condition in the throttle valve actuator Z-9001 output 1 h-bridge circuit, this fault will occur. Cause: The ECU A-9000 has detected a short to high source condition in the throttle valve actuator Z-9001 output 1 h-bridge circuit. Possible failure modes: 1. Faulty throttle valve actuator Z-9001 wiring, short to a voltage source. 2. Faulty throttle valve actuator Z-9001, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check the throttle valve actuator Z-9001 output 1 h-bridge wiring for a short to battery condition. Disconnect the engine harness (EN) from the throttle valve actuator Z-9001 at connector X-9011. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-9011 pin 6

To Chassis ground

Value There should be no voltage.

A. If there is voltage, there is a short to battery in the throttle valve actuator Z-9001 output 1 h-bridge circuit. Use the appropriate service manual if necessary, to locate and repair the shorted conductor. B. If there is no voltage, leave connectors X-9011 and X-9121 disconnected and continue to Step 3. 3. Check the throttle valve actuator Z-9001 engine harness (EN) wiring for a short to high source condition. Disconnect the vehicle harness (VE) from the engine interface connector X-9138. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From X-9011 pin 6 X-9011 pin 6 X-9011 pin 6 X-9138 pin 37

To X-9011 pin 1 X-9011 pin 2 Chassis ground All pins in connector X-9138

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Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

Electrical systems - FAULT CODES

A. If there is continuity, there is a short to high source in the throttle valve actuator Z-9001 output 1 h-bridge circuit. Locate and repair the shorted conductor. B. If there is no continuity, leave connector X-9138 disconnected and continue to Step 4. 4. Check the throttle valve actuator Z-9001 vehicle harness (VE) wiring for a short to high source condition. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9138 pin 37 X-9121 pin A49

To All pins in connector X-9138 All pins in connector X-9121

Value There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short to high source in the throttle valve actuator Z-9001 output 1 h-bridge circuit. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, continue to Step 5. 5. Replace the throttle valve actuator Z-9001. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is no longer active, return the machine to service. B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3823-Throttle valve actuator control circuit high side shorted to ground WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the throttle valve actuator Z-9001 output 1 and output 2 h-bridge circuits. If the ECU A-9000 detects a short to ground condition in the throttle valve actuator Z-9001 output 1 h-bridge circuit, this fault will occur. Cause: The ECU A-9000 has detected a short to ground condition in the throttle valve actuator Z-9001 output 1 h-bridge circuit. Possible failure modes: 1. Faulty throttle valve actuator Z-9001 wiring, short to ground condition. 2. Faulty throttle valve actuator Z-9001, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the throttle valve actuator Z-9001 output 1 h-bridge engine harness (EN) wiring for a short to ground condition. Disconnect the throttle valve actuator Z-9001 connector X-9011. Disconnect the vehicle harness (VE) from the engine interface connector X-9138. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From X-9011 pin 6 X-9011 pin 6 X-9011 pin 6 X-9138 pin 37

To Chassis ground X-9011 pin 2 X-9011 pin 3 All pins in connector X-9138

Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

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From X-9138 pin 37 X-9121 pin A49

To All pins in connector X-9138 All pins in connector X-9121

Value There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit in the throttle valve actuator Z-9001 output 1 h-bridge circuit. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, leave connector X-9011 disconnected and continue to Step 4. 4. Replace the throttle valve actuator Z-9001. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is no longer active, return the machine to service. B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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Electrical systems - FAULT CODES

3824-Throttle valve actuator control circuit low side shorted to ground WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the throttle valve actuator Z-9001 output 1 and output 2 h-bridge circuits. If the ECU A-9000 detects a short to ground condition in the throttle valve actuator Z-9001 output 2 h-bridge circuit, this fault will occur. Cause: The ECU A-9000 has detected a short to ground condition in the throttle valve actuator Throttle valve actuator H-bridge control circuit shorted to ground output 2 h-bridge circuit. Possible failure modes: 1. Faulty throttle valve actuator Z-9001 wiring, short to ground condition. 2. Faulty throttle valve actuator Z-9001, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the throttle valve actuator Z-9001 output 2 h-bridge engine harness (EN) wiring for a short to ground condition. Disconnect the engine harness (EN) from the throttle valve actuator Z-9001 at connector X-9011. Disconnect the vehicle harness (VE) from the engine interface at connector X-9138. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From X-9011 pin 2 X-9011 pin 2 X-9011 pin 2 X-9138 pin 38

To Chassis ground X-9011 pin 3 X-9011 pin 6 All pins in connector X-9138

Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit in the throttle valve actuator Z-9001 output 2 h-bridge circuit. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, leave connector X-9011 and X-9138 disconnected and continue to Step 3. 3. Check the throttle valve actuator Z-9001 output 2 h-bridge vehicle harness (VE) wiring for a short to ground condition. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side :

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From X-9138 pin 38 X-9121 pin A34

To All pins in connector X-9138 All pins in connector X-9121

Value There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit in the throttle valve actuator Z-9001 output 2 h-bridge circuit. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, continue to Step 4. 4. Replace the throttle valve actuator Z-9001. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is no longer active, return the machine to service. B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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Electrical systems - FAULT CODES

3825-Throttle valve actuator control circuit over load WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the throttle valve actuator Z-9001 output 1 and output 2 h-bridge circuits. The ECU A-9000 monitors both circuits for a short circuit condition. If the ECU A-9000 determines that the output 1 circuit and output 2 circuits are shorted together, this fault will occur. Cause: The ECU A-9000 has detected a short circuit between the throttle valve actuator Z-9001 output 1 and output 2 h-bridge circuits. Possible failure modes: 1. Faulty throttle valve actuator Z-9001 h-bridge wiring short circuit. 2. Faulty throttle valve actuator Z-9001, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the throttle valve actuator Z-9001 h-bridge circuits engine harness (EN) wiring for a short circuit. Disconnect the engine harness (EN) from the throttle valve actuator Z-9001 at connector X-9011. Disconnect the vehicle harness (VE) from the engine interface at connector X-9138. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From X-9011 pin 2

To X-9011 pin 6

Value There should be no continuity.

A. If there is continuity, there is a short circuit in the throttle valve actuator Z-9001 h-bridge wiring. Locate and repair the shorted conductor. B. If there is no continuity, leave the connectors disconnected and continue to Step 3. 3. Check the throttle valve actuator Z-9001 h-bridge circuits vehicle harness (VE) wiring for a short circuit. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9138 pin 37

To X-9138 pin 38

Value There should be no continuity.

A. If there is continuity, there is a short circuit in the throttle valve actuator Z-9001 h-bridge wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, leave the connectors disconnected and continue to Step 4.

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4. Replace the throttle valve actuator Z-9001. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is no longer active, return the machine to service. B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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Electrical systems - FAULT CODES

3827-Throttle valve actuator control circuit supply voltage too low WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 internally monitors the operation of the H-bridge Pulse Width Modulated (PWM) control circuit for the Throttle Valve Actuator (TVA) Z-9001 motor actuator for electrical defects. If the ECU A-9000 senses too low an output driver supply voltage, this fault will occur. Cause: The ECU A-9000 is sensing too high a system voltage fluctuation. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continues with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 4. 2. Check for related faults. Use the EST to check for faults relative to low battery, control system voltage level or throttle valve actuator Z-9001. A. If low voltage level faults are present, resolve those faults and then return to this fault. B. If no low voltage level faults are present, continue with Step 3. 3. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation.

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Electrical systems - FAULT CODES

3834-Throttle valve actuator position sensor voltage is higher than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the throttle valve actuator Z-9001 position sensor signal circuit. If the ECU A-9000 detects a voltage greater than 4.75 V in the throttle valve actuator Z-9001 position sensor signal circuit, this fault will occur. Cause: The ECU A-9000 has detected a voltage greater than 4.75 V in the throttle valve actuator Z-9001 position sensor signal circuit. Possible failure modes: 1. Faulty throttle valve actuator Z-9001 wiring, short to a voltage source. 2. Faulty throttle valve actuator Z-9001, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 7. 2. Check the throttle valve actuator Z-9001 position sensor wiring for a short to battery condition. Disconnect the engine harness (EN) from the throttle valve actuator Z-9001 at connector X-9011. Disconnect the vehicle harness (VE) from the engine interface at connector X-9138. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-9011 pin 5

To Chassis ground

Value There should be no voltage.

A. If there is voltage, there is a short to battery in the throttle valve actuator Z-9001 position sensor signal circuit. Use the appropriate service manual if necessary, to locate and repair the shorted conductor. B. If there is no voltage, leave connectors X-9011, X-9138, and X-9121 disconnected. Then, continue to Step 3. 3. Check the throttle valve actuator Z-9001 position sensor wiring for an open circuit. With the key in the OFF position, use a multimeter to perform the following continuity check on the harness side : From To Value X-9011 pin 5 X-9138 pin 42 There should be continuity. X-9138 pin 42 X-9121 pin A53 There should be continuity. NOTE: Wiggle the harness during the check to promote an intermittent electrical connection. A. If there is no continuity, there is an open circuit in the throttle valve actuator Z-9001 position sensor signal circuit. Use the appropriate service manual if necessary, to locate and repair the broken conductor. 47683911 27/02/2015

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B. If there is continuity, continue to Step 4. 4. Check the throttle valve actuator Z-9001 position sensor engine harness (EN) wiring for a short to high source condition. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From X-9011 pin 5 X-9011 pin 5 X-9011 pin 5 X-9138 pin 42

To X-9011 pin 6 X-9011 pin 2 X-9011 pin 1 All pins in connector X-9138

Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short to high source in the throttle valve actuator Z-9001 engine harness (EN) position sensor signal circuit. Locate and repair the shorted conductor. B. If there is no continuity, continue to Step 5. 5. Check the throttle valve actuator Z-9001 position sensor vehicle harness (VE) wiring for a short to high source condition. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9138 pin 42 X-9121 pin A53

To All pins in connector X-9138 All pins in connector X-9121

Value There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short to high source in the throttle valve actuator Z-9001 position sensor signal circuit in the vehicle harness (VE).Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, continue to Step 5. 6. Replace the throttle valve actuator Z-9001. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is no longer active, return the machine to service. B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3835-Throttle valve actuator position sensor voltage is lower than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the throttle valve actuator Z-9001 position sensor signal circuit. If the ECU A-9000 detects a voltage less than 0.25 V in the throttle valve actuator Z-9001 position sensor signal circuit, this fault will occur. Cause: The ECU A-9000 has detected a voltage less than 0.25 V in the throttle valve actuator Z-9001 position sensor signal circuit. Possible failure modes: 1. Faulty throttle valve actuator Z-9001 wiring, short to ground condition. 2. Faulty throttle valve actuator Z-9001, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the throttle valve actuator Z-9001 position sensor engine harness (EN) wiring for a short to ground condition. Disconnect the engine harness (EN) from the throttle valve actuator Z-9001 at connector X-9011. Disconnect the vehicle harness (VE) from the engine interface at connector X-9138. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From X-9011 pin 5 X-9011 pin 5 X-9011 pin 5 X-9138 pin 42

To Chassis ground X-9011 pin 3 X-9011 pin 2 All pins in connector X-9138

Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short to ground condition in the throttle valve actuator Z-9001 position sensor signal circuit in the engine harness (EN).Locate and repair the shorted conductor. B. If there is no continuity, leave connectors X-9011 and X-9138 disconnected and continue to Step 3. 3. Check the throttle valve actuator Z-9001 position sensor vehicle harness (VE) wiring for a short to ground condition. Disconnect the vehicle harness from the ECU A-9000 at connector X-9121. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9138 pin 42 X-9121 pin A53

To All pins in connector X-9138 All pins in connector X-9121 47683911 27/02/2015

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Value There should be no continuity. There should be no continuity.

Electrical systems - FAULT CODES

A. If there is continuity, there is a short to ground in the throttle valve actuator Z-9001 position sensor signal circuit in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, leave connector X-9011 disconnected and continue to Step 4. 4. Replace the throttle valve actuator Z-9001. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is no longer active, return the machine to service. B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3838-DOC inlet temperature sensor voltage is higher than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the Diesel Oxidation Catalyst (DOC) inlet temperature sensor B-9127. If the ECU A-9000 detects a voltage greater than 3.59 V in the diesel oxidation catalyst inlet temperature sensor B-9127 signal circuit, this fault will occur. Cause: The ECU A-9000 has detected a voltage greater than 3.59 V in the diesel oxidation catalyst inlet temperature sensor B-9127 signal circuit. For more information regarding the technical specifications of the DOC inlet temperature sensor B-9127, refer to the engine service manual Exhaust Gas Recirculation (EGR) temperature sensors Diesel Oxidation Catalyst (DOC) inlet temperature sensor - Technical Data (55.989). Possible failure modes: 1. Faulty diesel oxidation catalyst inlet temperature sensor B-9127 wiring, short to voltage source. 2. Faulty diesel oxidation catalyst inlet temperature sensor B-9127 wiring, open circuit. 3. Faulty diesel oxidation catalyst inlet temperature sensor B-9127, internal failure. 4. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check the diesel oxidation catalyst inlet temperature sensor B-9127 for an internal failure. Disconnect the engine harness (EN) from the diesel oxidation catalyst inlet temperature sensor B-9127 at connector X-9127. Use a multimeter to measure the resistance on the diesel oxidation catalyst inlet temperature sensor B-9127 : From X-9009 pin 1

To X-9009 pin 2

Value There should be between 170.2 849.7 Ω.

A. If there is between 170.2 - 849.7 Ω, leave connector X-9127 disconnected and continue to Step 3. B. If there is not between 170.2 - 849.7 Ω, the diesel oxidation catalyst inlet temperature sensor B-9127 has failed. Replace the diesel oxidation catalyst inlet temperature sensor B-9127. 3. Check the diesel oxidation catalyst inlet temperature sensor B-9127 vehicle harness (VE) wiring for a short circuit. With the key in the OFF position, use a multimeter to perform the following voltage check on the vehicle harness side : From X-9127 pin 1

To Chassis ground

Value There should be no voltage.

A. If there is voltage, there is a short to battery in the diesel oxidation catalyst inlet temperature sensor B-9127 wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no voltage, leave connector X-9127 disconnected and continue to Step 4. 47683911 27/02/2015

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4. Check the diesel oxidation catalyst inlet temperature sensor B-9127 vehicle harness (VE) wiring for an open circuit condition. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9127 pin 1 X-9127 pin 2

To X-9122 pin K84 X-9122 pin K83

Value There should be continuity. There should be continuity.

A. If there is no continuity, there is an open circuit in the diesel oxidation catalyst inlet temperature sensor B-9127 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the broken conductor. B. If there is continuity, leave connector X-9122 disconnected and continue to Step 5. 5. Check the diesel oxidation catalyst inlet temperature sensor B-9127 vehicle harness (VE) wiring for a short circuit condition. With the key in the OFF position, use a multimeter to perform the following continuity check at the vehicle harness (VE) side of the connectors from : From X-9122 pin K84

To All pins in connector X-9122

Value There should be no continuity.

A. If there is continuity, there is a short circuit in the diesel oxidation catalyst inlet temperature sensor B-9127 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 03 - Exhaust system and Controller Area Network (CAN) bus (55.100.DP-C.20.E.03) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3839-DOC inlet temperature sensor voltage is lower than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the Diesel Oxidation Catalyst (DOC) inlet temperature sensor B-9127. If the ECU A-9000 detects a voltage less than 459.40 mV in the diesel oxidation catalyst inlet temperature sensor B-9127 signal circuit, this fault will occur. Cause: The ECU A-9000 has detected a voltage less than 459.40 mV in the diesel oxidation catalyst inlet temperature sensor B-9127 signal circuit. For more information regarding the technical specifications of the DOC inlet temperature sensor B-9127, refer to the engine service manual Exhaust Gas Recirculation (EGR) temperature sensors Diesel Oxidation Catalyst (DOC) inlet temperature sensor - Technical Data (55.989). Possible failure modes: 1. Faulty diesel oxidation catalyst inlet temperature sensor B-9127 wiring, short circuit to ground. 2. Faulty diesel oxidation catalyst inlet temperature sensor B-9127, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the diesel oxidation catalyst inlet temperature sensor B-9127 for an internal failure. Disconnect the engine harness (EN) from the diesel oxidation catalyst inlet temperature sensor B-9127 at connector X-9127. Use a multimeter to measure the resistance on the diesel oxidation catalyst inlet temperature sensor B-9127 : From X-9009 pin 1

To X-9009 pin 2

Value There should be between 170.2 849.7 Ω.

A. If there is between 170.2 - 849.7 Ω, leave connector X-9127 disconnected and continue to Step 3. B. If there is not between 170.2 - 849.7 Ω, the diesel oxidation catalyst inlet temperature sensor B-9127 has failed. Replace the diesel oxidation catalyst inlet temperature sensor B-9127. 3. Check the diesel oxidation catalyst inlet temperature sensor B-9127 vehicle harness (VE) wiring for a short circuit condition. Disconnect the engine harness from the diesel oxidation catalyst inlet temperature sensor B-9127 at connector X-9127. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9127 pin 1 X-9127 pin 1

To X-9127 pin 2 Chassis ground

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Value There should be no continuity. There should be no continuity.

Electrical systems - FAULT CODES

To All pins in connector X-9122

Value There should be no continuity.

A. If there is continuity, there is a short circuit in the diesel oxidation catalyst inlet temperature sensor B-9127 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 03 - Exhaust system and Controller Area Network (CAN) bus (55.100.DP-C.20.E.03) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3840-PMCat inlet temperature sensor voltage is higher than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the Particulate Matter (PM) catalytic converter inlet temperature sensor B-9126. If the ECU A-9000 detects a voltage greater than 3.59 V in the PM catalytic converter inlet temperature sensor B-9126 signal circuit, this fault will occur. If this fault is active, the last valid temperature value will be frozen for a preliminary failure or set to a fixed replacement value of 99.96 °C (211.93 °F) if the failure is validated. Cause: The ECU A-9000 has detected a voltage greater than 3.59 V in the PM catalytic converter inlet temperature sensor B-9126 signal circuit. Possible failure modes: 1. Faulty PM catalytic converter inlet temperature sensor B-9126 wiring, short to a voltage source. 2. Faulty PM catalytic converter inlet temperature sensor B-9126, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check the PM catalytic converter inlet temperature sensor B-9126 for an internal failure. Disconnect the vehicle harness from the PM catalytic converter inlet temperature sensor B-9126 at connector X-9126. Use a multimeter to measure the resistance on the PM catalytic converter inlet temperature sensor B-9126 : From X-9126 pin 1

To X-9126 pin 2

Value There should be between 170.2 849.7 Ω.

A. If there is between 170.2 - 849.7 Ω, leave connector X-9126 disconnected and continue to Step 3. B. If there is between 170.2 - 849.7 Ω, the PM catalytic converter inlet temperature sensor B-9126 has failed. Replace the PM catalytic converter inlet temperature sensor B-9126. 3. Check the PM catalytic converter inlet temperature sensor B-9126 vehicle harness (VE) wiring for a short circuit to battery. With the key in the OFF position, use a multimeter to perform the following voltage check on the vehicle harness side : From X-9126 pin 2

To Chassis ground

Value There should be no voltage.

With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness side :

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From X-9126 pin 2

To Chassis ground

Value There should be less than 5.5 V

A. If the specified values are not measured, there is a short to battery in the PM catalytic converter inlet temperature sensor B-9126 wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If the specified values are measured, leave connector X-9126 disconnected and continue to Step 4. 4. Check the PM catalytic converter inlet temperature sensor B-9126 vehicle harness (VE) wiring for an open circuit condition. Disconnect the vehicle harness from the ECU A-9000 at connector X-9122. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9126 pin 2 X-9126 pin 1

To X-9122 pin K80 X-9122 pin K79

Value There should be continuity. There should be continuity.

A. If there is no continuity, there is an open circuit in the PM catalytic converter inlet temperature sensor B-9126 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the broken conductor. B. If there is continuity, leave connectors X-9122 and X-9126 disconnected and continue to Step 5. 5. Check the PM catalytic converter inlet temperature sensor B-9126 vehicle harness (VE) wiring for a short circuit condition. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9122 pin K80 X-9122 pin K79

To All pins in connector X-9122 All pins in connector X-9122

Value There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit in the PM catalytic converter inlet temperature sensor B-9126 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 03 - Exhaust system and Controller Area Network (CAN) bus (55.100.DP-C.20.E.03) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3841-PMCat inlet temperature sensor voltage is lower than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the Particulate Matter (PM) catalytic converter inlet temperature sensor B-9126. If the ECU A-9000 detects a voltage less than 459.40 mV in the PM catalytic converter inlet temperature sensor B-9126 signal circuit, this fault will occur. If this fault is active, the last valid temperature value will be frozen for a preliminary failure or set to a fixed replacement value of 99.96 °C (211.93 °F) if the failure is validated. Cause: The ECU A-9000 has detected a voltage less than 459.40 mV in the PM catalytic converter inlet temperature sensor B-9126 signal circuit. Possible failure modes: 1. Faulty PM catalytic converter inlet temperature sensor B-9126 wiring, short to ground condition. 2. Faulty PM catalytic converter inlet temperature sensor B-9126, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the PM catalytic converter inlet temperature sensor B-9126 for an internal failure. Disconnect the vehicle harness from the PM catalytic converter inlet temperature sensor B-9126 at connector X-9126. Use a multimeter to measure the resistance on the PM catalytic converter inlet temperature sensor B-9126 pins : From X-9126 pin 1

To X-9126 pin 2

Value There should be between 170.2 849.7 Ω.

A. If there is between 170.2 - 849.7 Ω, leave connector X-9126 disconnected and continue to Step 3. B. If there is between 170.2 - 849.7 Ω, the PM catalytic converter inlet temperature sensor B-9126 has failed. Replace the PM catalytic converter inlet temperature sensor B-9126. 3. Check the PM catalytic converter inlet temperature sensor B-9126 vehicle harness (VE) wiring for a short circuit condition. With the key in the OFF position, use a multimeter to perform the following continuity check on vehicle harness (VE) side : From X-9126 pin 2 X-9126 pin 2

To X-9126 pin 1 Chassis ground

Value There should be no continuity. There should be no continuity.

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B. If there is no continuity, leave the connectors disconnected and continue to Step 4. 4. Check the PM catalytic converter inlet temperature sensor B-9126 vehicle harness (VE) wiring for a short circuit condition. Disconnect the vehicle harness from the ECU A-9000 at connector X-9122. With the key in the OFF position, use a multimeter to perform the following continuity check at the vehicle harness (VE) side of the connectors from : From X-9122 pin K80

To All pins in connector X-9122

Value There should be no continuity.

A. If there is continuity, there is a short circuit in the PM catalytic converter inlet temperature sensor B-9126 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 03 - Exhaust system and Controller Area Network (CAN) bus (55.100.DP-C.20.E.03) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3842-Exhaust manifold temperature sensor voltage is higher than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the exhaust manifold temperature sensor B-9018. If the ECU A-9000 detects a voltage greater than 3.59 V in the exhaust manifold temperature sensor B-9018 signal circuit, this fault will occur. The sensor value will be frozen at the last valid value for a preliminary failure or jump to a fixed replacement value of 350 °C (662 °F) if the failure is validated. For more information regarding the technical specifications of the exhaust manifold temperature sensor B-9018, refer to the engine service manual Exhaust manifold temperature sensor - Technical Data (55.014). Cause: The ECU A-9000 has detected a voltage greater than 3.59 V in the exhaust manifold temperature sensor B-9018 signal circuit. Possible failure modes: 1. Faulty exhaust manifold temperature sensor B-9018 circuit wiring, shorted to a voltage source. 2. Faulty exhaust manifold temperature sensor B-9018 circuit wiring, open circuit. 3. Faulty exhaust manifold temperature sensor B-9018, internal failure. 4. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 7. 2. Check the exhaust manifold temperature sensor B-9018 for an internal failure. Disconnect the engine harness (EN) from the exhaust manifold temperature sensor B-9018 at connector X-9009. Use a multimeter to measure the resistance on the exhaust manifold temperature sensor B-9018 pins : From X-9009 pin 1

To X-9009 pin 2

Value There should be between 170.2 849.7 Ω.

A. If there is between 170.2 - 849.7 Ω, leave connector X-9009 disconnected and continue to Step 3. B. If there is not between 170.2 - 849.7 Ω, the exhaust manifold temperature sensor B-9018 has failed. Replace the exhaust manifold temperature sensor B-9018. 3. Check the exhaust manifold temperature sensor B-9018 engine harness (EN) wiring. With the key in the OFF position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-9009 pin 1

To Chassis ground

Value There should be no voltage.

With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : 47683911 27/02/2015

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From X-9009 pin 1

To Chassis ground

Value There should be less than 5.5 V.

A. If the specified values are not measured, there is a short to battery condition in the exhaust manifold temperature sensor B-9018 signal circuit wiring. Use the appropriate service manual, if necessary, to locate and repair the damaged conductors. B. If the specified values are measured, leave connector X-9009 disconnected and continue to Step 4. 4. Check the exhaust manifold temperature sensor B-9018 circuit wiring for an open circuit condition. Disconnect the vehicle harness (VE) from the engine interface connector at connector X-9138. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From X-9009 pin 1 X-9009 pin 2

To X-9138 pin 26 X-9138 pin 25

Value There should be continuity. There should be continuity.

With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9138 pin 26 X-9138 pin 25

To X-9121 pin A43 X-9121 pin A27

Value There should be continuity. There should be continuity.

A. If there is no continuity, there is an open circuit in the exhaust manifold temperature sensor B-9018 signal circuit wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is continuity on both checks, leave connector X-9138 and connector X-9121 disconnected and continue to Step 5. 5. Check the exhaust manifold temperature sensor B-9018 engine harness (EN) wiring. With the key in the OFF position, use a multimeter to perform the following continuity check at the engine harness (EN) side : From X-9138 pin 26 X-9138 pin 25

To All pins in connector X-9138 All pins in connector X-9138

Value There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short to a voltage source condition in the exhaust manifold temperature sensor B-9018 signal circuit in the engine harness (EN) wiring. Locate and repair the shorted conductor. B. If there is no continuity, continue to Step 6. 6. Check the exhaust manifold temperature sensor B-9018 vehicle harness (VE) wiring. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : X-9138 X-9138 X-9121 X-9121

pin pin pin pin

From 26 25 A43 A27

To All pins in connector X-9138 All pins in connector X-9138 All pins in connector X-9121 All pins in connector X-9121

Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short to voltage source condition in the exhaust manifold temperature sensor B-9018 signal circuit in the vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the damaged conductors.

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Electrical systems - FAULT CODES

B. If there is no continuity, Check the ECU A-9000 software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3843-Exhaust manifold temperature sensor voltage is lower than expected WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the exhaust manifold temperature sensor B-9018. If the ECU A-9000 detects a voltage less than 0.45 V in the exhaust manifold temperature sensor B-9018 signal circuit, this fault will occur. The sensor value will be frozen at the last valid value for a preliminary failure or jump to a fixed replacement value of 350 °C (662 °F) if the failure is validated. Cause: The ECU A-9000 has detected a voltage less than 0.45 V in the exhaust manifold temperature sensor B-9018 signal circuit. For more information regarding the technical specifications of the exhaust manifold temperature sensor B-9018, refer to the engine service manual Exhaust manifold temperature sensor - Technical Data (55.014). Possible failure modes: 1. Faulty exhaust manifold temperature sensor B-9018 wiring, short circuit to ground. 2. Faulty exhaust manifold temperature sensor B-9018, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the exhaust manifold temperature sensor B-9018 for an internal failure. Disconnect the engine harness (EN) from the exhaust manifold temperature sensor B-9018 at connector X-9009. Use a multimeter to measure the resistance on the exhaust manifold temperature sensor B-9018 pins : From X-9009 pin 1

To X-9009 pin 2

Value There should be between 170.2 849.7 Ω.

A. If there is between 170.2 - 849.7 Ω, leave connector X-9009 disconnected and continue to Step 3. B. If there is not between 170.2 - 849.7 Ω, the exhaust manifold temperature sensor B-9018 has failed. Replace the exhaust manifold temperature sensor B-9018. 3. Check the exhaust manifold temperature sensor B-9018 engine harness (EN) wiring. Disconnect the vehicle harness (VE) from the engine interface connector X-9138. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From X-9138 pin 26 X-9138 pin 26

To X-9138 pin 25 All pins in connector X-9138

Value There should be no continuity. There should be no continuity.

A. If there is continuity , there is a short circuit in the exhaust manifold temperature sensor B-9018 signal circuit in the engine harness (EN) wiring. Locate and repair the shorted conductor. 47683911 27/02/2015

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B. If there is no continuity, leave connector X-9138 disconnected and continue to Step 4. 4. Check the exhaust manifold temperature sensor B-9018 vehicle harness (VE) wiring. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-9138 pin 26 X-9138 pin 26 X-9121 pin A43

To X-9138 pin 25 All pins in connector X-9138 All pins in connector X-9121

Value There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit in the exhaust manifold temperature sensor B-9018 signal circuit in the vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, check the ECU A-9000 for the appropriate service manual and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 05 - Engine Control Unit (ECU) engine connector (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 06 - Engine control and fuel injection (55.100.DP-C.20.E.06)

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3844-Error in comparing energizing time to maximum value for injector in cylinder 1 C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Zero Fuel Calibration (ZFL) evaluates energizing time for injectors at low idle. The ZFL uses learned calibration values to change the energizing time of the pilot fuel injection. If the Engine Control Unit (ECU) A-9000 determines that there is an error during this process, this fault will occur. Cause: The ECU A-9000 has determined that there is an error in the ZFL process for fuel injector number 1 Y-9001. Solution: 1. Verify that the correct IMA injector code has been programmed to injector number 1. A. If the correct IMA code is present, continue to Step 2. B. If the correct IMA code has not been uploaded, program the correct IMA code. NOTE: The IMA code may be under the paint on the fuel injector. NOTE: For more information regarding programming IMA codes, refer to the engine service manual Fuel injectors - Configure - IMA codes (10.218). 2. Replace the fuel injector number 1 Y-9001. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, continue to Step 3. 3. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3845-Error in comparing energizing time to maximum value for injector in cylinder 2 C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Zero Fuel Calibration (ZFL) evaluates energizing time for injectors at low idle. The ZFL uses learned calibration values to change the energizing time of the pilot fuel injection. If the Engine Control Unit (ECU) A-9000 determines that there is an error during this process, this fault will occur. Cause: The ECU A-9000 has determined that there is an error in the ZFL process for fuel injector number 2 Y-9002. Solution: 1. Verify that the correct IMA injector code has been programmed to injector number 2. A. If the correct IMA code is present, continue to Step 2. B. If the correct IMA code has not been uploaded, program the correct IMA code. NOTE: The IMA code may be under the paint on the fuel injector. NOTE: For more information regarding programming IMA codes, refer to the engine service manual Fuel injectors - Configure - IMA codes (10.218). 2. Replace the fuel injector number 2 Y-9002. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, continue to Step 3. 3. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3846-Error in comparing energizing time to maximum value for injector in cylinder 3 C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Zero Fuel Calibration (ZFL) evaluates energizing time for injectors at low idle. The ZFL uses learned calibration values to change the energizing time of the pilot fuel injection. If the Engine Control Unit (ECU) A-9000 determines that there is an error during this process, this fault will occur. Cause: The ECU A-9000 has determined that there is an error in the ZFL process for fuel injector number 3 Y-9003. Solution: 1. Verify that the correct IMA injector code has been programmed to injector number 3. A. If the correct IMA code is present, continue to Step 2. B. If the correct IMA code has not been uploaded, program the correct IMA code. 2. Replace the fuel injector number 3 Y-9003. Use the Electronic Service Tool (EST) to verify the status of this fault, 3846 - Error in comparing energizing time to maximum value for injector in cylinder 3. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, continue to Step 3. 3. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3847-Error in comparing energizing time to maximum value for injector in cylinder 4 C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Zero Fuel Calibration (ZFL) evaluates energizing time for injectors at low idle. The ZFL uses learned calibration values to change the energizing time of the pilot fuel injection. If the Engine Control Unit (ECU) A-9000 determines that there is an error during this process, this fault will occur. Cause: The ECU A-9000 has determined that there is an error in the ZFL process for fuel injector number 4 Y-9004. Solution: 1. Verify that the correct IMA injector code has been programmed to injector number 4. A. If the correct IMA code is present, continue to Step 2. B. If the correct IMA code has not been uploaded, program the correct IMA code. 2. Replace the fuel injector number 4 Y-9004. Use the Electronic Service Tool (EST) to verify the status of this fault, 3847 - Error in comparing energizing time to maximum value for injector in cylinder 4. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, continue to Step 3. 3. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3848-Error in comparing energizing time to minimum value for injector in cylinder 1 C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

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3849-Error in comparing energizing time to minimum value for injector in cylinder 2 C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Zero Fuel Calibration (ZFL) evaluates energizing time for injectors at low idle. The ZFL uses learned calibration values to change the energizing time of the pilot fuel injection. If the Engine Control Unit (ECU) A-9000 determines that there is an error during this process, this fault will occur. Cause: The ECU A-9000 has determined that there is an error in the ZFL process for fuel injector number 2 Y-9002. Solution: 1. Verify that the correct IMA injector code has been programmed to injector number 2. A. If the correct IMA code is present, continue to Step 2. B. If the correct IMA code has not been uploaded, program the correct IMA code. NOTE: The IMA code may be under the paint on the fuel injector. NOTE: For more information regarding programming IMA codes, refer to the engine service manual Fuel injectors - Configure - IMA codes (10.218). 2. Replace the fuel injector number 2 Y-9002. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, continue to Step 3. 3. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3850-Error in comparing energizing time to minimum value for injector in cylinder 3 C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Zero Fuel Calibration (ZFL) evaluates energizing time for injectors at low idle. The ZFL uses learned calibration values to change the energizing time of the pilot fuel injection. If the Engine Control Unit (ECU) A-9000 determines that there is an error during this process, this fault will occur. Cause: The ECU A-9000 has determined that there is an error in the ZFL process for fuel injector number 3 Y-9003. Solution: 1. Verify that the correct IMA injector code has been programmed to injector number 3. A. If the correct IMA code is present, continue to Step 2. B. If the correct IMA code has not been uploaded, program the correct IMA code. 2. Replace the fuel injector number 3 Y-9003. Use the Electronic Service Tool (EST) to verify the status of this fault, 3850 - Error in comparing energizing time to minimum value for injector in cylinder 3. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, continue to Step 3. 3. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3851-Error in comparing energizing time to minimum value for injector in cylinder 4 C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Zero Fuel Calibration (ZFL) evaluates energizing time for injectors at low idle. The ZFL uses learned calibration values to change the energizing time of the pilot fuel injection. If the Engine Control Unit (ECU) A-9000 determines that there is an error during this process, this fault will occur. Cause: The ECU A-9000 has determined that there is an error in the ZFL process for fuel injector number 4 Y-9004. Solution: 1. Verify that the correct IMA injector code has been programmed to injector number 4. A. If the correct IMA code is present, continue to Step 2. B. If the correct IMA code has not been uploaded, program the correct IMA code. 2. Replace the fuel injector number 4 Y-9004. Use the Electronic Service Tool (EST) to verify the status of this fault, 3851 - Error in comparing energizing time to minimum value for injector in cylinder 4. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, continue to Step 3. 3. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3899-Engine coolant temperature has exceeded the pre-warning threshold WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the engine coolant temperature. Two engine temperature thresholds are monitored by the ECU A-9000, a pre-warning, and a warning. If the ECU A-9000 monitors a temperature greater than 107.96 °C (226.33 °F), a pre-warning is set and this fault will occur. For more information regarding cooling system troubleshooting, refer to the engine service manual Engine cooling system - Troubleshooting (10.400). Cause: A coolant temperature level pre-warning has been set by the ECU A-9000. Possible failure modes: 1. Coolant level low. 2. Faulty cooling system, leakage or blockage. 3. Extremely high environmental temperature or heavy machine use. 4. Faulty coolant temperature sensor B-9003, wiring or internal failure of sensor. 5. Faulty ECU A-9000, software.

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3900-Engine coolant temperature has exceeded the warning threshold WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the engine coolant temperature. Two engine temperature thresholds are monitored by the ECU A-9000, a pre-warning, and a warning. If the ECU A-9000 monitors a temperature greater than 111.96 °C (233.53 °F), a warning is set and this fault will occur. For more information regarding cooling system troubleshooting, see Engine cooling system - Troubleshooting (10.400) in the engine service manual. Cause: A coolant temperature level warning has been set by the ECU A-9000. Possible failure modes: 1. Coolant level low. 2. Faulty cooling system, leakage or blockage. 3. Extremely high environmental temperature or heavy machine use. 4. Faulty coolant temperature sensor B-9003, wiring or internal failure of sensor. 5. Faulty ECU A-9000, software.

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Electrical systems - FAULT CODES

3906-Number of injections is limited by quantity balance of high pressure pump C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors the requested number of fuel injections and the current capability of the fuel injection system to fulfill that request. If the ECU A-9000 determines that the requested number of fuel injections can not be reached, this fault will occur. Cause: The ECU A-9000 has determined that the requested number of fuel injections is greater than the current capability of the fuel injection system. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3910-Fuel metering unit intermittent electrical connection failure WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the fuel metering unit Y-9000 signal circuit. If the ECU A-9000 detects an intermittent connection in the fuel metering unit Y-9000 signal circuit, this fault will occur. Cause: The ECU A-9000 has detected a intermittent connection in the fuel metering unit Y-9000 signal circuit. Possible failure modes: 1. Faulty fuel metering unit Y-9000 wiring, open circuit. 2. Faulty fuel metering unit Y-9000, internal failure. 3. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Test the fuel metering unit Y-9000 internal resistance. Disconnect the engine harness (EN) from the fuel metering unit Y-9000 at connector X-9007. Use a multimeter to measure the resistance on the fuel metering unit Y-9000 pins : From X-9007 pin 1

To X-9007 pin 2

Value There should be between 2.6 - 3.2 Ω at approximately 20.0 °C (68.0 °F).

A. If there is between 2.6 - 3.2 Ω, leave connector X-9007 disconnected and continue to Step 3. B. If there is not between 2.6 - 3.2 Ω, the fuel metering unit Y-9000 has failed. Replace the fuel metering unit Y-9000. 3. Check the fuel metering unit Y-9000 engine harness (EN) wiring for an open circuit. Disconnect the vehicle harness (VE) from the engine interface at connector X-9138. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From

X-9007 pin 1 X-9007 pin 2

X-9138 pin 1 X-9138 pin 2

Value NOTE: Wiggle the harness during the check to promote an intermittent electrical connection. There should be continuity. There should be continuity.

A. If there is continuity, leave connector X-9138 disconnected and continue to Step 4.

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X-9138 pin 1 X-9138 pin 2

X-9121 pin A15 X-9121 pin A60

Value NOTE: Wiggle the harness during the check to promote an intermittent electrical connection. There should be continuity. There should be continuity.

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3915-Averaged rail pressure is outside the expected tolerance range WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Common rail Relief valve - Configure - Reset ECU data (10.218), if necessary. NOTE: If the rail pressure sensor B-9004 is replaced, it is necessary to perform the Replacement of the Rail Pressure sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Common rail pressure sensor - Configure - Reset ECU data (Rail pressure sensor) (55.010), if necessary. Context: The Engine Control Unit (ECU) A-9000 monitors fuel rail pressure using the rail pressure sensor B-9004. After a fuel pressure evaluation, if the ECU A-9000 suspects that the Pressure Relief Valve (PRV) should be open but has not opened, this fault occur. If this fault is active, the ECU A-9000 has performed step one for achieving limp home mode, a fuel pressure increase. Other active faults may have caused this fault to occur. For more information regarding fuel system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218). Cause: The ECU A-9000 has determined that the PRV should be open but is not open. Possible failure modes: 1. Faulty PRV, unable to open or partially open. 2. Faulty PRV fuel back-flow, clogged or damaged. 3. Faulty rail pressure sensor B-9004, drifted signal. 4. Faulty ECU A-9000, software.

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3916-Fuel pressure relief valve has reached maximum allowed open time WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Common rail Relief valve - Configure - Reset ECU data (10.218), if necessary. Context: The Engine Control Unit (ECU) A-9000 monitors the fuel Pressure Relief Valve (PRV). If the ECU A-9000 determines that the PRV has been open for too long, this fault will occur. The PRV opening duration is monitored by the ECU A-9000 and stored in the EEPROM during after run. This fault is for informational purposes only. If this fault is active, other fuel system faults may be active that caused this fault to occur. Diagnose any faults that may have caused this one to occur first, and then return to this fault, 3916 - Fuel pressure relief valve has reached maximum allowed open time. For more information regarding fuel system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218). Cause: The ECU A-9000 has determined that the PRV has reached its maximum allowed open time. Possible failure modes: 1. Faulty PRV, stuck open or worn. 2. Faulty fuel back-flow, clogged or damaged. 3. Faulty fuel metering unit Y-9000, internal failure. 4. Faulty rail pressure sensor B-9004, internal failure. 5. Faulty ECU A-9000, software.

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Electrical systems - FAULT CODES

3978-PM Catalyst load high C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors the Particulate Matter Catalytic Converter (PMcat) soot load level. If the ECU A-9000 determines that the soot load level is high, this fault will occur. If this fault is active, it may be necessary to use the Electronic Service Tool (EST) to perform a service regeneration.

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Electrical systems - FAULT CODES

3979-PM Catalyst load very high C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors the Particulate Matter Catalytic Converter (PMcat) soot load level. If the ECU A-9000 determines that the soot load level is very high, this fault will occur. If this fault is active, it may be necessary to use the Electronic Service Tool (EST) to perform a service regeneration.

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Electrical systems - FAULT CODES

3993-EGR valve will not close during after run C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) A-9000 monitors the position of the Exhaust Gas Recirculation (EGR) valve Z-9000 by monitoring the potentiometer feedback voltage. During after run, the EGR valve Z-9000 will open and close in attempt to remove any build-up from the valve seat. If during after run, the ECU A-9000 determines that the feedback voltage is not within the desired range 0.5 s after full closure, this fault will occur. For information regarding the functional operation of the Exhaust Gas Recirculation (EGR) valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Overview (10.501). For more information regarding the technical specifications of the EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve actuator - Technical Data (55.989). Cause: The ECU A-9000 has detected an EGR valve Z-9000 actuator feedback voltage outside of the 0.75 - 1.30 V range for the closed position. Possible failure modes: 1. Faulty EGR valve Z-9000, dirt or debris on valve seat, requires cleaning. 2. Faulty EGR valve Z-9000, blocked or mechanically damaged, does not fully close. 3. Faulty EGR valve Z-9000 position sensor, internal failure. 4. Faulty ECU A-9000, software.

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Electrical systems - FAULT CODES

3995-Cold start bypass valve has an over-temperature error WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 controls the cold start bypass valve relay K-9122 using a low side driver. If the ECU A-9000 detects an over temperature/current condition in the low side driver circuit, this fault will occur. Cause: The ECU A-9000 has detected an over temperature/current condition in the cold start bypass valve relay K-9122 low side driver circuit. Possible failure modes: 1. Faulty cold start bypass valve relay K-9122, wiring or internal failure. 2. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check the cold start bypass valve relay K-9122 coil. Remove the cold start bypass valve relay K-9122. Using a multimeter, perform the following resistance check on the cold start bypass valve relay K-9122 pins from : From X-9116 pin 85

To X-9116 pin 86

Value There should be approximately 70 130 Ω.

A. If there is approximately 70 - 130 Ω, leave the relay disconnected and continue to Step 3. B. If there is not approximately 70 - 130 Ω, the relay has failed. Replace the relay. 3. Check the cold start bypass valve relay K-9122 low side driver vehicle harness (VE) wiring for a short circuit. With the key in the ON position, use a multimeter to perform the following voltage check from the vehicle harness (VE) side of the connector from : From X-9116 pin 86

To Chassis ground.

Value There should be no voltage.

With the key in the OFF position, use a multimeter to perform the following continuity check from the vehicle harness (VE) side of the connector from : From X-9120 pin 86 X-9120 pin 86

To Chassis ground X-9120 pin 85

Value There should be no voltage. There should be no continuity.

A. If the specified values are not measured, there is a short circuit in the cold start bypass valve relay K-9122 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If the specified values are measured, leave the connector disconnected and continue to Step 4. 47683911 27/02/2015

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4. Check the cold start bypass valve relay K-9122 low side driver vehicle harness (VE) wiring for a short circuit. Disconnect the ECU A-9000 connector X-9122. With the key in the OFF position, use a multimeter to perform the following continuity check from the vehicle harness (VE) side of the connector from : From X-9122 pin K73

To All pins in connector X-9122

Value There should be no continuity.

A. If there is continuity, there is a short circuit in the cold start bypass valve relay K-9122 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, continue to Step 5. 5. Replace the cold start bypass valve relay K-9122. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is no longer active, return the machine to service. B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 02 - Pre-start and Selective Catalytic Reduction (SCR) (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 04 - Engine Control Unit (ECU) vehicle connector (55.100.DP-C.20.E.04)

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3996-Cold start bypass valve is shorted to battery voltage WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 controls the cold start bypass valve relay K-9122 using a low side driver. If the ECU A-9000 detects a short circuit to battery in the low side driver circuit, this fault will occur. Cause: The ECU A-9000 has detected a short circuit to battery in the cold start bypass valve relay K-9122 low side driver circuit. Possible failure modes: 1. Faulty cold start bypass valve relay K-9122, wiring or internal failure. 2. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check the cold start bypass valve relay K-9122 coil. Remove the cold start bypass valve relay K-9122. Using a multimeter, perform the following resistance check on the cold start bypass valve relay K-9122 pins from : From X-9116 pin 85

To X-9116 pin 86

Value There should be approximately 70 130 Ω.

A. If there is approximately 70 - 130 Ω, leave the relay disconnected and continue to Step 3. B. If there is not approximately 70 - 130 Ω, the relay has failed. Replace the relay. 3. Check the cold start bypass valve relay K-9122 low side driver vehicle harness (VE) wiring for a short circuit. With the key in the ON position, use a multimeter to perform the following voltage check from the vehicle harness (VE) side of the connector from : From X-9116 pin 86

To Chassis ground.

Value There should be no voltage.

With the key in the OFF position, use a multimeter to perform the following continuity check from the vehicle harness (VE) side of the connector from : From X-9120 pin 86 X-9120 pin 86

To Chassis ground X-9120 pin 85

Value There should be no voltage. There should be no continuity.

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To All pins in connector X-9122

Value There should be no continuity.

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3997-Cold start bypass valve is shorted to ground WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 controls the cold start bypass valve relay K-9122 using a low side driver. If the ECU A-9000 detects a short circuit to ground in the low side driver circuit, this fault will occur. Cause: The ECU A-9000 has detected a short circuit to ground in the cold start bypass valve relay K-9122 low side driver circuit. Possible failure modes: 1. Faulty cold start bypass valve relay K-9122, wiring or internal failure. 2. Faulty ECU A-9000, software. Solution: 1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with Step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with Step 5. 2. Check the cold start bypass valve relay K-9122 coil. Remove the cold start bypass valve relay K-9122. Using a multimeter, perform the following resistance check on the cold start bypass valve relay K-9122 pins from : From X-9116 pin 85

To X-9116 pin 86

Value There should be approximately 70 130 Ω.

A. If there is approximately 70 - 130 Ω, leave the relay disconnected and continue to Step 3. B. If there is not approximately 70 - 130 Ω, the relay has failed. Replace the relay. 3. Check the cold start bypass valve relay K-9122 low side driver vehicle harness (VE) wiring for a short circuit. Disconnect the ECU A-9000 connector X-9122. With the key in the OFF position, use a multimeter to perform the following continuity check from the vehicle harness (VE) side of the connector from : From X-9122 pin K73 X-9122 pin K73

To Chassis ground All pins in connector X-9122

Value There should be no continuity. There should be no continuity.

A. If there is continuity, there is a short circuit to ground in the cold start bypass valve relay K-9122 vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor. B. If there is no continuity, continue to Step 4. 4. Replace the cold start bypass valve relay K-9122. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is no longer active, return the machine to service. 47683911 27/02/2015

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4043-Hydraulic Oil Temperature Sensor Shorted To Ground WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The hydraulic oil temperature signal is shorted to ground. Cause: The hydraulic oil temperature signal, X-C23 pin 16 has a short circuit to ground. The oil temperature sensor resistance is less than 25 Ω. Possible failure modes: 1. Faulty wiring or connections from the hydraulic oil temperature sensor to the instrument cluster. 2. A faulty temperature sensor. 3. A faulty instrument cluster Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4043 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the instrument cluster connector X-C23 and the hydraulic oil temperature sensor connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the instrument cluster to the hydraulic oil temperature sensor. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the instrument cluster connector X-C23. Disconnect the hydraulic oil temperature sensor connector. Measure the resistance between X-C23 pin 16 and chassis ground. The resistance should be greater than 20,000 Ω . Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Go to step 4. B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the resistance of the temperature sensor. Measure the resistance of the temperature sensor to chassis ground.

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4044-Hydraulic Oil Temperature Sensor Open Circuit WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The instrument cluster detects an open circuit in the hydraulic oil temperature signal. Cause: The hydraulic oil temperature signal, X-C23 pin 16 has an open circuit. The oil temperature sensor resistance is greater than 30,000 Ω. Possible failure modes: 1. Faulty wiring or connections from the hydraulic oil temperature sensor to the instrument cluster. 2. A faulty hydraulic oil temperature sensor. 3. A faulty instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4044 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the instrument cluster connector X-C23 and the hydraulic oil temperature sensor connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the instrument cluster to the hydraulic oil temperature sensor. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the temperature signal wire. Turn the ignition switch OFF. Disconnect the instrument cluster connector X-C23. Disconnect the hydraulic oil temperature sensor connector. Measure the resistance from the hydraulic oil temperature sensor pin 1 to X-C23 pin 16. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance from the hydraulic oil temperature sensor pin 2 to chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 4. B. The resistance is greater than 10 Ω. There is an open circuit in the wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the voltage on the temperature signal wire.

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Turn the ignition switch ON. Measure the voltage from X-C23 pin 16 to chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 5. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance of the temperature sensor. Measure the resistance of the temperature sensor. Temperature 110 °C (230 °F) 105 °C (221 °F) 100 °C (212 °F) 95 °C (203 °F) 92 °C (198 °F) 88 °C (190 °F) 85 °C (185 °F) 81 °C (178 °F) 78 °C (172 °F) 74 °C (165 °F) 68 °C (154 °F) 16 °C (61 °F)

Hydraulic Oil Temperature Sensor Open Circuit Resistance Measurements Resistance in ohms (± 10%) 130 Ω 151 Ω 175 Ω 202 Ω 223 Ω 258 Ω 280 Ω 323 Ω 358 Ω 412 Ω 511 Ω 4250 Ω

A. The resistance measurements are within the values from the table. The measured resistance is less than 10,000 Ω. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of fault. B. The resistance measurements were not within range. The measured resistance is greater than 10,000 Ω. Temporarily replace the temperature sensor and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 Instrument Cluster (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 10 Cab to Chassis Interface (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 26 Instrument Cluster (55.100.DP-C.20.E.26) Wiring harnesses - Electrical schematic sheet 12 Cab to Chassis Interface (55.100.DP-C.20.E.12)

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4055-Park Brake Valve (On/Off) - Solenoid Supply Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the voltage on CN3A pin 4 is less than 1 V or greater than 8 V. Diagnostic Trouble Code 4055 - Park Brake Valve (On/Off) - Solenoid Supply Open Circuit has an error priority of Red. Ground drive is disabled while Diagnostic Trouble Code 4055 - Park Brake Valve (On/Off) - Solenoid Supply Open Circuit is active. Cause: The UCM has sensed that the voltage on CN3A pin 4 is less than 1 V or greater than 8 V. Possible failure modes: 1. An open circuit in the wiring. 2. The park brake valve solenoid has failed. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4055 - Park Brake Valve (On/Off) - Solenoid Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the park brake solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the park brake solenoid. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the signal wire. Turn the ignition switch OFF. Disconnect UCM connector CN3A. Disconnect the brake valve solenoid connector X-BRK. Fabricate a jumper wire that will connect between X-BRK pin 1 and X-BRK pin 2. Connect the jumper wire between X-BRK pin 1 and X-BRK pin 2. Measure the resistance between CN3A pin 4 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 4.

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B. The resistance is greater than 10 Ω. There is an open circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the resistance through the solenoid. Disconnect the brake valve solenoid connector X-BRK. Measure the resistance across the solenoid terminals. The resistance should be less than 100 Ω. A. The resistance is less than 100 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 100 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09)

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4056-Park Brake Valve (On/Off) - Solenoid Supply Short to Ground WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the current on CN3A pin 4 is greater than 3 A. Diagnostic Trouble Code 4056 - Park Brake Valve (On/Off) - Solenoid Supply Short to Ground has an error priority of Red. Ground drive is disabled while Diagnostic Trouble Code 4056 - Park Brake Valve (On/Off) - Solenoid Supply Short to Ground is active. Cause: The UCM has sensed short circuit to ground on CN3A pin 4. The current on the park brake valve signal line is greater than 3 A. Possible failure modes: 1. The signal wire has a short circuit to chassis ground. 2. The park brake valve has failed. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4056 - Park Brake Valve (On/Off) - Solenoid Supply Short to Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the park brake solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the park brake solenoid. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid wire. Turn the ignition switch OFF. Disconnect UCM connector CN3A. Disconnect the park brake solenoid connector X-BRK. Measure the resistance between CN3A pin 4 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Go to step 4. B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault.

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4. Measure the resistance through the solenoid. Disconnect the brake valve solenoid connector X-BRK. Measure the resistance across the solenoid terminals. The resistance should be between 7 Ω and 10 Ω. A. The resistance is between 7 Ω and 10 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 5 Ω. There is a short circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09)

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4057-Park Brake Valve (On/Off) - Solenoid Supply Short to Power WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has tried to turn off the park brake valve solenoid, but the voltage on CN3A pin 4 is still greater than 8 V. Diagnostic Trouble Code 4057 - Park Brake Valve (On/Off) - Solenoid Supply Short to Power has an error priority of Red. Ground drive is disabled while Diagnostic Trouble Code 4057 - Park Brake Valve (On/Off) - Solenoid Supply Short to Power is active. Cause: The UCM has tried to turn off the park brake valve solenoid, but the voltage on CN3A pin 4 is still greater than 8 V. The fault is active while the hydraulics are disabled or the park brake is enabled and the voltage on the park brake solenoid pin, CN3A pin 4 is greater than 8 V. Possible failure modes: 1. The solenoid signal wire has a short circuit to another voltage source. 2. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault is not recorded again. OK to return the machine to service. B. Fault code 4057 - Park Brake Valve (On/Off) - Solenoid Supply Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the park brake solenoid connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the park brake solenoid. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the solenoid wire. Turn the ignition switch OFF. Disconnect UCM connector CN3A. Disconnect the park brake solenoid connector X-BRK. Turn the ignition switch ON. Measure the voltage between CN3A pin 4 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 47683911 27/02/2015

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B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09)

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4061-Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed an open circuit in the right drive pump forward solenoid signal line. Diagnostic Trouble Code 4061 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit has an error priority of Red. Forward ground drive is disabled while Diagnostic Trouble Code 4061 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit is active. Cause: The UCM has sensed an open circuit in CN3B pin 32. The fault is active while the hydraulics are enabled and the solenoid resistance is greater than normal. Possible failure modes: 1. An open circuit in the wiring. 2. There is an open circuit in the right drive pump forward solenoid. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4061 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right drive pump forward solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right drive pump forward solenoid. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the harness. Turn the ignition switch OFF. Disconnect UCM connectors CN3B and CN2B. Disconnect the right drive pump forward solenoid connector X-17. Fabricate a jumper wire that will connect between the right drive pump forward solenoid connector X-17 pin 1 and X-17 pin 2. Connect the jumper wire between X-17 pin 1 and X-17 pin 2.

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Measure the resistance between CN3B pin 32 and CN2B pin 25. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 4. B. The resistance is greater than 10 Ω. There is an open circuit in the solenoid signal wire or the solenoid ground line. Check splice SP-098. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Leave the jumper wire installed between X-17 pin 1 and X-17 pin 2. Reconnect UCM connectors CN3B and CN2B. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4061 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit should no longer be active. Fault code 4062 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground should become active. A. Fault code 4062 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground is active and fault code 4061 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4061 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit is still active. Fault code 4062 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09) Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19)

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4062-Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE Electro hydraulic controls WE WE Electro hydraulic controls

Context: The UCM has sent a signal to the right forward ground drive solenoid to energize, but no voltage was detected. Diagnostic Trouble Code 4062 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground has an error priority of Red. Forward ground drive is disabled while Diagnostic Trouble Code 4062 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground is active. Cause: The UCM has sent a signal to the right forward ground drive solenoid to energize, but no voltage was detected. The current on CN3B pin 32 is greater than 3 A. The fault is active while the hydraulics are enabled and the current on CN3B pin 32 is greater than 3 A. Possible failure modes: 1. A short circuit in the wiring. 2. The right drive pump forward solenoid has an internal short circuit. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4062 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right drive pump forward solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right drive pump forward solenoid. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector CN3B, CN2B, and the right drive pump forward solenoid connector X-17. Measure the resistance between CN3B pin 32 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN2B pin 25 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition.

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A. Both resistance measurements are greater than 20,000 Ω. Go to step 4. B. One or both resistance measurements are less than 20,000 Ω. There is a short circuit to chassis ground in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Reconnect UCM connectors CN3B and CN2B. Leave the right drive pump forward solenoid connector, X-17 disconnected. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4062 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground should no longer be active. Fault code 4061 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit should become active. A. Fault code 4061 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit is active and fault code 4062 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4062 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground is still active. Fault code 4061 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09) Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

4071-Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed an open circuit in the left drive pump forward solenoid signal line. Diagnostic Trouble Code 4071 has an error priority of Red. Forward ground drive is disabled while Diagnostic Trouble Code 4071 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit is active. Cause: The UCM has sensed an open circuit in CN3B pin 33. The fault is active while the hydraulics are enabled and the solenoid resistance is greater than normal. Possible failure modes: 1. An open circuit in the wiring. 2. There is an open circuit in the left drive pump forward solenoid. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4071 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the left drive pump forward solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the left drive pump forward solenoid. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the harness. Turn the ignition switch OFF. Disconnect UCM connectors CN3B and CN2B. Disconnect the left drive pump forward solenoid connector X-13. Fabricate a jumper wire that will connect between the left drive pump forward solenoid connector X-13 pin 1 and X-13 pin 2. Connect the jumper wire between X-13 pin 1 and X-13 pin 2.

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Measure the resistance between CN3B pin 33 and CN2B pin 25. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 4. B. The resistance is greater than 10 Ω. There is an open circuit in the solenoid signal wire or the solenoid ground line. Check splice SP-098. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Leave the jumper wire installed between X-13 pin 1 and X-13 pin 2. Reconnect UCM connectors CN3B and CN2B. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4071 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit should no longer be active. Fault code 4072 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground should become active. A. Fault code 4072 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground is active and fault code 4071 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4071 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit is still active. Fault code 4072 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09) Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

4072-Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE Electro hydraulic controls WE WE Electro hydraulic controls

Context: The UCM has sent a signal to the left forward ground drive solenoid to energize, but no voltage was detected. Diagnostic Trouble Code 4072 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground has an error priority of Red. Forward ground drive is disabled while Diagnostic Trouble Code 4072 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground is active. Cause: The UCM has sent a signal to the left forward ground drive solenoid to energize, but no voltage was detected. The current on CN3B pin 33 is greater than 3 A. The fault is active while the hydraulics are enabled and the current on CN3B pin 33 is greater than 3 A. Possible failure modes: 1. A short circuit in the wiring. 2. The left drive pump forward solenoid has an internal short circuit. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4072 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the left drive pump forward solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the left drive pump forward solenoid. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector CN3B, CN2B, and the left drive pump forward solenoid connector X-13. Measure the resistance between CN3B pin 33 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN2B pin 25 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition.

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A. Both resistance measurements are greater than 20,000 Ω. Go to step 4. B. One or both resistance measurements are less than 20,000 Ω. There is a short circuit to chassis ground in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Reconnect UCM connectors CN3B and CN2B. Leave the left drive pump forward solenoid connector X-13 disconnected. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4072 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground should no longer be active. Fault code 4071 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit should become active. A. Fault code 4071 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit is active and fault code 4072 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4072 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground is still active. Fault code 4071 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09) Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

4081-Forward Pump Control Valves (Directional) - Common Solenoid Return Short to Power WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the voltage on CN3B pin 32, CN3B pin 33, and CN2B pin 25 is greater than 5 V. Diagnostic Trouble Code 4081 - Forward Pump Control Valves (Directional) - Common Solenoid Return Short to Power has an error priority of Red. Forward ground drive is disabled while Diagnostic Trouble Code 4081 - Forward Pump Control Valves (Directional) - Common Solenoid Return Short to Power is active. Cause: The UCM has sensed a higher than normal voltage on the forward ground drive valve solenoids lines. The fault is active while the hydraulics are disabled and the solenoid voltage feedback is greater than 5 V. Possible failure modes: 1. A short circuit to another voltage source in the wiring. 2. The UCM has internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4081 - Forward Pump Control Valves (Directional) - Common Solenoid Return Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the right drive pump forward solenoid and the left drive pump forward solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right drive pump forward solenoid and the left drive pump forward solenoid. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage of the solenoid wires to chassis ground. Turn the ignition switch OFF. Disconnect solenoid connectors X-17 and X-13. Disconnect UCM connectors CN2B and CN3B. Turn the ignition switch ON. Measure the voltage between X-17 pin 1 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-17 pin 2 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. 47683911 27/02/2015

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Measure the voltage between X-13 pin 1 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-13 pin 2 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. All voltage measurement are less than 0.5 V. Go to step 4. B. One or more voltage measurements are greater than 0.5 V. There is an short circuit to another voltage source in the harness. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connectors CN2B and CN3B. Leave connectors X-17 and X-13 disconnected. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4083 - Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit should no longer be active. Fault code 4081 - Forward Pump Control Valves (Directional) - Common Solenoid Return Short to Power should become active. A. Fault code 4083 - Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit is active and fault code 4081 - Forward Pump Control Valves (Directional) - Common Solenoid Return Short to Power is no longer active. Temporarily replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4081 - Forward Pump Control Valves (Directional) - Common Solenoid Return Short to Power is still active. Fault code 4083 - Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09) Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19)

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55.17 [55.DTC] / 542

Electrical systems - FAULT CODES

4082-Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the voltage on CN3B pin 32, CN3B pin 33, and CN2B pin 25 is less than 5 V. Diagnostic Trouble Code 4082 - Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground has an error priority of Red. Forward ground drive is disabled while Diagnostic Trouble Code 4082 - Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground is active. Cause: The UCM has sensed that the voltage on CN3B pin 32, CN3B pin 33, and CN2B pin 25 is less than 5 V. The fault is active while the hydraulics are disabled and solenoid return voltage feedback is low. Possible failure modes: 1. A short circuit in the wiring. 2. The UCM has internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4082 - Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the right drive pump forward and the left drive pump forward connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right drive pump forward solenoid and the left drive pump forward solenoid. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the solenoid wires to chassis ground. Turn the ignition switch OFF. Disconnect solenoid connectors X-17 and X-13. Disconnect UCM connectors CN2B and CN3B. Measure the resistance between X-17 pin 1 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-17 pin 2 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition.

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Measure the resistance between X-13 pin 1 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-13 pin 2 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are greater than 20,000 Ω. Go to step 4. B. One or more resistance measurements are less than 20,000 Ω. There is an short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connectors CN2B and CN3B. Leave connectors X-17 and X-13 disconnected. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4082 - Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground should no longer be active. Fault code 4083 Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit should become active. A. Fault code 4083 - Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit is active and fault code 4082 - Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground is no longer active. Temporarily replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4082 - Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground is still active. Fault code 4083 - Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09) Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

4083-Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed an open circuit on CN2B pin 25. Diagnostic Trouble Code 4083 - Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit has an error priority of Red. Forward ground drive operating mode is disabled while Diagnostic Trouble Code 4083 - Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit is active. Cause: The UCM has sensed improper forward pump control valve solenoid current, CN2B pin 25. The fault is active when the hydraulics are enabled and the solenoid return current is incorrect. Possible failure modes: 1. An open circuit in solenoid ground circuit. 2. Faulty forward drive pump solenoids. 3. The UCM has internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4083 - Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the right drive pump forward solenoid and the left drive pump forward solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right drive pump forward solenoid and the left drive pump forward solenoid. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the signal wires. Turn the ignition switch OFF. Disconnect solenoid connectors X-17 and X-13. Disconnect UCM connectors CN2B and CN3B. Fabricate a jumper wire that will connect between X-17 pin 1 and X-17 pin 2. Connect the jumper wire between X-17 pin 1 and X-17 pin 2. Measure the resistance between CN3B pin 32 and CN2B pin 25.

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The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Remove the jumper wire from connector X-17. Connect the jumper wire between X-13 pin 1 and X-13 pin 2. Measure the resistance between CN3B pin 33 and CN2B pin 25. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurement are less than 10 Ω. Go to step 4. B. One or both resistance measurement are greater than 10 Ω. There is an open circuit in the harness. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connectors CN2B and CN3B. Leave connectors X-17 and X-13 disconnected. Fabricate a jumper wire that will connect between X-17 pin 1 and X-17 pin 2. Connect the jumper wire between X-17 pin 1 and X-17 pin 2. Fabricate a jumper wire that will connect between X-13 pin 1 and X-13 pin 2. Connect the jumper wire between X-13 pin 1 and X-13 pin 2. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4083 - Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit should no longer be active. Fault code 4082 - Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground should become active. A. Fault code 4082 - Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground is active and fault code 4083 - Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit is no longer active. Temporarily replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4083 - Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit is still active. Fault code 4082 - Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09) Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19)

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55.17 [55.DTC] / 546

Electrical systems - FAULT CODES

4309-Park Brake Button - Park Brake Button Timeout (30 sec) WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has detected that the voltage on CN2B pin 22 is greater than 10 V. Diagnostic Trouble Code 4309 - Park Brake Button - Park Brake Button Timeout (30 sec) has an error priority of White. There are no restrictions while Diagnostic Trouble Code 4309 - Park Brake Button - Park Brake Button Timeout (30 sec) is active. Cause: The UCM has sensed that the voltage on CN2B pin 22 is greater than 10 V. The fault is active while the voltage on the park brake input, CN2B pin 22 is greater than 10 V for more than 30 s. Possible failure modes: 1. The signal wire has a short circuit to another voltage source. 2. Failure of the park brake switch. 3. Failure of the UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4309 - Park Brake Button - Park Brake Button Timeout (30 sec) is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the park brake switch connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the park brake switch. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the signal wire. Turn the ignition switch OFF. Disconnect UCM connector CN2B. Disconnect the park brake switch connector X-365. Turn the ignition switch ON. Measure the voltage between connector X-365 pin 3 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4.

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Electrical systems - FAULT CODES

B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Verify wire is not shorted to another voltage source. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 4. Test the switch. Turn the ignition switch OFF. Leave connector X-365 disconnected. Verify that the parking brake switch is in the OFF position. Measure the resistance between the parking brake switch connector, X-365 pin 2 and X-365 pin 3. The resistance should be greater than 20,000 Ω. A. The resistance is greater than 20,000 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 20,000 Ω. The switch has an internal short circuit. Replace the switch and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 13 Cab to Chassis Interface (55.100.DP-C.20.E.13) Wiring harnesses - Electrical schematic sheet 17 Right-Hand Control Handle (55.100.DP-C.20.E.17) Wiring harnesses - Electrical schematic sheet 15 Cab Console Switches (55.100.DP-C.20.E.15)

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55.17 [55.DTC] / 548

Electrical systems - FAULT CODES

4361-Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed an open circuit in the right drive pump reverse solenoid signal line. Diagnostic Trouble Code 4361 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit has an error priority of Red. Reverse ground drive is disabled while Diagnostic Trouble Code 4361 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit is active. Cause: The UCM has sensed an open circuit in CN2A pin 8. The fault is active while the hydraulics are enabled and the solenoid resistance is greater than normal. Possible failure modes: 1. An open circuit in the wiring. 2. There is an open circuit in the right drive pump reverse solenoid. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4361 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right drive pump reverse solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right drive pump reverse solenoid. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the harness. Turn the ignition switch OFF. Disconnect UCM connectors CN2A and CN1A. Disconnect the right drive pump reverse solenoid connector X-18. Fabricate a jumper wire that will connect between the right drive pump reverse solenoid connector X-18 pin 1 and X-18 pin 2. Connect the jumper wire between X-18 pin 1 and X-18 pin 2.

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Electrical systems - FAULT CODES

Measure the resistance between CN2A pin 8 and CN1A pin 19. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 4. B. The resistance is greater than 10 Ω. There is an open circuit in the solenoid signal wire or the solenoid ground line. Check splice SP-099. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Leave the jumper wire installed between X-18 pin 1 and X-18 pin 2. Reconnect UCM connectors CN2A and CN1A. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4361 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit should no longer be active. Fault code 4362 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground should become active. A. Fault code 4362 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground is active and fault code 4361 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4361 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit is still active. Fault code 4362 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09)

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55.17 [55.DTC] / 550

Electrical systems - FAULT CODES

4362-Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE Electro hydraulic controls WE WE Electro hydraulic controls

Context: The UCM has sent a signal to the right reverse ground drive solenoid to energize, but no voltage was detected. Diagnostic Trouble Code 4362 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground has an error priority of Red. Reverse ground drive is disabled while Diagnostic Trouble Code 4362 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground is active. Cause: The UCM has sent a signal to the right reverse ground drive solenoid to energize, but no voltage was detected. The current on X-CN3B pin 32 is greater than 3 A. The fault is active while the hydraulics are enabled and the current on CN2A pin 8 is greater than 3 A. Possible failure modes: 1. A short circuit in the wiring. 2. The right drive pump forward solenoid has an internal short circuit. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4362 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right drive pump reverse solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right drive pump reverse solenoid. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connectors CN2A, CN1A, and the right drive pump reverse solenoid connector X-18. Measure the resistance between CN2A pin 8 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN1A pin 19 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition.

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A. Both resistance measurements are greater than 20,000 Ω. Go to step 4. B. One or both resistance measurements are less than 20,000 Ω. There is a short circuit to chassis ground in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Reconnect UCM connectors CN2A and CN1A. Leave the right drive pump reverse solenoid connector, X-18 disconnected. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4362 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground should no longer be active. Fault code 4361 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit should become active. A. Fault code 4361 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit is active and fault code 4362 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4362 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground is still active. Fault code 4361 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09)

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Electrical systems - FAULT CODES

4371-Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed an open circuit in the left drive pump reverse solenoid signal line. Diagnostic Trouble Code 4371 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit has an error priority of Red. Reverse ground drive is disabled while Diagnostic Trouble Code 4371 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit is active. Cause: The UCM has sensed an open circuit in CN2A pin 14. The fault is active while the hydraulics are enabled and the solenoid resistance is greater than normal. Possible failure modes: 1. An open circuit in the wiring. 2. There is an open circuit in the left drive pump reverse solenoid. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4371 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the left drive pump reverse solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the left drive pump reverse solenoid. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the harness. Turn the ignition switch OFF. Disconnect UCM connectors CN2A and CN1A. Disconnect the left drive pump reverse solenoid connector X-16. Fabricate a jumper wire that will connect between the left drive pump reverse solenoid connector X-16 pin 1 and X-16 pin 2. Connect the jumper wire between X-16 pin 1 and X-16 pin 2.

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Measure the resistance between CN2A pin 14 and CN1A pin 19. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 4. B. The resistance is greater than 10 Ω. There is an open circuit in the solenoid signal wire or the solenoid ground line. Check splice SP-099. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Leave the jumper wire installed between X-16 pin 1 and X-16 pin 2. Reconnect UCM connectors CN2A and CN1A. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4371 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit should no longer be active. Fault code 4372 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground should become active. A. Fault code 4372 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground is active and fault code 4371 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4371 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit is still active. Fault code 4372 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09)

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Electrical systems - FAULT CODES

4372-Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE Electro hydraulic controls WE WE Electro hydraulic controls

Context: The UCM has sent a signal to the left reverse ground drive solenoid to energize, but no voltage was detected. Diagnostic Trouble Code 4372 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground has an error priority of Red. Reverse ground drive is disabled while Diagnostic Trouble Code 4372 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground is active. Cause: The UCM has sent a signal to the left reverse ground drive solenoid to energize, but no voltage was detected. The current on CN2A pin 14 is greater than 3 A. The fault is active while the hydraulics are enabled and the current on CN2A pin 14 is greater than 3 A. Possible failure modes: 1. A short circuit in the wiring. 2. The left drive pump reverse solenoid has an internal short circuit. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4372 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the left drive pump reverse solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the left drive pump reverse solenoid. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector CN2A, CN1A, and the left drive pump reverse solenoid connector X-16. Measure the resistance between CN2A pin 14 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN1A pin 19 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition.

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A. Both resistance measurements are greater than 20,000 Ω. Go to step 4. B. One or both resistance measurements are less than 20,000 Ω. There is a short circuit to chassis ground in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Reconnect UCM connectors CN2A and CN1A. Leave the left drive pump reverse solenoid connector X-16 disconnected. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4372 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground should no longer be active. Fault code 4371 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit should become active. A. Fault code 4371 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit is active and fault code 4372 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4372 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground is still active. Fault code 4371 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09)

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Electrical systems - FAULT CODES

4381-Reverse Pump Control Valves (Directional) - Common Solenoid Return Short to Power WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the voltage on CN2A pin 8, CN2A pin 14, and CN1A pin 19 is greater than 5 V. Diagnostic Trouble Code 4381 - Reverse Pump Control Valves (Directional) - Common Solenoid Return Short to Power has an error priority of Red. Reverse ground drive is disabled while Diagnostic Trouble Code 4381 - Reverse Pump Control Valves (Directional) - Common Solenoid Return Short to Power is active. Cause: UCM has sensed higher than normal voltage on the reverse ground drive valve solenoids ground line. The fault is active while the hydraulics are disabled and the solenoid voltage feedback is greater than 5 V. Possible failure modes: 1. Shorted wire in circuit. 2. UCM has internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4381 - Reverse Pump Control Valves (Directional) - Common Solenoid Return Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the right drive pump reverse solenoid and the left drive pump reverse solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right drive pump reverse solenoid and the left drive pump reverse solenoid. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage of the solenoid wires to chassis ground. Turn the ignition switch OFF. Disconnect solenoid connector X-18 and X-16. Disconnect UCM connector CN2A and CN1A. Turn the ignition switch ON. Measure the voltage between X-18 pin 1 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-18 pin 2 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. 47683911 27/02/2015

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Measure the voltage between X-16 pin 1 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-16 pin 2 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. All voltage measurement are less than 0.5 V. Go to step 4. B. One or more voltage measurements are greater than 0.5 V. There is an short circuit to another voltage source in the harness. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connectors CN2A and CN1A. Leave connectors X-18 and X-16 disconnected. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4381 - Reverse Pump Control Valves (Directional) - Common Solenoid Return Short to Power should no longer be active. Fault code 4383 - Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit should become active. A. Fault code 4383 - Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit is active and fault code 4381 - Reverse Pump Control Valves (Directional) - Common Solenoid Return Short to Power is no longer active. Temporarily replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4381 - Reverse Pump Control Valves (Directional) - Common Solenoid Return Short to Power is still active. Fault code 4383 - Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09)

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Electrical systems - FAULT CODES

4382-Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the voltage on CN2A pin 8, CN2A pin 14, and CN1A pin 19 is less than 5 V. Diagnostic Trouble Code 4382 - Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground has an error priority of Red. Reverse ground drive is disabled while Diagnostic Trouble Code 4382 - Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground is active. Cause: The UCM has sensed that the voltage on CN2A pin 8, CN2A pin 14, and CN1A pin 19 is less than 5 V. The fault is active while the hydraulics are disabled and solenoid return voltage feedback is low. Possible failure modes: 1. A short circuit in the wiring. 2. The UCM has internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4382 - Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the right drive pump reverse solenoid and the left drive pump reverse solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right drive pump reverse solenoid and the left drive pump reverse solenoid. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the solenoid wires to chassis ground. Turn the ignition switch OFF. Disconnect solenoid connectors X-18 and X-16. Disconnect UCM connectors CN2A and CN1A. Measure the resistance between X-18 pin 1 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-18 pin 2 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition.

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Measure the resistance between X-16 pin 1 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-16 pin 2 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are greater than 20,000 Ω. Go to step 4. B. One or more resistance measurements are less than 20,000 Ω. There is an short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connectors CN2A and CN1A. Leave connectors X-18 and X-16 disconnected. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4382 - Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground should no longer be active. Fault code 4383 Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit should become active. A. Fault code 4383 - Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit is active and fault code 4382 - Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground is no longer active. Temporarily replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4382 - Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground is still active. Fault code 4383 - Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09)

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Electrical systems - FAULT CODES

4383-Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed an open circuit on CN1A pin 19. Diagnostic Trouble Code 4383 - Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit has an error priority of Red. Reverse ground drive operating mode is disabled while Diagnostic Trouble Code 4383 - Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit is active. Cause: The UCM has sensed improper reverse pump control valve solenoid current, CN1A pin 19. The fault is active when the hydraulics are enabled and the solenoid return current is incorrect. Possible failure modes: 1. An open circuit in solenoid ground circuit. 2. Faulty reverse drive pump solenoids. 3. The UCM has internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4383 - Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the right drive pump reverse solenoid and the left drive pump reverse solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right drive pump reverse solenoid and the left drive pump reverse solenoid. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the signal wires. Turn the ignition switch OFF. Disconnect solenoid connectors X-18 and X-16. Disconnect UCM connectors CN2A and CN1A. Fabricate a jumper wire that will connect between X-18 pin 1 and X-18 pin 2. Connect the jumper wire between X-18 pin 1 and X-18 pin 2. Measure the resistance between CN2A pin 8 and CN1A pin 19.

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Electrical systems - FAULT CODES

The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Remove the jumper wire from connector X-18. Connect the jumper wire between X-16 pin 1 and X-16 pin 2. Measure the resistance between CN2A pin 14 and CN1A pin 19. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurement are less than 10 Ω. Go to step 4. B. One or both resistance measurement are greater than 10 Ω. There is an open circuit in the harness. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connectors CN2A and CN1A. Leave connectors X-18 and X-16 disconnected. Fabricate a jumper wire that will connect between X-18 pin 1 and X-18 pin 2. Connect the jumper wire between X-18 pin 1 and X-18 pin 2. Fabricate a jumper wire that will connect between X-16 pin 1 and X-16 pin 2. Connect the jumper wire between X-16 pin 1 and X-16 pin 2. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4383 - Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit should no longer be active. Fault code 4382 - Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground should become active. A. Fault code 4382 - Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground is active and fault code 4383 - Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit is no longer active. Temporarily replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4383 - Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit is still active. Fault code 4382 - Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09)

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Electrical systems - FAULT CODES

4401-Park Brake (Mechanical Machines) Solenoid Open Circuit WE Mechanical hydraulic controls WE WE Mechanical hydraulic controls

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The instrument cluster has sent a signal to the brake valve solenoid to energize, but the solenoid is off. Diagnostic Trouble Code 4401 has an error priority of Red. Cause: The instrument cluster has sent a signal to the brake valve solenoid to energize, but the solenoid is off. The fault is activate while the instrument cluster solenoid output, X-C23 pin 28 is off and brake commanded state, X-C23 pin 21 is high. Possible failure modes: 1. An open circuit in the wiring. 2. The brake valve solenoid has failed. 3. The instrument cluster has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4401 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the instrument cluster and the park brake solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the instrument cluster to the park brake solenoid. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid wire. Turn the ignition switch OFF. Disconnect instrument cluster connector X-C23. Measure the resistance between X-C23 pin 28 and chassis ground. The resistance should be less than 100 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 100 Ω. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 100 Ω. There is an open circuit in the harness. Go to step 4. 4. Measure the resistance through the solenoid. Disconnect the brake valve solenoid connector X-BRK. Measure the resistance across the solenoid terminals. The resistance should be less than 100 Ω. 47683911 27/02/2015

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Electrical systems - FAULT CODES

A. The resistance is less than 100 Ω. Go to step 5. B. The resistance is greater than 100 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the solenoid ground wire. Leave connector X-BRK disconnected. Measure the resistance between X-BRK pin 2 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. There is an open circuit in the solenoid ground connection. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 10 Ω. There is an open circuit in the solenoid ground wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 Instrument Cluster (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 10 Cab to Chassis Interface (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 11 Cab Console Switches (55.100.DP-C.20.E.11)

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Electrical systems - FAULT CODES

4402-Park Brake (Mechanical Machines) Shorted To Power WE Mechanical hydraulic controls WE WE Mechanical hydraulic controls

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The instrument cluster has sent a signal to the brake valve solenoid to de-energize, but the solenoid remains on. Diagnostic Trouble Code 4402 has an error priority of Red. The vehicle is disabled while Diagnostic Trouble Code 4402 is active. Cause: The instrument cluster has sent a signal to the brake valve solenoid to de-energize, but the solenoid remains on. The fault is activate while the instrument cluster solenoid output, X-C23 pin 28 is on and the brake commanded state, X-C23 pin 21 is low. Possible failure modes: 1. The signal wire has a short circuit to another voltage source. 2. The instrument cluster has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4402 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the instrument cluster and the park brake solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the instrument cluster to the park brake solenoid. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage through the solenoid wire. Turn the ignition switch OFF. Disconnect the instrument cluster connector X-C23. Disconnect the park brake solenoid connector X-BRK. Turn the ignition switch ON. Measure the voltage between X-C23 pin 28 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 47683911 27/02/2015

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Wiring harnesses - Electrical schematic sheet 21 Instrument Cluster (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 10 Cab to Chassis Interface (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 11 Cab Console Switches (55.100.DP-C.20.E.11)

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4431-Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed a disagreement between the park brake pressure switch and the park brake solenoid. Diagnostic Trouble Code 4431 - Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) has an error priority of amber. There are no restrictions while Diagnostic Trouble Code 4431 - Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) is active. Cause: The UCM has sensed a disagreement between the park brake pressure switch and the park brake solenoid. The fault is active while the engine is running and the park brake pressure switch input CN2B pin 13 is ON and the solenoid current output CN3A pin 4 is less than 1 A or the park brake pressure switch input CN2B pin 13 is OFF and the solenoid current output CN3A pin 4 is greater than 1 A. Possible failure modes: 1. Low charge pressure. 2. An open circuit or a short circuit in the wiring. 3. A faulty park brake solenoid. 4. A faulty park brake pressure switch. 5. A faulty UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4431 - Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) is recorded again. Go to step 2. 2. Verify the charge pressure. Verify the charge pressure is approximately 2482 kPa (360 psi) at low idle. Verify the charge pressure is approximately 2758 kPa (400 psi) at full throttle. A. Charge pressure is in the correct range and fault code 4431 - Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) is still active. Go to step 3. B. Charge pressure is not correct. Repair the cause of the low charge pressure and retest. Return to step 1 to confirm elimination of the fault. 3. Verify that the wiring and connectors are free of damage. Inspect the UCM, the park brake solenoid, and the park brake switch connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the park brake solenoid and the park brake switch. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment.

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A. The connectors are secure and the harness is free of damage. Go to step 4. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 4. Use EST to test the system. Turn the ignition switch ON. Turn the park brake switch OFF. Use the EST to access the status of the park brake pressure switch. The switch status should be OFF. Reference 534 670 539 518 502

EST park brake parameters Data Description Park Brake Button Park Brake Indicator Lamp Park Brake Pressure Switch Park Brake Solenoid Output (EH machines only) Park Brake Status

Source UCM Instrument Cluster UCM UCM UCM

Enable the hydraulic system. Use the EST to access the status of the park brake valve. The valve status should OFF. A. The park brake switch status is ON. The solenoid status is OFF. Fault code 4309 - Park Brake Button - Park Brake Button Timeout (30 sec) will be come active after 30 minutes. Go to troubleshooting procedure 4309 - Park Brake Button - Park Brake Button Timeout (30 sec). B. The park brake switch status is OFF. The solenoid status is ON. Fault code 4056 - Park Brake Valve (On/Off) - Solenoid Supply Short to Ground is active. Go to troubleshooting procedure 4056 - Park Brake Valve (On/Off) - Solenoid Supply Short to Ground. C. The park brake switch status is OFF and the solenoid status is OFF. Fault code 4431 - Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) is active. Go to step 5. 5. Use EST to test the system. Turn the ignition switch ON and start the engine. Turn the park brake switch ON. Use the EST to access the status of the park brake pressure switch. The switch status should be ON. Use the EST to access the status of the park brake valve. The valve status should ON. A. The park brake switch status is OFF. The solenoid status is ON. Fault code 4431 - Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) is active. Go to step 6. B. The park brake switch status is ON and the solenoid status is ON. Fault code 4431 - Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) is not active. There does not appear to be a problem at this time. OK to return the machine to service. 6. Measure the resistance through the solenoid wire. Turn the key switch OFF. Disconnect park brake switch connector X-BRKPRS. Fabricate a jumper wire that will connect between X-BRKPRS pin 1 and X-BRKPRS pin 2. Install the jumper wire between X-BRKPRS pin 1 and X-BRKPRS pin 2. Turn the ignition switch ON. Start the engine. 47683911 27/02/2015

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Turn the park brake switch ON. Use the EST to access the status of the park brake pressure switch. The switch status should be ON. A. The park brake status is ON. Fault code 4431 - Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) is no longer active. Replace the pressure switch. Return to step 1 to confirm elimination of the fault. B. The park brake status is OFF. Fault code 4431 - Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) is still active. Go to step 7. 7. Measure the resistance through the wire. Turn the ignition switch OFF. Leave the jumper wire installed between X-BRKPRS pin 1 and X-BRKPRS pin 2. Disconnect UCM connector CN2B. Measure the resistance between CN2B pin 13 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 10 Ω. There is an open circuit in the wire. Go to step 8. 8. Measure the resistance of the solenoid ground wire. Turn the ignition switch OFF. Remove the jumper wire between X-BRKPRS pin 1 and X-BRKPRS pin 2. Measure the resistance between X-BRKPRS pin 2 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. There is an open circuit in the wiring between the UCM and the park brake pressure switch. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 10 Ω. There is an open circuit in the ground circuit. Verify the chassis ground connections are tight and secure. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09)

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Electrical systems - FAULT CODES

4731-Right Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the swash plate angle sensor signal has failed. Diagnostic Trouble Code 4731 - Right Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 4731 - Right Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the swash plate angle sensor signal has failed low. The fault is active while the engine is ON and the right swash plate angle sensor voltage, CN2B pin 32 is less than 0.2 V. Possible failure modes: 1. The sensor signal wire is shorted to chassis ground. 2. An open circuit in the sensor signal wire. 3. A failure of the swash plate angle sensor. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4731 - Right Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the left-hand swash plate sensor connection and the right-hand swash plate sensor connection. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the swash plate sensors. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the sensor. Turn the ignition switch OFF. Disconnect the right-hand swash plate sensor connector X-93. Turn the ignition switch ON. Measure the voltage between X-93 pin 5 and X-93 pin 1. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-93 pin 2 and X-93 pin 6. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. 47683911 27/02/2015

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A. The voltage measurement is approximately 12 V. Go to step 4. B. The voltage measurement is less than 10 V. There is a problem in the voltage supply or sensor ground wire to the sensor. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector CN2B. Disconnect the right-hand swash plate sensor connector X-93. Measure the resistance between CN2B pin 32 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is greater than 20,000 Ω. Go to step 5. B. The resistance measurement is less than 20,000 Ω. There is a short circuit to chassis ground in the signal wire. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Turn the ignition switch OFF. Disconnect UCM connector X-CN2B. Disconnect connector X-93. Fabricate a jumper wire that will connect between the UCM connector CN2B pin 32 and chassis ground. Connect the jumper wire between CN2B pin 32 and chassis ground. Measure the resistance between X-93 pin 4 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is less than 10 Ω. Go to step 6. B. The resistance measurement is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 6. Test the UCM. Turn the ignition switch OFF. Remove the jumper wire. Reconnect the UCM connector CN2B. Disconnect the swash plate sensor connectors X-93 and X-94. Connect the left hand swash plate sensor into the right hand swash plate sensor connector X-93. Connect the right hand swash plate sensor into the left hand swash plate sensor connector X-94. Turn the ignition switch ON. Monitor the active diagnostic screen. Fault code 4731 - Right Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit should no longer be active. Fault code 4744 - Left Swash Plate Angle Sensor Pin B Open Or Shorted To Ground is active. A. Fault code 4731 - Right Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit is no longer active. Fault code 4744 - Left Swash Plate Angle Sensor Pin B Open Or Shorted To Ground is active. Replace the Swash Plate Angle sensor and retest. Return to step 1 to confirm elimination of the fault.

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B. Fault code 4731 - Right Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit is still active. Fault code 4744 - Left Swash Plate Angle Sensor Pin B Open Or Shorted To Ground did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09)

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Electrical systems - FAULT CODES

4732-Right Swash Plate Angle Sensor - Pin A Short to Power WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed a higher than normal voltage from the right-hand swash plate sensor. Diagnostic Trouble Code 4732 - Right Swash Plate Angle Sensor - Pin A Short to Power has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 4732 - Right Swash Plate Angle Sensor - Pin A Short to Power is active. Cause: The UCM has sensed a higher than normal voltage from the right-hand swash plate sensor. The fault is active while the engine is ON and the swash plate angle sensor voltage, CN2B pin 32 is greater than 4.8 V. Possible failure modes: 1. The signal wire has a short circuit to another voltage source. 2. A failure of the swash plate sensor. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4732 - Right Swash Plate Angle Sensor - Pin A Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the left-hand swash plate sensor connection and the right-hand swash plate sensor connection. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the swash plate sensors. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the sensor signal wire. Turn the ignition switch OFF. Disconnect UCM connector CN2B. Disconnect the right-hand swash plate sensor connector X-93. Turn the ignition switch ON. Measure the voltage between X-93 pin 4 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage measurement is less than 0.5 V. Go to step 4. B. The voltage measurement is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 47683911 27/02/2015

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4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connector CN2B. Disconnect swash plate sensor connectors X-93 and X-94. Connect the left-hand swash plate sensor into the right-hand swash plate sensor connector X-93. Connect the right-hand swash plate sensor into the left-hand swash plate sensor connector X-94. Turn the ignition switch ON. Monitor the active diagnostic screen. Fault code 4732 - Right Swash Plate Angle Sensor - Pin A Short to Power should no longer be active. Fault code 4745 - Left Swash Plate Angle Sensor - Pin B Short to Power is active. A. Fault code 4732 - Right Swash Plate Angle Sensor - Pin A Short to Power is no longer active. Fault code 4745 - Left Swash Plate Angle Sensor - Pin B Short to Power is active. Replace the right hand swash plate angle sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4732 - Right Swash Plate Angle Sensor - Pin A Short to Power is still active. Fault code 4745 Left Swash Plate Angle Sensor - Pin B Short to Power did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09)

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Electrical systems - FAULT CODES

4734-Right Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the swash plate angle sensor signal has failed. Diagnostic Trouble Code 4734 - Right Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 4734 - Right Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the swash plate angle sensor signal has failed low. The fault is active while the engine is ON and the right swash plate angle sensor voltage, CN2B pin 33 is less than 0.2 V. Possible failure modes: 1. The sensor signal wire is shorted to chassis ground. 2. An open circuit in the sensor signal wire. 3. A failure of the swash plate angle sensor. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4734 - Right Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the left-hand swash plate sensor connection and the right-hand swash plate sensor connection. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the swash plate sensors. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the sensor. Turn the ignition switch OFF. Disconnect the right-hand swash plate sensor connector X-93. Turn the ignition switch ON. Measure the voltage between X-93 pin 5 and X-93 pin 1. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-93 pin 2 and X-93 pin 6. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. 47683911 27/02/2015

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A. The voltage measurement is approximately 12 V. Go to step 4. B. The voltage measurement is less than 10 V. There is a problem in the voltage supply or sensor ground wire to the sensor. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector CN2B. Disconnect the right-hand swash plate sensor connector X-93. Measure the resistance between CN2B pin 33 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is greater than 20,000 Ω. Go to step 5. B. The resistance measurement is less than 20,000 Ω. There is a short circuit to chassis ground in the signal wire. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Turn the ignition switch OFF. Disconnect UCM connector CN2B. Disconnect connector X-93. Fabricate a jumper wire that will connect between the UCM connector CN2B pin 33 and chassis ground. Connect the jumper wire between CN2B pin 33 and chassis ground. Measure the resistance between X-93 pin 3 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is less than 10 Ω. Go to step 6. B. The resistance measurement is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 6. Test the UCM. Turn the ignition switch OFF. Remove the jumper wire. Reconnect UCM connector CN2B. Disconnect swash plate sensor connectors X-93 and X-94. Connect the left-hand swash plate sensor into the right-hand swash plate sensor connector X-93. Connect the right-hand swash plate sensor into the left-hand swash plate sensor connector X-94. Turn the ignition switch ON. Monitor the active diagnostic screen. Fault code 4734 - Right Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit should no longer be active. Fault code 4741 - Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit is active. A. Fault code 4734 - Right Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit is no longer active. Fault code 4741 - Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit is active. Replace the Swash Plate Angle sensor and retest. Return to step 1 to confirm elimination of the fault.

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B. Fault code 4734 - Right Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit is still active. Fault code 4741 - Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09)

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Electrical systems - FAULT CODES

4735-Right Swash Plate Angle Sensor - Pin B Short to Power WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed a higher than normal voltage from the right-hand swash plate sensor. Diagnostic Trouble Code 4735 - Right Swash Plate Angle Sensor - Pin B Short to Power has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 4735 - Right Swash Plate Angle Sensor - Pin B Short to Power is active. Cause: The UCM has sensed a higher than normal voltage from the right-hand swash plate sensor. The fault is active while the engine is ON and the swash plate angle sensor voltage, CN2B pin 33 is greater than 4.8 V. Possible failure modes: 1. The signal wire has a short circuit to another voltage source. 2. A failure of the swash plate sensor. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4735 - Right Swash Plate Angle Sensor - Pin B Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the left-hand swash plate sensor connection and the right-hand swash plate sensor connection. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the swash plate sensors. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the sensor signal wire. Turn the ignition switch OFF. Disconnect UCM connector CN2B. Disconnect the right-hand swash plate sensor connector X-93. Turn the ignition switch ON. Measure the voltage between X-93 pin 3 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage measurement is less than 0.5 V. Go to step 4. B. The voltage measurement is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 47683911 27/02/2015

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4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connector CN2B. Disconnect swash plate sensor connectors X-93 and X-94. Connect the left-hand swash plate sensor into the right-hand swash plate sensor connector X-93. Connect the right-hand swash plate sensor into the left-hand swash plate sensor connector X-94. Turn the ignition switch ON. Monitor the active diagnostic screen. Fault code 4735 - Right Swash Plate Angle Sensor - Pin B Short to Power should no longer be active. Fault code 4742 - Left Swash Plate Angle Sensor - Pin A Short to Power is active. A. Fault code 4735 - Right Swash Plate Angle Sensor - Pin B Short to Power is no longer active. Fault code 4742 - Left Swash Plate Angle Sensor - Pin A Short to Power is active. Replace the right hand swash plate angle sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4735 - Right Swash Plate Angle Sensor - Pin B Short to Power is still active. Fault code 4742 Left Swash Plate Angle Sensor - Pin A Short to Power did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09)

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Electrical systems - FAULT CODES

4737-Right Swash Plate Angle Sensor - In Range Fault WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the right swash plate angle sensor has failed. Diagnostic Trouble Code 4737 - Right Swash Plate Angle Sensor - In Range Fault has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 4737 - Right Swash Plate Angle Sensor - In Range Fault is active. Cause: The UCM has sensed that the right swash plate angle sensor has failed. The fault is active while of the swash plate angle sensor inputs, CN2B pin 32 and CN2B pin 33 are less than 4.4 V or greater than 5.6 V. Possible failure modes: 1. An open circuit in the supply voltage to the sensor. 2. A failure of the swash plate angle sensor. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4737 - Right Swash Plate Angle Sensor - In Range Fault is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the left-hand swash plate sensor connection and the right-hand swash plate sensor connection. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the swash plate sensors. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the sensor. Turn the ignition switch OFF. Disconnect the right-hand swash plate sensor connector X-93. Turn the ignition switch ON. Measure the voltage between X-93 pin 5 and X-93 pin 1. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-93 pin 2 and X-93 pin 6. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage measurement is approximately 12 V. Go to step 4.

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Electrical systems - FAULT CODES

B. The voltage measurement is less than 10 V. There is a problem with the voltage supply to the sensor or a problem with the sensor ground connections. Check splice SP-136. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector CN2B. Disconnect the right-hand swash plate sensor connector X-93. Measure the resistance between connector CN2B pin 32 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector CN2B pin 33 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurement are greater than 20,000 Ω. Go to step 5. B. One or both resistance measurements are less than 20,000 Ω. There is a short circuit to chassis ground in the signal wire. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Turn the ignition switch OFF. Disconnect UCM connector CN2B. Disconnect connector X-93. Fabricate a jumper wire that will connect between the UCM connector CN2B pin 32 and chassis ground. Connect the jumper wire between CN2B pin 32 and chassis ground. Measure the resistance between X-93 pin 4 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Remove the jumper wire from CN2B pin 32. Use the jumper wire to connect CN2B pin 33 to chassis ground. Measure the resistance between X-93 pin 3 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 Ω. Go to step 6. B. One or both resistance measurements are greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 6. Test the UCM. Turn the ignition switch OFF. Remove the jumper wire. Reconnect UCM connector CN2B. Disconnect the swash plate sensor connectors X-93 and X-94. Connect the left-hand swash plate sensor into the right-hand swash plate sensor connector X-93. Connect the right-hand swash plate sensor into the left-hand swash plate sensor connector X-94. Turn the ignition switch ON.

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Electrical systems - FAULT CODES

Monitor the active diagnostic screen. Fault code 4737 - Right Swash Plate Angle Sensor - In Range Fault should no longer be active. Fault code 4747 - Left Swash Plate Angle Sensor - In Range Fault is active. A. Fault code 4737 - Right Swash Plate Angle Sensor - In Range Fault is no longer active. Fault code 4747 - Left Swash Plate Angle Sensor - In Range Fault is active. Replace the Swash Plate Angle sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4737 - Right Swash Plate Angle Sensor - In Range Fault is still active. Fault code 4747 - Left Swash Plate Angle Sensor - In Range Fault did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09)

47683911 27/02/2015

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Electrical systems - FAULT CODES

4741-Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the swash plate angle sensor signal has failed. Diagnostic Trouble Code 4741 - Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 4741 - Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the swash plate angle sensor signal has failed low. The fault is active while the engine is ON and the left swash plate angle sensor voltage, CN3A pin 9 is less than 0.2 V. Possible failure modes: 1. The sensor signal wire is shorted to chassis ground. 2. An open circuit in the sensor signal wire. 3. A failure of the swash plate angle sensor. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4741 - Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the left-hand swash plate sensor connection and the right-hand swash plate sensor connection. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the swash plate sensors. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the sensor. Turn the ignition switch OFF. Disconnect the left-hand swash plate sensor connector X-94. Turn the ignition switch ON. Measure the voltage between X-94 pin 5 and X-94 pin 1. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-94 pin 2 and X-94 pin 6. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. 47683911 27/02/2015

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Electrical systems - FAULT CODES

A. The voltage measurement is approximately 12 V. Go to step 4. B. The voltage measurement is less than 10 V. There is a problem in the voltage supply or sensor ground wire to the sensor. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector CN3A. Disconnect the left-hand swash plate sensor connector X-94. Measure the resistance between CN3A pin 9 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is greater than 20,000 Ω. Go to step 5. B. The resistance measurement is less than 20,000 Ω. There is a short circuit to chassis ground in the signal wire. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Turn the ignition switch OFF. Disconnect UCM connector CN3A. Disconnect connector X-94. Fabricate a jumper wire that will connect between the UCM connector CN3A pin 9 and chassis ground. Connect the jumper wire between CN3A pin 9 and chassis ground. Measure the resistance between X-94 pin 3 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is less than 10 Ω. Go to step 6. B. The resistance measurement is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 6. Test the UCM. Turn the ignition switch OFF. Remove the jumper wire. Reconnect UCM connector CN3A. Disconnect swash plate sensor connectors X-93 and X-94. Connect the left hand swash plate sensor into the right hand swash plate sensor connector X-93. Connect the right hand swash plate sensor into the left hand swash plate sensor connector X-94. Turn the ignition switch ON. Monitor the active diagnostic screen. Fault code 4741 - Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit should no longer be active. Fault code 4734 - Right Swash Plate Angle Sensor Pin B Open Or Shorted To Ground is active. A. Fault code 4741 - Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit is no longer active. Fault code 4734 - Right Swash Plate Angle Sensor Pin B Open Or Shorted To Ground is active. Replace the Swash Plate Angle sensor and retest. Return to step 1 to confirm elimination of the fault.

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Electrical systems - FAULT CODES

B. Fault code 4741 - Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit is still active. Fault code 4734 - Right Swash Plate Angle Sensor Pin B Open Or Shorted To Ground did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09)

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Electrical systems - FAULT CODES

4742-Left Swash Plate Angle Sensor - Pin A Short to Power WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed a higher than normal voltage from the left-hand swash plate sensor. Diagnostic Trouble Code 4742 - Left Swash Plate Angle Sensor - Pin A Short to Power has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 4742 - Left Swash Plate Angle Sensor - Pin A Short to Power is active. Cause: The UCM has sensed a higher than normal voltage from the left hand swash plate sensor. The fault is active while the engine is ON and the swash plate angle sensor voltage, CN3A pin 9 is greater than 4.8 V. Possible failure modes: 1. A faulty ground connection on the rear right-hand ground lug. 2. The signal wire has a short circuit to another voltage source. 3. A failure of the swash plate sensor. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4742 - Left Swash Plate Angle Sensor - Pin A Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the left-hand swash plate sensor connection and the right-hand swash plate sensor connection. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the swash plate sensors. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Check the ground connection on the rear right-hand ground lugs. Verify that the grounding boss is free of paint, oil, dirt, and debris. Verify that the ground connection is tight and secure. A. The grounding boss is clean and free of paint. The grounding connection is secure. Go to step 4. B. The grounding boss is dirty or cover with paint. Remove the dirt. Remove the paint. Repair as required. Return to step 1 to confirm elimination of fault. 4. Measure the voltage on the sensor signal wire. Turn the ignition switch OFF. Disconnect UCM connector CN3A. 47683911 27/02/2015

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Electrical systems - FAULT CODES

Disconnect the left-hand swash plate sensor connector X-94. Turn the ignition switch ON. Measure the voltage between X-94 pin 3 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage measurement is less than 0.5 V. Go to step 5. B. The voltage measurement is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 5. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connector CN3A. Disconnect swash plate sensor connectors X-93 and X-94. Connect the left-hand swash plate sensor into the right-hand swash plate sensor connector X-93. Connect the right-hand swash plate sensor into the left-hand swash plate sensor connector X-94. Turn the ignition switch ON. Monitor the active diagnostic screen. Fault code 4742 - Left Swash Plate Angle Sensor - Pin A Short to Power should no longer be active. Fault code 4735 - Right Swash Plate Angle Sensor - Pin B Short to Power is active. A. Fault code 4742 - Left Swash Plate Angle Sensor - Pin A Short to Power is no longer active. Fault code 4735 - Right Swash Plate Angle Sensor - Pin B Short to Power is active. Replace the right hand swash plate angle sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4742 - Left Swash Plate Angle Sensor - Pin A Short to Power is still active. Fault code 4735 - Right Swash Plate Angle Sensor - Pin B Short to Power did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09)

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Electrical systems - FAULT CODES

4744-Left Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the swash plate angle sensor signal has failed low. Diagnostic Trouble Code 4744 - Left Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 4744 - Left Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the swash plate angle sensor signal has failed low. The fault is active while the engine is ON and the left swash plate angle sensor voltage, CN3A pin 10 is less than 0.2 V. Possible failure modes: 1. The sensor signal wire is shorted to chassis ground. 2. An open circuit in the sensor signal wire. 3. A failure of the swash plate angle sensor. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4744 - Left Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the left-hand swash plate sensor connection and the right-hand swash plate sensor connection. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the swash plate sensors. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the supply voltage to the sensor. Turn the ignition switch OFF. Disconnect the left-hand swash plate sensor connector X-94. Turn the ignition switch ON. Measure the voltage between X-94 pin 5 and X-94 pin 1. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-94 pin 2 and X-94 pin 6. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. 47683911 27/02/2015

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Electrical systems - FAULT CODES

A. The voltage measurement is approximately 12 V. Go to step 4. B. The voltage measurement is less than 10 V. There is a problem in the voltage supply or sensor ground wire to the sensor. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector CN3A. Disconnect the left-hand swash plate sensor connector X-94. Measure the resistance between CN3A pin 10 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is greater than 20,000 Ω. Go to step 5. B. The resistance measurement is less than 20,000 Ω. There is a short circuit to chassis ground in the signal wire. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Turn the ignition switch OFF. Disconnect UCM connector CN3A. Disconnect connector X-94. Fabricate a jumper wire that will connect between the UCM connector CN3A pin 10 and chassis ground. Connect the jumper wire between CN3A pin 10 to chassis ground. Measure the resistance between X-94 pin 4 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is less than 10 Ω. Go to step 6. B. The resistance measurement is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 6. Test the UCM. Turn the ignition switch OFF. Remove the jumper wire. Reconnect UCM connector CN3A. Disconnect swash plate sensor connectors X-93 and X-94. Connect the left-hand swash plate sensor into the right-hand swash plate sensor connector X-93. Connect the right-hand swash plate sensor into the left-hand swash plate sensor connector X-94. Turn the ignition switch ON. Monitor the active diagnostic screen. Fault code 4744 - Left Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit should no longer be active. Fault code 4731 - Right Swash Plate Angle Sensor Pin A Open Or Shorted To Ground is active. A. Fault code 4744 - Left Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit is no longer active. Fault code 4731 - Right Swash Plate Angle Sensor Pin A Open Or Shorted To Ground is active. Replace the Swash Plate Angle sensor and retest. Return to step 1 to confirm elimination of the fault.

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Electrical systems - FAULT CODES

B. Fault code 4744 - Left Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit is still active. Fault code 4731 - Right Swash Plate Angle Sensor Pin A Open Or Shorted To Ground did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09)

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Electrical systems - FAULT CODES

4745-Left Swash Plate Angle Sensor - Pin B Short to Power WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed a higher than normal voltage from the left-hand swash plate sensor. Diagnostic Trouble Code 4745 - Left Swash Plate Angle Sensor - Pin B Short to Power has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 4745 - Left Swash Plate Angle Sensor - Pin B Short to Power is active. Cause: The UCM has sensed a higher than normal voltage from the left-hand swash plate sensor. The fault is active while the engine is on and the swash plate angle sensor voltage, CN3A pin 10 is greater than 4.8 V. Possible failure modes: 1. The signal wire has a short circuit to another voltage source. 2. A failure of the swash plate sensor. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4745 - Left Swash Plate Angle Sensor - Pin B Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the left-hand swash plate sensor connection and the right-hand swash plate sensor connection. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the swash plate sensors. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the sensor signal wire. Turn the ignition switch OFF. Disconnect UCM connector CN3A. Disconnect the left-hand swash plate sensor connector X-94. Turn the ignition switch ON. Measure the voltage between X-94 pin 4 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage measurement is less than 0.5 V. Go to step 4. B. The voltage measurement is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 47683911 27/02/2015

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Electrical systems - FAULT CODES

4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connector CN3A. Disconnect swash plate sensor connectors X-93 and X-94. Connect the left-hand swash plate sensor into the right-hand swash plate sensor connector X-93. Connect the right-hand swash plate sensor into the left-hand swash plate sensor connector X-94. Turn the ignition switch ON. Monitor the active diagnostic screen. Fault code 4745 - Left Swash Plate Angle Sensor - Pin B Short to Power should no longer be active. Fault code 4732 - Right Swash Plate Angle Sensor - Pin A Short to Power is active. A. Fault code 4745 - Left Swash Plate Angle Sensor - Pin B Short to Power is no longer active. Fault code 4732 - Right Swash Plate Angle Sensor - Pin A Short to Power is active. Replace the right hand swash plate angle sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4745 - Left Swash Plate Angle Sensor - Pin B Short to Power is still active. Fault code 4732 - Right Swash Plate Angle Sensor - Pin A Short to Power did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09)

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Electrical systems - FAULT CODES

4747-Left Swash Plate Angle Sensor - In Range Fault WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the left swash plate angle sensor has failed. Diagnostic Trouble Code 4747 - Left Swash Plate Angle Sensor - In Range Fault has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 4747 - Left Swash Plate Angle Sensor - In Range Fault is active. Cause: The UCM has sensed that the left swash plate angle sensor has failed. The fault is active while of the swash plate angle sensor inputs, CN3A pin 9 and CN3A pin 10 are less than 4.4 V or greater than 5.6 V. Possible failure modes: 1. An open circuit in the supply voltage to the sensor. 2. Failure of the swash plate angle sensor. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4747 - Left Swash Plate Angle Sensor - In Range Fault is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the left-hand swash plate sensor connection and the right-hand swash plate sensor connection. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the swash plate sensors. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the sensor. Turn the ignition switch OFF. Disconnect the left-hand swash plate sensor connector X-94. Turn the ignition switch ON. Measure the voltage between X-94 pin 5 and X-94 pin 1. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-94 pin 2 and X-94 pin 6. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage measurement is approximately 12 V. Go to step 4.

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Electrical systems - FAULT CODES

B. The voltage measurement is less than 10 V. There is a problem with the voltage supply to the sensor or a problem with the sensor ground connections. Check splice SP-136. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector CN3A. Disconnect left-hand swash plate sensor connector X-94. Measure the resistance between connector CN3A pin 9 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector CN3A pin 10 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurement are greater than 20,000 Ω. Go to step 5. B. One or both resistance measurements are less than 20,000 Ω. There is a short circuit to chassis ground in the signal wire. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Turn the ignition switch OFF. Disconnect UCM connector CN3A. Disconnect connector X-94. Fabricate a jumper wire that will connect between the UCM connector CN3A pin 9 and chassis ground. Connect the jumper wire between CN3A pin 9 and chassis ground. Measure the resistance between X-94 pin 3 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Remove the jumper wire from CN3A pin 9. Connect the jumper wire between CN3A pin 10 and chassis ground. Measure the resistance between X-94 pin 4 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 Ω. Go to step 6. B. One or both resistance measurements are greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 6. Test the UCM. Turn the ignition switch OFF. Remove the jumper wire. Reconnect UCM connector CN3A. Disconnect swash plate sensor connectors X-93 and X-94. Connect the left-hand swash plate sensor into the right-hand swash plate sensor connector X-93. Connect the right-hand swash plate sensor into the left-hand swash plate sensor connector X-94. Turn the ignition switch ON.

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Electrical systems - FAULT CODES

Monitor the active diagnostic screen. Fault code 4747 - Left Swash Plate Angle Sensor - In Range Fault should no longer be active. Fault code 4737 - Right Swash Plate Angle Sensor - In Range Fault is active. A. Fault code 4747 - Left Swash Plate Angle Sensor - In Range Fault is no longer active. Fault code 4737 Right Swash Plate Angle Sensor - In Range Fault is active. Replace the Swash Plate Angle sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4747 - Left Swash Plate Angle Sensor - In Range Fault is still active. Fault code 4737 - Right Swash Plate Angle Sensor - In Range Fault did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09)

47683911 27/02/2015

55.17 [55.DTC] / 595

Electrical systems - FAULT CODES

4752-Left Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the swash plate sensor signal does not agree with the direction of vehicle travel. Diagnostic Trouble Code 4752 - Left Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle has an error priority of Red. Forward ground drive and reverse ground drive functions are disabled while Diagnostic Trouble Code 4752 - Left Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle is active. Cause: The UCM has sensed that the swash plate sensor signal does not agree with the direction of vehicle travel. The fault active is when the swash plate sensor senses vehicle movement while the solenoids are not energized or while vehicle movement is opposite of the energized solenoid. Possible failure modes: 1. A faulty ground connection on the rear right-hand ground lug. 2. Improper wiring in the circuit. 3. Mechanical pump adjustment. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4752 - Left Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the left-hand swash plate sensor connection and the right-hand swash plate sensor connection. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the swash plate sensors. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Check the ground connection on the rear right-hand ground lugs. Verify that the grounding boss is free of paint, oil, dirt, and debris. Verify that the ground connection is tight and secure. A. The grounding boss is clean and free of paint. The grounding connection is secure. Go to step 4. B. The grounding boss is dirty or cover with paint. Remove the dirt. Remove the paint. Repair as required. Return to step 1 to confirm elimination of fault. 4. Verify that the pump harness is installed correctly. 47683911 27/02/2015

55.17 [55.DTC] / 596

Electrical systems - FAULT CODES

Verify that connector X-18 is connected to the right-drive pump reverse solenoid. Verify that connector X-17 is connected to the right-drive pump forward solenoid. Verify that connector X-16 is connected to the left-drive pump reverse solenoid. Verify that connector X-13 is connected to the left-drive pump forward solenoid. A. The connectors are secure and installed in the proper location. Go to step 5. B. The connectors are not secure or are not installed in the proper locations. Repair the harness or connectors as required. Return to step 1 to confirm elimination of fault. 5. Verify that the swash plate sensors are connected properly. Verify that connector X-93 is connected to the right-hand pump swash plate sensor. Verify that connector X-94 is connected to the left-hand pump swash plate sensor. A. The connectors are secure and installed in the proper location. Check the adjustment for mechanical neutral in the left-hand pump drive circuit. Return to step 1. B. The connectors are not secure or are not installed in the proper locations. Repair the harness or connectors as required. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09)

47683911 27/02/2015

55.17 [55.DTC] / 597

Electrical systems - FAULT CODES

4754-Right Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the swash plate sensor signal does not agree with the direction of vehicle travel. Diagnostic Trouble Code 4754 - Right Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle has an error priority of Red. Forward and reverse ground drive functions are disabled while Diagnostic Trouble Code 4754 - Right Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle is active. Cause: The UCM has sensed that the swash plate sensor signal does not agree with the direction of vehicle travel. The fault active is when the swash plate sensor senses vehicle movement while the solenoids are not energized or while vehicle movement is opposite of the energized solenoid. Possible failure modes: 1. Improper wiring in the circuit. 2. Mechanical pump adjustment. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4754 - Right Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the left-hand swash plate sensor connection and the right-hand swash plate sensor connection. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the swash plate sensors. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Verify that the pump harness is installed correctly. Verify that connector X-18 is connected to the right-drive pump reverse solenoid. Verify that connector X-17 is connected to the right-drive pump forward solenoid. Verify that connector X-16 is connected to the left-drive pump reverse solenoid. Verify that connector X-13 is connected to the left-drive pump forward solenoid. A. The connectors are secure and installed in the proper location. Go to step 4. B. The connectors are not secure or are not installed in the proper locations. Repair the harness or connectors as required. Return to step 1 to confirm elimination of fault. 47683911 27/02/2015

55.17 [55.DTC] / 598

Electrical systems - FAULT CODES

4. Verify that the swash plate sensors are connected properly. Verify that connector X-93 is connected to the right hand pump swash plate sensor. Verify that connector X-94 is connected to the left hand pump swash plate sensor. A. The connectors are secure and installed in the proper location. Check the adjustment for mechanical neutral in the right-hand pump drive circuit. Return to step 1. B. The connectors are not secure or are not installed in the proper locations. Repair the harness or connectors as required. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09)

47683911 27/02/2015

55.17 [55.DTC] / 599

Electrical systems - FAULT CODES

4781-Solenoid Valve - Solenoid Supply Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sent a signal to the two speed solenoid to energize, but the UCM does not sense proper voltage. Diagnostic Trouble Code 4781 - Solenoid Valve - Solenoid Supply Open Circuit has an error priority of White. The two speed operating mode is disabled while Diagnostic Trouble Code 4781 - Solenoid Valve - Solenoid Supply Open Circuit is active. Cause: The UCM has sent a signal to the two speed solenoid to energize, but the UCM does not sense proper voltage. The fault is active while the engine is ON and the solenoid output CN3A pin 25 is greater than 8 V or less than 1 V. Possible failure modes: 1. An open circuit in the wiring. 2. A short circuit in the wiring. 3. The two speed solenoid has failed. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4781 - Solenoid Valve - Solenoid Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and two speed solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the two speed solenoid. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the harness. Turn the ignition switch OFF. Disconnect the two speed connector, X-2SPD. Fabricate a jumper wire that will connect between the two speed solenoid connector X-2SPD pin A and X-2SPD pin B. Use the jumper wire to short X-2SPD pin A to X-SPD pin B. Disconnect UCM connector CN3A. Measure the resistance between CN3A pin 25 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. 47683911 27/02/2015

55.17 [55.DTC] / 600

Electrical systems - FAULT CODES

A. The resistance is less than 10 Ω. Go to step 4. B. The resistance is greater than 10 Ω. There is an open circuit in the solenoid signal or the solenoid ground line. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Leave the jumper wire installed between X-2SPD pin A and X-2SPD pin B. Reconnect UCM connectors CN3A. Turn the ignition switch ON. Activate the two speed feature while monitoring the fault code screen. Fault code 4781 - Solenoid Valve - Solenoid Supply Open Circuit should no longer be active. Fault code 4782 - Solenoid Valve - Solenoid Supply Short to Ground should become active. A. Fault code 4782 - Solenoid Valve - Solenoid Supply Short to Ground is active and fault code 4781 - Solenoid Valve - Solenoid Supply Open Circuit is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4781 - Solenoid Valve - Solenoid Supply Open Circuit is still active. Fault code 4782 - Solenoid Valve - Solenoid Supply Short to Ground did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 16 Left-Hand Control Handle (55.100.DP-C.20.E.16) Wiring harnesses - Electrical schematic sheet 04 System Power and Grounds (55.100.DP-C.20.E.04)

47683911 27/02/2015

55.17 [55.DTC] / 601

Electrical systems - FAULT CODES

4782-Solenoid Valve - Solenoid Supply Short to Ground C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE Electro hydraulic controls WE WE Electro hydraulic controls

Context: The UCM has sent a signal to the two speed solenoid to energize, but no voltage was detected. Diagnostic Trouble Code 4782 - Solenoid Valve - Solenoid Supply Short to Ground has an error priority of White. The two speed operating mode is disabled while Diagnostic Trouble Code 4782 - Solenoid Valve - Solenoid Supply Short to Ground is active. Cause: The UCM has sent a signal to the two speed solenoid to energize, but no voltage was detected. The fault is active while the two speed operating mode is on and the solenoid output, CN3A pin 25 current is high. Possible failure modes: 1. A short circuit in the wiring. 2. The two speed solenoid has failed. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4782 - Solenoid Valve - Solenoid Supply Short to Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the two speed solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the two speed solenoid. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector CN3A. Disconnect solenoid connector X-2SPD. Measure the resistance between X-2SPD pin A and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is greater than 20,000 Ω. Go to step 4. B. The resistance measurement is less than 20,000 Ω. There is an short circuit to chassis ground in the harness. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. 47683911 27/02/2015

55.17 [55.DTC] / 602

Electrical systems - FAULT CODES

Turn the ignition switch OFF. Reconnect UCM connector CN3A. Leave connector X-2SPD disconnected. Turn the ignition switch ON. Activate the two speed function while monitoring the fault code screen. Fault code 4782 - Solenoid Valve - Solenoid Supply Short to Ground should no longer be active. Fault code 4781 - Solenoid Valve - Solenoid Supply Open Circuit should become active. A. Fault code 4781 - Solenoid Valve - Solenoid Supply Open Circuit is active and fault code 4782 - Solenoid Valve - Solenoid Supply Short to Ground is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4782 - Solenoid Valve - Solenoid Supply Short to Ground is still active. Fault code 4781 Solenoid Valve - Solenoid Supply Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 16 Left-Hand Control Handle (55.100.DP-C.20.E.16) Wiring harnesses - Electrical schematic sheet 04 System Power and Grounds (55.100.DP-C.20.E.04)

47683911 27/02/2015

55.17 [55.DTC] / 603

Electrical systems - FAULT CODES

4783-Solenoid Valve - Solenoid Supply Short to Power C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE Electro hydraulic controls WE WE Electro hydraulic controls

Context: The UCM has sensed higher than normal voltage on the two speed solenoid. Diagnostic Trouble Code 4783 - Solenoid Valve - Solenoid Supply Short to Power has an error priority of Amber. Ground Drive Limp Home operating mode is enabled while Diagnostic Trouble Code 4783 - Solenoid Valve - Solenoid Supply Short to Power is active. Cause: The UCM has sensed higher than normal voltage on the two speed solenoid. The fault is active when the Two Speed function is off and the two speed solenoid output voltage, CN3A pin 25 is greater than 8 V. Possible failure modes: 1. A short circuit in the wiring. 2. The two speed solenoid has failed. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4783 - Solenoid Valve - Solenoid Supply Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the two speed solenoid connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the two speed solenoid. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage of the solenoid wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector CN3A. Disconnect solenoid connector X-2SPD. Turn the ignition switch ON. Measure the voltage between X-2SPD pin A and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage measurement is less than 0.5 V. Go to step 4. B. The voltage measurement is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 47683911 27/02/2015

55.17 [55.DTC] / 604

Electrical systems - FAULT CODES

4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connector CN3A. Leave connector X-2SPD disconnected. Turn the ignition switch ON. Activate the two speed function while monitoring the fault code screen. Fault code 4783 - Solenoid Valve - Solenoid Supply Short to Power should no longer be active. Fault code 4781 - Solenoid Valve - Solenoid Supply Open Circuit should become active. A. Fault code 4781 - Solenoid Valve - Solenoid Supply Open Circuit is active. Fault code 4783 - Solenoid Valve - Solenoid Supply Short to Power is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4783 - Solenoid Valve - Solenoid Supply Short to Power is still active. Fault code 4781 - Solenoid Valve - Solenoid Supply Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 16 Left-Hand Control Handle (55.100.DP-C.20.E.16) Wiring harnesses - Electrical schematic sheet 04 System Power and Grounds (55.100.DP-C.20.E.04)

47683911 27/02/2015

55.17 [55.DTC] / 605

Electrical systems - FAULT CODES

4951-Hydraulic Interlock Solenoid Shorted To Power WE Mechanical hydraulic controls WE WE Mechanical hydraulic controls

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The instrument cluster has sensed a short circuit to another voltage source in the hydraulic interlock circuit. Diagnostic Trouble Code 4951 has an error priority of Red. The vehicle is disabled while Diagnostic Trouble Code 4951 is active. Cause: The instrument cluster has sensed a short circuit to another voltage source in the hydraulic interlock circuit. The fault is active while the ignition switch is ON and the hydraulic enable commanded state is low and hydraulic enable solenoid is energized. Possible failure modes: 1. Faulty wiring or connectors. 2. A faulty instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4951 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the instrument cluster connector X-C23 and the hydraulic interlock solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the instrument cluster to the hydraulic interlock solenoid. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the signal wire. Turn the ignition switch OFF. Disconnect the instrument cluster connector X-C23. Disconnect the Telematics connector X-TELE. Disconnect connector X-PORT_LK. Turn the ignition switch ON. Measure the voltage between the instrument cluster connector X-C23 pin 30 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm the elimination of the fault.

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Electrical systems - FAULT CODES

B. The voltage is greater than 0.5 V. The solenoid wire is shorted to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 Instrument Cluster (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 10 Cab to Chassis Interface (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 09 Control Valve Interlock & 2nd Aux Hydraulics (55.100.DP-C.20.E.09) Wiring harnesses - Electrical schematic sheet 25 Telematics (55.100.DP-C.20.E.25)

47683911 27/02/2015

55.17 [55.DTC] / 607

Electrical systems - FAULT CODES

4952-Hydraulic Interlock Solenoid Open Circuit WE Mechanical hydraulic controls WE WE Mechanical hydraulic controls

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

NOTE: A machine with Loader Lock on will trigger trouble code 4952. This is normal. Context: The instrument cluster has sensed an open circuit condition in the hydraulic interlock circuit. Diagnostic Trouble Code 4952 has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 4952. Cause: The instrument cluster has sensed an open circuit condition in the hydraulic interlock circuit. The fault is active while the ignition switch is ON and the hydraulic enable commanded state is high but the hydraulic enable solenoid is not energized. Possible failure modes: 1. Faulty wiring or connectors. 2. An open circuit in the hydraulic interlock solenoid wiring. 3. An open circuit in the hydraulic interlock solenoid. 4. A faulty instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4952 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the instrument cluster connector X-C23 and the hydraulic interlock solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the instrument cluster to the hydraulic interlock solenoid. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the signal wire. Turn the ignition switch OFF. Disconnect the instrument cluster connector X-C23. Measure the resistance between X-C23 pin 30 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm the elimination of the fault. B. The resistance is greater than 10 Ω. There is a problem in the solenoid circuit. Go to step 4.

47683911 27/02/2015

55.17 [55.DTC] / 608

Electrical systems - FAULT CODES

4. Measure the resistance of the hydraulic interlock solenoid. Turn the ignition switch OFF. Disconnect connector X-PORT_LK from the hydraulic interlock solenoid. Measure the resistance across the solenoid terminals of the solenoid. The resistance should be approximately 7.25 Ω. A. The resistance is between 6.5 Ω and 8 Ω. Go to step 5. B. The resistance is greater than 8 Ω. The hydraulic interlock solenoid has an internal open circuit. Replace the hydraulic interlock solenoid and retest. Return to step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Disconnect the instrument cluster connector X-C23 and the hydraulic interlock solenoid connector, X-PORT_LK. Fabricate a jumper wire that will connect between connector X-PORT_LK pin 1 and X-PORT_LK pin 2. Connect the jumper wire between connector X-PORT_LK pin 1 and X-PORT_LK pin 2. Measure the resistance between X-C23 pin 30 and X-C23 pin 34 (chassis ground). The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 10 Ω. There is an open circuit in the harness. Inspect connectors from the instrument cluster to the hydraulic interlock solenoid. Verify all connections are tight and secure and free of damage. Repair or replace the wires as required. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 Instrument Cluster (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 10 Cab to Chassis Interface (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 09 Control Valve Interlock & 2nd Aux Hydraulics (55.100.DP-C.20.E.09) Wiring harnesses - Electrical schematic sheet 25 Telematics (55.100.DP-C.20.E.25)

47683911 27/02/2015

55.17 [55.DTC] / 609

Electrical systems - FAULT CODES

5051-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed an open circuit in the solenoid signal line, CN2A pin 4. Diagnostic Trouble Code 5051 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Open Circuit has an error priority of Red. Loader hydraulics are disabled while Diagnostic Trouble Code 5051 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Open Circuit is active. Cause: The UCM has sensed an open circuit in the solenoid signal line, CN2A pin 4. The fault is active while the engine is ON and the voltage on CN2A pin 4 is less 1 V or greater than 8 V. Possible failure modes: 1. An open circuit in the solenoid wiring. 2. The loader pilot interlock valve has failed. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5051 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader pilot interlock connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader pilot interlock. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connector CN2A. Fabricate a jumper wire that will connect between CN2A pin 4 and chassis ground. Connect the jumper wire between CN2A pin 4 and chassis ground. Disconnect connector X-PLTLK. Measure the resistance between X-PLTLK pin A and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. 47683911 27/02/2015

55.17 [55.DTC] / 610

Electrical systems - FAULT CODES

Measure the resistance between X-PLTLK pin B and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 Ω. Go to step 4 to confirm elimination of the fault. B. One or both resistance measurements are greater than 10 Ω. There is an open circuit in the wiring. repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the resistance through the solenoid. Measure the resistance across the loader interlock solenoid terminals, pin A and pin B. The resistance should be less than 1,000 Ω. A. The resistance is less than 1,000 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 1,000 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 10 Hydraulic Interlocks (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 04 System Power and Grounds (55.100.DP-C.20.E.04)

47683911 27/02/2015

55.17 [55.DTC] / 611

Electrical systems - FAULT CODES

5052-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Ground WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sent a signal to the Loader Pilot Interlock solenoid to energize, but no voltage was detected. Diagnostic Trouble Code 5052 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Ground has an error priority of Red. Loader hydraulics are disabled while Diagnostic Trouble Code 5052 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Ground is active. Cause: The UCM has sent a signal to the loader pilot interlock solenoid to energize, but no voltage was detected. The fault is active while the hydraulics are enabled and the loader pilot interlock solenoid output, CN2A pin 4 is greater than 3 A. Possible failure modes: 1. A short circuit in the solenoid wiring. 2. The loader pilot interlock valve has failed. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5052 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader pilot interlock connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader pilot interlock. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connector CN2A. Disconnect solenoid connector X-PLTLK. Measure the resistance between CN2A pin 4 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is greater than 20,000 Ω. Go to step 4.

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Electrical systems - FAULT CODES

B. The resistance measurement is less than 20,000 Ω. There is a short circuit to chassis ground in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the solenoid resistance. Measure the resistance across the loader interlock solenoid terminals, pin A and pin B. The resistance should be greater than 1 Ω. A. The resistance is greater than 1 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 1 Ω. There is a short circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 10 Hydraulic Interlocks (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 04 System Power and Grounds (55.100.DP-C.20.E.04)

47683911 27/02/2015

55.17 [55.DTC] / 613

Electrical systems - FAULT CODES

5053-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the voltage on X-CN2A pin 4 is greater than 8 V. Diagnostic Trouble Code 5053 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power has an error priority of Red. Loader hydraulics are disabled while Diagnostic Trouble Code 5053 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power is active. Cause: The UCM has sent a signal to the loader pilot interlock solenoid to de-energize, but the UCM detects a voltage on the output. The fault is active when the hydraulics are disabled and the loader port lock solenoid output, CN2A pin 4 is greater than 8 V. Possible failure modes: 1. A short circuit in the solenoid wiring. 2. The loader pilot interlock valve has failed. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5053 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader pilot interlock connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader pilot interlock. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connector CN2A. Disconnect solenoid connector X-PLTLK. Turn the ignition switch ON. Measure the voltage between CN2A pin 4 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition.

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Measure the voltage between X-PLTLK pin B and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. Both voltage measurements are less than 0.5 V. Go to step 4. B. One or both voltage measurements are greater than 0.5 V. There is a short circuit to another voltage source in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Turn the ignition switch OFF. Connect UCM connector CN2A. Leave connector X-PLTLK disconnected. Turn the ignition switch ON. Access the EST fault code screen and refresh the screen. Fault code 5053 - Loader Pilot Interlock Valve (On/ Off) - Solenoid Supply Short to Power should not be active. Fault code 5053 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power should be active. A. Fault code 5053 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power is not active. Fault code 5053 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power is active. Temporarily replace the loader pilot interlock and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5053 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power is still active. Fault code 5053 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power is not active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 10 Hydraulic Interlocks (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 04 System Power and Grounds (55.100.DP-C.20.E.04)

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5061-Port Lock Valve (On/Off) - Solenoid Supply Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed an open circuit in the solenoid signal line, CN2A pin 5. Diagnostic Trouble Code 5061 - Port Lock Valve (On/Off) - Solenoid Supply Open Circuit has an error priority of Red. Loader hydraulics are disabled while Diagnostic Trouble Code 5061 - Port Lock Valve (On/Off) - Solenoid Supply Open Circuit is active. Cause: The UCM has sensed an open circuit in the solenoid supply. The fault is active when the engine is ON and the UCM pin voltage, CN2A pin 5 is less 1 V or greater than 8 V. Possible failure modes: 1. A faulty ground connection on the rear right-hand ground lug. 2. An open circuit in the solenoid wiring. 3. The loader lock interlock valve has failed. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5061 - Port Lock Valve (On/Off) - Solenoid Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader port lock connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader port lock. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Check the ground connection on the rear right-hand ground lugs. Verify that the grounding boss is free of paint, oil, dirt, and debris. Verify that the ground connection is tight and secure. A. The grounding boss is clean and free of paint. The grounding connection is secure. Go to step 4. B. The grounding boss is dirty or cover with paint. Remove the dirt. Remove the paint. Repair as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connector CN2A. 47683911 27/02/2015

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Fabricate a jumper wire that will connect between CN2A pin 5 and chassis ground. Connect the jumper wire between CN2A pin 5 and chassis ground. Disconnect connector X-PORT_LK. Measure the resistance between X-PORT_LK pin 1 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-PORT_LK pin 2 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 Ω. Go to step 5 to confirm elimination of the fault. B. One or both resistance measurements are greater than 10 Ω. There is an open circuit in the wiring. Repair or replace the harness as required. Check splice SP-187. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the solenoid. Measure the resistance across the loader interlock solenoid terminals, pin 1 and pin 2. The resistance should be less than 1,000 Ω. A. The resistance is less than 1,000 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 1,000 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 10 Hydraulic Interlocks (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 31 Telematics (55.100.DP-C.20.E.31) Wiring harnesses - Electrical schematic sheet 04 System Power and Grounds (55.100.DP-C.20.E.04)

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Electrical systems - FAULT CODES

5062-Port Lock Valve (On/Off) - Solenoid Supply Short to Ground WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sent a signal to the loader port lock solenoid to energize, but no voltage was detected. Diagnostic Trouble Code 5062 - Port Lock Valve (On/Off) - Solenoid Supply Short to Ground has an error priority of Red. Loader hydraulics are disabled while Diagnostic Trouble Code 5062 - Port Lock Valve (On/Off) - Solenoid Supply Short to Ground is active. Cause: The UCM has sent a signal to the loader port lock solenoid to energize, but no voltage was detected. The fault is active while hydraulics are enabled and the loader port lock solenoid output, CN2A pin 5 is greater than 3 A. Possible failure modes: 1. A short circuit in the solenoid wiring. 2. The loader port lock solenoid has failed. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5062 - Port Lock Valve (On/Off) - Solenoid Supply Short to Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader port lock connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader port lock solenoid. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connector CN2A. Disconnect solenoid connector X-PORT_LK. Measure the resistance between CN2A pin 5 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is greater than 20,000 Ω. Go to step 4. B. The resistance measurement is less than 20,000 Ω. There is a short circuit to chassis ground in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault.

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4. Measure the solenoid resistance. Measure the resistance across the loader port lock solenoid terminals, pin 1 and pin 2. The resistance should be greater than 1 Ω. A. The resistance is greater than 1 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 1 Ω. There is a short circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 10 Hydraulic Interlocks (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 31 Telematics (55.100.DP-C.20.E.31) Wiring harnesses - Electrical schematic sheet 04 System Power and Grounds (55.100.DP-C.20.E.04)

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Electrical systems - FAULT CODES

5063-Port Lock Valve (On/Off) - Solenoid Supply Short to Power WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the voltage on CN2A pin 5 is greater than 8 V. Diagnostic Trouble Code 5063 - Port Lock Valve (On/Off) - Solenoid Supply Short to Power has an error priority of Red. Loader hydraulics are disabled while Diagnostic Trouble Code 5063 - Port Lock Valve (On/Off) - Solenoid Supply Short to Power is active. Cause: The UCM has sent a signal to the loader port lock solenoid to de-energize, but the UCM detects a voltage on the output. The fault is active when the hydraulics are disabled and the loader port lock solenoid output, CN2A pin 5 is greater than 8 V. Possible failure modes: 1. A faulty ground connection on the rear right-hand ground lug. 2. A short circuit in the solenoid wiring. 3. The loader port lock valve has failed. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5063 - Port Lock Valve (On/Off) - Solenoid Supply Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader port lock connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader port lock solenoid. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Check the ground connection on the rear right-hand ground lugs. Verify that the grounding boss is free of paint, oil, dirt, and debris. Verify that the ground connection is tight and secure. A. The grounding boss is clean and free of paint. The grounding connection is secure. Go to step 4. B. The grounding boss is dirty or cover with paint. Remove the dirt. Remove the paint. Repair as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. 47683911 27/02/2015

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Electrical systems - FAULT CODES

Disconnect UCM connector CN2A. Disconnect solenoid connector X-PORT_LK. Turn the ignition switch ON. Measure the voltage between CN2A pin 5 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-PORT_LK pin 2 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. Both voltage measurements are less than 0.5 V. Go to step 5. B. One or both voltage measurements are greater than 0.5 V. There is a short circuit to another voltage source in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 5. Test the UCM. Turn the ignition switch OFF. Connect UCM connector CN2A. Leave connector X-PORT_LK disconnected. Turn the ignition switch ON. Access the EST fault code screen and refresh the screen. Fault code 5063 - Port Lock Valve (On/Off) - Solenoid Supply Short to Power should not be active. Fault code 5061 - Port Lock Valve (On/Off) - Solenoid Supply Open Circuit should be active. A. Fault code 5063 - Port Lock Valve (On/Off) - Solenoid Supply Short to Power is not active. Fault code 5061 - Port Lock Valve (On/Off) - Solenoid Supply Open Circuit is active. Temporarily replace the loader port lock valve and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5063 - Port Lock Valve (On/Off) - Solenoid Supply Short to Power is still active. Fault code 5061 - Port Lock Valve (On/Off) - Solenoid Supply Open Circuit is not active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 10 Hydraulic Interlocks (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 31 Telematics (55.100.DP-C.20.E.31) Wiring harnesses - Electrical schematic sheet 04 System Power and Grounds (55.100.DP-C.20.E.04)

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55.17 [55.DTC] / 621

Electrical systems - FAULT CODES

5121-Right Joystick F-B Axis - Pin A Short to Power/ Short to Ground/ Open Circuit C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE Electro hydraulic controls WE WE Electro hydraulic controls

Context: The UCM has sensed that the right joystick F-B signal has failed. Diagnostic Trouble Code 5121 - Right Joystick F-B Axis - Pin A Short to Power/ Short to Ground/ Open Circuit has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 5121 - Right Joystick F-B Axis - Pin A Short to Power/ Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the right joystick F-B signal has failed. The fault is active while the voltage on CN4A pin 17 is less than 0.2 V or the voltage is greater than 4.8 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor with the joystick in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire. 2. An open circuit in the signal wire. 3. A failure of the right control handle. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5121 - Right Joystick F-B Axis - Pin A Short to Power/ Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right joystick. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector CN4A. Disconnect the right joystick connector X-UJMR. Turn the ignition switch ON. Measure the voltage between X-UJMR pin 3 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition.

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Electrical systems - FAULT CODES

A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector CN4A. Disconnect the right joystick connector X-UJMR. Measure the resistance between X-UJMR pin 3 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Go to step 5. B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Fabricate a jumper wire that will connect between connector CN4A pin 17 and chassis ground. Connect the jumper wire between CN4A pin 17 and chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-UJMR pin 3 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage to the sensor. Turn the ignition switch OFF. Disconnect the right joystick connector X-UJMR. Reconnect the UCM connector(s). Turn the ignition switch ON. Measure the voltage between X-UJMR pin 1 and X-UJMR pin 4. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.

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Electrical systems - FAULT CODES

RAPH12SSL0351FA

(1) (2)

Connector X-UJMR Joystick X-Y Position Sensor

Schematic legend (3) (4)

DVM set to measure voltage. Right joystick F-B CN4A pin 17

A. The voltage is approximately 5 V. Go to step 7. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is a problem in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 7. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the right joystick connector X-UJMR. Fabricate a breakout harness to measure the voltage output of the sensor.

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Electrical systems - FAULT CODES

RAPH12SSL0352GA

(1)

Schematic legend Dealer supplied breakout harness (2)

DVM set to measure voltage.

Connect the breakout harness between the two mating connectors on X-UJMR. Turn the ignition switch ON. Measure the voltage between pin 3 and pin 4 on the break out harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the F-B position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. The voltage is approximately 2.5 V in the neutral position and the voltage changes between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 14 Cab to Chassis Interface (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 17 Right-Hand Control Handle (55.100.DP-C.20.E.17)

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Electrical systems - FAULT CODES

5122-Right Joystick F-B Axis - Pin B Short to Power/ Short to Ground/ Open Circuit C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE Electro hydraulic controls WE WE Electro hydraulic controls

Context: The UCM has sensed that the right joystick F-B signal has failed. Diagnostic Trouble Code 5122 - Right Joystick F-B Axis - Pin B Short to Power/ Short to Ground/ Open Circuit has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 5122 - Right Joystick F-B Axis - Pin B Short to Power/ Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the right joystick F-B signal has failed. The fault is active while the voltage on CN1B pin 13 is less than 0.2 V or the voltage is greater than 4.8 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor with the joystick in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire. 2. An open circuit in the signal wire. 3. A failure of the right control handle. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5122 - Right Joystick F-B Axis - Pin B Short to Power/ Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the right joystick. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector CN1B. Disconnect the right joystick connector X-UJMR. Turn the ignition switch ON. Measure the voltage between X-UJMR pin 9 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition.

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Electrical systems - FAULT CODES

A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector CN1B. Disconnect the right joystick connector X-UJMR. Measure the resistance between X-UJMR pin 9 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Go to step 5. B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Fabricate a jumper wire that will connect between connector CN1B pin 13 and chassis ground. Connect the jumper wire between CN1B pin 13 and chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-UJMR pin 9 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage to the sensor. Turn the ignition switch OFF. Disconnect the right joystick connector X-UJMR. Reconnect the UCM connector(s). Turn the ignition switch ON. Measure the voltage between X-UJMR pin 7 and X-UJMR pin 10. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.

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Electrical systems - FAULT CODES

RAPH12SSL0353FA

(1) (2)

Connector X-UJMR Joystick X-Y Position Sensor

Schematic legend (3) (4)

DVM set to measure voltage. Right joystick F-B CN1B pin 13

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Electrical systems - FAULT CODES

RAPH12SSL0354GA

(1)

Schematic legend Dealer supplied breakout harness (2)

DVM set to measure voltage.

Connect the breakout harness between the two mating connectors on X-UJMR. Turn the ignition switch ON. Measure the voltage between pin 3 and pin 4 on the break out harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the F-B position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. The voltage is approximately 2.5 V in the neutral position and the voltage changes between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 13 Cab to Chassis Interface (55.100.DP-C.20.E.13) Wiring harnesses - Electrical schematic sheet 17 Right-Hand Control Handle (55.100.DP-C.20.E.17)

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Electrical systems - FAULT CODES

5124-Right Joystick F-B Axis - In Range Fault WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the right joystick F-B signal has failed. Diagnostic Trouble Code 5124 - Right Joystick F-B Axis - In Range Fault has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 5124 - Right Joystick F-B Axis - In Range Fault is active. Cause: The UCM has sensed that the right joystick F-B signal has failed. The fault is active while the voltage on CN4A pin 17 and CN1B pin 13 is less than 0.2 V or the voltage is greater than 4.8 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor in the neutral position is approximately 2.5 V. Possible failure modes: 1. An open circuit in the signal wire. 2. A short circuit in the signal wire. 3. Failure of the right control handle. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5124 - Right Joystick F-B Axis - In Range Fault is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right joystick. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connectors CN4A and CN1B. Disconnect the right joystick connector X-UJMR. Turn the ignition switch ON. Measure the voltage between X-UJMR pin 3 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition.

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55.17 [55.DTC] / 630

Electrical systems - FAULT CODES

Measure the voltage between X-UJMR pin 9 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector CN4A and CN1B. Disconnect the right joystick connector X-UJMR. Measure the resistance between X-UJMR pin 3 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-UJMR pin 9 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Go to step 5. B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Turn the ignition switch OFF. Fabricate a jumper wire that will connect between connector CN4A pin 17 and chassis ground. Connect the jumper wire between CN4A pin 17 and chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-UJMR pin 3 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Remove the jumper wire. Connect the jumper wire between CN1B pin 13 and chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-UJMR pin 9 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 Ω. Go to step 6. B. One of both resistance measurements are greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage to the sensor. Turn the ignition switch OFF. Disconnect the right joystick connector X-UJMR. Reconnect the UCM connector(s). Turn the ignition switch ON. Measure the voltage between X-UJMR pin 1 and X-UJMR pin 4. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-UJMR pin 7 and X-UJMR pin 10. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.

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Electrical systems - FAULT CODES

RAPH12SSL0355FA

Schematic legend (4)

(1)

Connector X-UJMR

(2)

Joystick X-Y position sensor

(3)

DVM set to measure voltage.

(5)

Right joystick F-B CN4A pin 17 Right joystick F-B CN1B pin 13

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Electrical systems - FAULT CODES

RAPH12SSL0356GA

(1)

Schematic legend Dealer supplied breakout harness. (2)

DVM set to measure voltage.

Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJMR. Turn the ignition switch ON. Measure the voltage between pin 3 and pin 4 on the break out harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the F-B position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. Measure the voltage between pin 9 and pin 10 on the break out harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the F-B position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. For both measurements, the voltage is approximately 2.5 V in the neutral position and the voltage changes at a smooth rate between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 47683911 27/02/2015

55.17 [55.DTC] / 633

Electrical systems - FAULT CODES

B. For one or both measurements, the voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 14 Cab to Chassis Interface (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 13 Cab to Chassis Interface (55.100.DP-C.20.E.13) Wiring harnesses - Electrical schematic sheet 17 Right-Hand Control Handle (55.100.DP-C.20.E.17)

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Electrical systems - FAULT CODES

5131-Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Ground/ Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the right joystick R-L signal has failed low. Diagnostic Trouble Code 5131 - Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Ground/ Open Circuit has an error priority of Amber. Implement functions will operate in limp home mode while Diagnostic Trouble Code 5131 - Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the right joystick R-L signal has failed low. The fault is active while the engine is ON and the voltage on CN4A pin 24 is less than 0.2 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor with the joystick in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire. 2. An open circuit in the signal wire. 3. A failure of the right control handle. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5131 - Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the right joystick. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector CN4A. Disconnect the right joystick connector X-UJMR. Measure the resistance between X-UJMR pin 2 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition.

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Electrical systems - FAULT CODES

A. The resistance is greater than 20,000 Ω. Go to step 4. B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance through the signal wire. Fabricate a jumper wire that will connect between connector CN4A pin 24 and chassis ground. Connect the jumper wire between CN4A pin 24 and chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-UJMR pin 2 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 5. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the voltage to the sensor. Turn the ignition switch OFF. Reconnect the UCM connector(s). Disconnect the right joystick connector X-UJMR. Turn the ignition switch ON. Measure the voltage between X-UJMR pin 1 and X-UJMR pin 4. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.

RAPH12SSL0351FA

(1) (2)

Connector X-UJMR Joystick X-Y position sensor

Schematic legend (3) (4)

A. The voltage is approximately 5 V. Go to step 6.

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DVM set to measure voltage. Right joystick R-L CN4A pin 24

Electrical systems - FAULT CODES

B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is a problem in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the right joystick connector X-UJMR. Fabricate a breakout harness to measure the voltage output of the sensor.

RAPH12SSL0373GA

(1)

Schematic legend Dealer supplied breakout harness. (2)

DVM set to measure voltage.

55.17 [55.DTC] / 637

Electrical systems - FAULT CODES

A. The voltage is approximately 2.5 V in the neutral position and the voltage changes between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 14 Cab to Chassis Interface (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 16 Left-Hand Control Handle (55.100.DP-C.20.E.16)

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Electrical systems - FAULT CODES

5132-Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Power WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the right joystick R-L signal has failed. Diagnostic Trouble Code 5132 - Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Power has an error priority of Amber. Implement functions will operate in limp home mode while Diagnostic Trouble Code 5132 - Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Power is active. Cause: The UCM has sensed that the right joystick R-L signal has failed. The fault is active when the voltage on CN4A pin 24 is greater than 4.8 V. Normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor with the joystick in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire to another voltage source. 2. A failure of the right control handle. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5132 - Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right joystick. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector CN4A. Disconnect the right joystick connector X-UJMR. Turn the ignition switch ON. Measure the voltage between X-UJMR pin 2 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. 47683911 27/02/2015

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Electrical systems - FAULT CODES

B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance through the signal wire. Turn the ignition switch OFF. Fabricate a jumper wire that will connect between connector CN4A pin 24 and chassis ground. Connect the jumper wire between CN4A pin 24 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-UJMR pin 2 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 5. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the voltage to the sensor. Turn the ignition switch OFF. Disconnect the right joystick connector X-UJMR. Reconnect the UCM connector(s). Turn the ignition switch ON. Measure the voltage between X-UJMR pin 1 and X-UJMR pin 4. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.

RAPH12SSL0351FA

(1) (2)

Connector X-UJMR Joystick X-Y Position Sensor

Schematic legend (3) (4)

DVM set to measure voltage. Right joystick R-L CN4A pin 24

A. The voltage is approximately 5 V. Go to step 6. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is a problem in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 47683911 27/02/2015

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Electrical systems - FAULT CODES

6. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the right joystick connector X-UJMR. Fabricate a breakout harness to measure the voltage output of the sensor.

RAPH12SSL0373GA

(1)

Schematic legend Dealer supplied breakout harness. (2)

DVM set to measure voltage.

55.17 [55.DTC] / 641

Electrical systems - FAULT CODES

B. The voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 14 Cab to Chassis Interface (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 16 Left-Hand Control Handle (55.100.DP-C.20.E.16)

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Electrical systems - FAULT CODES

5134-Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Ground/ Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the right joystick R-L signal has failed low. Diagnostic Trouble Code 5134 - Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Ground/ Open Circuit has an error priority of Amber. Implement functions will operate in limp home mode while Diagnostic Trouble Code 5134 - Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the right joystick R-L signal has failed low. The fault is active while the voltage on CN3A pin 11 is less than 0.2 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor with the joystick in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire. 2. An open circuit in the signal wire. 3. A failure of the right control handle. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5134 - Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right joystick. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector CN3A. Disconnect the right joystick connector X-UJMR. Measure the resistance between X-UJMR pin 8 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition.

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Electrical systems - FAULT CODES

A. The resistance is greater than 20,000 Ω. Go to step 4. B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance through the signal wire. Fabricate a jumper wire that will connect between connector CN3A pin 11 to chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Connect the jumper wire between connector CN3A pin 11 to chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil and paint. Measure the resistance between connector X-UJMR pin 8 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 5. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the voltage to the sensor. Turn the ignition switch OFF. Reconnect the UCM connector(s). Disconnect the right joystick connector X-UJMR. Turn the ignition switch ON. Measure the voltage between X-UJMR pin 7 and X-UJMR pin 10. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.

RAPH12SSL0353FA

(1) (2)

Connector X-UJMR Joystick X-Y position sensor

Schematic legend (3) (4)

A. The voltage is approximately 5 V. Go to step 6. 47683911 27/02/2015

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DVM set to measure voltage. Right joystick R-L CN3A pin 11

Electrical systems - FAULT CODES

RAPH12SSL0374GA

(1)

Schematic legend Dealer supplied breakout harness. (2)

DVM set to measure voltage.

Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJMR. Turn the ignition switch ON. Measure the voltage between pin 8 and pin 10 on the breakout harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the R-L position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. 47683911 27/02/2015

55.17 [55.DTC] / 645

Electrical systems - FAULT CODES

A. The voltage is approximately 2.5 V in the neutral position and the voltage changes between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 13 Cab to Chassis Interface (55.100.DP-C.20.E.13) Wiring harnesses - Electrical schematic sheet 17 Right-Hand Control Handle (55.100.DP-C.20.E.17)

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Electrical systems - FAULT CODES

5135-Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Power WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the right joystick R-L signal has failed. Diagnostic Trouble Code 5135 - Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Power has an error priority of Amber. Implement functions will operate in limp home mode while Diagnostic Trouble Code 5135 - Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Power is active. Cause: The UCM has sensed that the right joystick R-L signal has failed. The fault is active when the voltage on CN3A pin 11 is greater than 4.8 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor with the joystick in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire to another voltage source. 2. A failure of the right control handle. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5135 - Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right joystick. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector CN3A. Disconnect the right joystick connector X-UJMR. Turn the ignition switch ON. Measure the voltage between X-UJMR pin 8 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. 47683911 27/02/2015

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Electrical systems - FAULT CODES

B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance through the signal wire. Turn the ignition switch OFF. Fabricate a jumper wire that will connect between connector CN3A pin 11 and chassis ground. Connect the jumper wire between connector CN3A pin 11 and chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-UJMR pin 8 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 5. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the voltage to the sensor. Turn the ignition switch OFF. Reconnect the UCM connector(s). Disconnect the right joystick connector X-UJMR. Turn the ignition switch ON. Measure the voltage between X-UJMR pin 7 and X-UJMR pin 10. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.

RAPH12SSL0353FA

(1) (2)

Connector X-UJMR Joystick X-Y position sensor

Schematic legend (3) (4)

A. The voltage is approximately 5 V. Go to step 6.

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DVM set to measure voltage. Right Joystick R-L CN3A pin 11

Electrical systems - FAULT CODES

RAPH12SSL0374GA

(1)

Schematic legend Dealer supplied breakout harness. (2)

DVM set to measure voltage.

Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJMR. Turn the ignition switch ON. Measure the voltage between pin 8 and pin 10 on the breakout harness. The voltage should be approximately 2.5 V while the joystick is in the neutral position. Continue measuring the voltage while slowly moving the throttle in the R-L position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. 47683911 27/02/2015

55.17 [55.DTC] / 649

Electrical systems - FAULT CODES

A. The voltage is approximately 2.5 V in the neutral position and the voltage changes between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 13 Cab to Chassis Interface (55.100.DP-C.20.E.13) Wiring harnesses - Electrical schematic sheet 17 Right-Hand Control Handle (55.100.DP-C.20.E.17)

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Electrical systems - FAULT CODES

5137-Right Joystick R-L Axis (ISO/H Pattern) - In Range Fault WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the right joystick R-L signal has failed. Diagnostic Trouble Code 5137 - Right Joystick R-L Axis (ISO/H Pattern) - In Range Fault has an error priority of Red. The bucket functions are disabled while Diagnostic Trouble Code 5137 - Right Joystick R-L Axis (ISO/H Pattern) In Range Fault is active. Cause: The UCM has sensed that the right joystick R-L signal has failed. The fault is active while the engine is ON and the voltage on CN4A pin 24 and CN3A pin 11 is less than 0.2 V or greater than 4.8 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire. 2. An open circuit in the signal wire. 3. A failure of the right control handle. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5137 - Right Joystick R-L Axis (ISO/H Pattern) - In Range Fault is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right joystick. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connectors CN4A and CN3A. Disconnect the right joystick connector X-UJMR. Turn the ignition switch ON. Measure the voltage between X-UJMR pin 2 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition.

47683911 27/02/2015

55.17 [55.DTC] / 651

Electrical systems - FAULT CODES

Measure the voltage between X-UJMR pin 8 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connectors CN4A and CN3A. Disconnect the right joystick connector X-UJMR. Measure the resistance between X-UJMR pin 2 X-UJMR pin 2 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-UJMR pin 8 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Go to step 5. B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Fabricate a jumper wire that will connect between connector CN4A pin 24 and chassis ground. Connect the jumper wire between connector CN4A pin 24 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-UJMR pin 2 to chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect the jumper wire between connector CN3A pin 11 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-UJMR pin 8 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage to the sensor. Turn the ignition switch OFF. Reconnect the UCM connectors. Disconnect the right joystick connector X-UJMR. Turn the ignition switch ON. Measure the voltage between X-UJMR pin 1 and X-UJMR pin 4. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-UJMR pin 7 and X-UJMR pin 10. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.

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Electrical systems - FAULT CODES

RAPH12SSL0355FA

Schematic legend (4)

(1)

Connector X-UJMR

(2)

Joystick X-Y position sensor

(3)

DVM set to measure voltage.

(5)

Right joystick R-L CN4A pin 24 Right joystick R-L CN3A pin 11

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RAPH12SSL0375GA

(1)

Schematic legend Dealer supplied breakout harness. (2)

DVM set to measure voltage.

Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJMR. Turn the ignition switch ON. Measure the voltage between pin 2 and pin 4 on the break out harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the R-L position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. Measure the voltage between pin 8 and pin 10 on the break out harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the R-L position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. For both measurements, the voltage is approximately 2.5 V in the neutral position and the voltage changes at a smooth rate between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 47683911 27/02/2015

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B. For one or both measurements, the voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 14 Cab to Chassis Interface (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 16 Left-Hand Control Handle (55.100.DP-C.20.E.16) Wiring harnesses - Electrical schematic sheet 13 Cab to Chassis Interface (55.100.DP-C.20.E.13) Wiring harnesses - Electrical schematic sheet 17 Right-Hand Control Handle (55.100.DP-C.20.E.17)

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Electrical systems - FAULT CODES

5141-Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the auxiliary thumbwheel signal has failed. Diagnostic Trouble Code 5141 - Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit has an error priority of White. The auxiliary hydraulics are disabled while Diagnostic Trouble Code 5141 - Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the auxiliary thumbwheel signal has failed. The fault is active when the ignition is ON and the aux thumbwheel axis input voltage, CN2B pin 28 is less than 0.2 V. Possible failure modes: 1. A short circuit in the signal wire. 2. An open circuit in the signal wire. 3. A failure of the right control handle. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5141 - Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the right joystick. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the thumbwheel supply voltage. Turn the ignition switch OFF. Disconnect connector X-403 from the right joystick. Turn the ignition switch ON. Measure the voltage between X-403 pin 1 and X-403 pin 3. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 5 V. Go to step 4.

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Electrical systems - FAULT CODES

B. The voltage is less than 4 V. There is a problem in the voltage supply or a problem with ground connection to the sensor. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector CN2B. Disconnect connector X-403. Measure the resistance between CN2B pin 28 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Go to step 5. B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 5. Check for an open circuit in the signal wire. Fabricate a jumper that will connect between X-403 pin 2 and chassis ground. Connect the jumper wire between X-403 pin 2 and chassis ground. The chassis ground connection must be clean and free of paint, dirt, oil, and grease. Measure the resistance between CN2B pin 28 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 6. Test the UCM. Disconnect the jumper wire. Reconnect UCM connector CN2B. Remove the wire from X-403 pin 1. Remove the wire from X-403 pin 2. Use a jumper wire with alligator clips to connect X-403 pin 1 to X-403 pin 2. Reconnect X-403 on to the joystick. Turn the ignition switch ON. Use EST to access the fault code screen. Fault code 5141 - Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit should no longer be active. Fault code 5142 - Aux Thumbwheel Axis - Pin A Short to Power is now active. A. Fault code 5141 - Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit is no longer active. Fault code 5142 - Aux Thumbwheel Axis - Pin A Short to Power is now active. Replace the aux thumbwheel and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5141 - Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit is active. Fault code 5142 Aux Thumbwheel Axis - Pin A Short to Power did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 14 Cab to Chassis Interface (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 17 Right-Hand Control Handle (55.100.DP-C.20.E.17)

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Electrical systems - FAULT CODES

5142-Aux Thumbwheel Axis - Pin A Short to Power WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the auxiliary thumbwheel signal has failed. Diagnostic Trouble Code 5142 - Aux Thumbwheel Axis - Pin A Short to Power has an error priority of White. The auxiliary hydraulics are disabled while Diagnostic Trouble Code 5142 - Aux Thumbwheel Axis - Pin A Short to Power is active. Cause: The UCM has sensed that the auxiliary thumbwheel signal has failed. The fault is active when the ignition is ON and the aux thumbwheel axis input voltage, CN2B pin 28 is greater than 4.8 V. Possible failure modes: 1. The signal wire had a short circuit to another voltage source. 2. A failure of the right control handle. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5142 - Aux Thumbwheel Axis - Pin A Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right joystick. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector CN2B. Disconnect connector X-403. Turn the ignition switch ON. Measure the voltage between CN2B pin 28 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 47683911 27/02/2015

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Electrical systems - FAULT CODES

4. Test the UCM. Reconnect UCM connector CN2B. Remove the wire from X-403 pin 2. Remove the wire from X-403 pin 3. Use a jumper wire with alligator clips to connect X-403 pin 2 to X-403 pin 3. Reconnect joystick connector X-403. Turn the ignition switch ON. Use EST to access the fault code screen. Fault code 5142 - Aux Thumbwheel Axis - Pin A Short to Power should no longer be active. Fault code 5141 - Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit is now active. A. Fault code 5142 - Aux Thumbwheel Axis - Pin A Short to Power is no longer active. Fault code 5141 - Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit is now active. Replace the aux thumbwheel and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5142 - Aux Thumbwheel Axis - Pin A Short to Power is active. Fault code 5141 - Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 14 Cab to Chassis Interface (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 17 Right-Hand Control Handle (55.100.DP-C.20.E.17)

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Electrical systems - FAULT CODES

5144-Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the auxiliary thumbwheel signal has failed. Diagnostic Trouble Code 5144 - Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit has an error priority of White. The auxiliary hydraulics are disabled while Diagnostic Trouble Code 5144 - Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the auxiliary thumbwheel signal has failed. The fault is active when the ignition is ON and the aux thumbwheel axis input voltage, CN4B pin 21 is less than 0.2 V. Possible failure modes: 1. A short circuit in the signal wire. 2. An open circuit in the signal wire. 3. A failure of the right control handle. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5144 - Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right joystick. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the thumbwheel supply voltage. Turn the ignition switch OFF. Disconnect connector X-403 from the right joystick. Turn the ignition switch ON. Measure the voltage between X-403 pin 10 and X-403 pin 12. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 5 V. Go to step 4.

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Electrical systems - FAULT CODES

B. The voltage is less than 4 V. There is a problem in the voltage supply or ground to the sensor. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector CN4B. Disconnect connector X-403. Measure the resistance between CN4B pin 21 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Go to step 5. B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 5. Check for an open circuit in the signal wire. Fabricate a jumper that will connect between X-403 pin 11 and chassis ground. Connect the jumper wire between X-403 pin 11 and chassis ground. The chassis ground connection must be clean and free of paint, dirt, oil, and grease. Measure the resistance between CN4B pin 21 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 6. Test the UCM. Disconnect the jumper wire. Reconnect UCM connector CN4B. Remove the wire from X-403 pin 10. Remove the wire from X-403 pin 11. Use a jumper wire with alligator clips to connect X-403 pin 10 to X-403 pin 11. Reconnect X-403 to the joystick. Turn the ignition switch ON. Use EST to access the fault code screen. Fault code 5144 - Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit should no longer be active. Fault code 5145 - Aux Thumbwheel Axis - Pin B Short to Power is now active. A. Fault code 5144 - Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit is no longer active. Fault code 5145 - Aux Thumbwheel Axis - Pin B Short to Power is now active. Replace the aux thumbwheel and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5144 - Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit is active. Fault code 5145 Aux Thumbwheel Axis - Pin B Short to Power did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 14 Cab to Chassis Interface (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 17 Right-Hand Control Handle (55.100.DP-C.20.E.17)

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Electrical systems - FAULT CODES

5145-Aux Thumbwheel Axis - Pin B Short to Power WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the auxiliary thumbwheel signal has failed. Diagnostic Trouble Code 5145 - Aux Thumbwheel Axis - Pin B Short to Power has an error priority of White. The auxiliary hydraulics are disabled while Diagnostic Trouble Code 5145 - Aux Thumbwheel Axis - Pin B Short to Power is active. Cause: The UCM has sensed that the auxiliary thumbwheel signal has failed. The fault is active when the ignition is ON and the aux thumbwheel axis input voltage, CN4B pin 21 is greater than 4.8 V. Possible failure modes: 1. The signal wire had a short circuit to another voltage source. 2. A failure of the right control handle. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5145 - Aux Thumbwheel Axis - Pin B Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right joystick. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector CN4B. Disconnect connector X-403. Turn the ignition switch ON. Measure the voltage between CN4B pin 21 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 47683911 27/02/2015

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Electrical systems - FAULT CODES

4. Test the UCM. Reconnect UCM connector CN4B. Remove the wire from X-403 pin 11. Remove the wire from X-403 pin 12. Use a jumper wire with alligator clips to connect X-403 pin 11 to X-403 pin 12. Reconnect joystick connector X-403. Turn the ignition switch ON. Use EST to access the fault code screen. Fault code 5145 - Aux Thumbwheel Axis - Pin B Short to Power should no longer be active. Fault code 5144 - Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit is now active. A. Fault code 5145 - Aux Thumbwheel Axis - Pin B Short to Power is no longer active. Fault code 5144 - Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit is now active. Replace the aux thumbwheel and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5145 - Aux Thumbwheel Axis - Pin B Short to Power is active. Fault code 5144 - Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 14 Cab to Chassis Interface (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 17 Right-Hand Control Handle (55.100.DP-C.20.E.17)

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55.17 [55.DTC] / 663

Electrical systems - FAULT CODES

5147-Aux Thumbwheel Axis - In Range Fault WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the aux thumbwheel has failed. Diagnostic Trouble Code 5147 - Aux Thumbwheel Axis - In Range Fault has an error priority of White. The auxiliary hydraulics are disabled while Diagnostic Trouble Code 5147 - Aux Thumbwheel Axis - In Range Fault is active. Cause: The UCM has sensed that the aux thumbwheel has failed. The fault is active while the engine is ON and the sum of aux thumbwheel output voltages, CN2B pin 28 and CN4B pin 21 is greater than 5.2 V or less than 4.8 V. Possible failure modes: 1. A short circuit in the signal wire. 2. An open circuit in the signal wire. 3. A failure of the right control handle. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5147 - Aux Thumbwheel Axis - In Range Fault is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right joystick. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. Inspect the cab to chassis interface harness. Inspect the chassis ground and minus battery connections. Verify that the connections are free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the thumbwheel supply voltage. Turn the ignition switch OFF. Disconnect connector X-403 from the right joystick. Turn the ignition switch ON. Measure the voltage between X-403 pin 1 and X-403 pin 3. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.

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Electrical systems - FAULT CODES

Measure the voltage between X-403 pin 10 and X-403 pin 12. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 5 V. Go to step 4. B. The voltage is less than 4 V. There is a problem in the voltage supply or ground to the sensor. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the voltage on the signal wire. Turn the ignition switch OFF. Disconnect UCM connector CN2B. Disconnect UCM connector CN4B. Disconnect connector X-403. Turn the ignition switch ON. Measure the voltage between CN2B pin 28 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between CN4B pin 21 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. Both voltage measurements are less than 0.5 V. Go to step 5. B. One or both measurements are greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 5. Check for an open circuit in the signal wire. Turn the ignition switch OFF. Leave UCM connectors CN2B and CN4B disconnected. Fabricate a jumper that will connect between X-403 pin 2 and X-403 pin 11. Connect the jumper wire between X-403 pin 2 and X-403 pin 11. Measure the resistance between CN2B pin 28 and CN4B pin 21. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wires. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 6. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector CN2B. Disconnect UCM connector CN4B. Disconnect connector X-403. Measure the resistance between CN2B pin 28 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN4B pin 21 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 Ω. Temporarily replace the thumb wheel switch and retest. Return to step 1 to confirm elimination of the fault. 47683911 27/02/2015

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Electrical systems - FAULT CODES

B. One or both measurements are greater than 10 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 14 Cab to Chassis Interface (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 17 Right-Hand Control Handle (55.100.DP-C.20.E.17) Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20)

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55.17 [55.DTC] / 666

Electrical systems - FAULT CODES

5201-Left Joystick L-R Axis - Pin A Short to Power/ Short to Ground/ Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the left joystick L-R signal has failed. Diagnostic Trouble Code 5201 - Left Joystick L-R Axis - Pin A Short to Power/ Short to Ground/ Open Circuit has an error priority of Amber. Implement functions will operate in limp home mode while Diagnostic Trouble Code 5201 - Left Joystick L-R Axis Pin A Short to Power/ Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the left joystick L-R signal has failed. The fault is active while the voltage on CN4A pin 25 is less than 0.2 V or the voltage is greater than 4.8 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire. 2. An open circuit in the signal wire. 3. A failure of the left control handle. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5201 - Left Joystick L-R Axis - Pin A Short to Power/ Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the left joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the left joystick. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector CN4A. Disconnect the left joystick connector X-UJML. Turn the ignition switch ON.

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Electrical systems - FAULT CODES

Measure the voltage between X-UJML pin 2 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector CN4A. Disconnect the left joystick connector X-UJML. Measure the resistance between X-UJML pin 2 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Go to step 5. B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Fabricate a jumper wire that will connect between connector CN4A pin 25 and chassis ground. Connect the jumper wire between connector CN4A pin 25 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-UJML pin 2 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage to the sensor. Turn the ignition switch OFF. Reconnect the UCM connector. Disconnect the left joystick connector X-UJML. Turn the ignition switch ON. Measure the voltage between X-UJML pin 1 and X-UJML pin 4. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.

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Electrical systems - FAULT CODES

RAPH12SSL0339FA

(1) (2)

Connector X-UJML Joystick X-Y position sensor

Schematic legend (3) (4)

DVM set to measure voltage. Left Joystick L-R CN4A pin 25

A. The voltage is approximately 5 V. Go to step 7. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is a problem in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 7. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the left joystick connector X-UJML. Fabricate a breakout harness to measure the voltage output of the sensor.

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Electrical systems - FAULT CODES

RAPH12SSL0363GA

(1)

Schematic legend Dealer supplied breakout harness. (2)

DVM set to measure voltage.

Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJML. Turn the ignition switch ON. Measure the voltage between pin 2 and pin 4 on the breakout harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the L-R position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. The voltage is approximately 2.5 V in the neutral position and the voltage changes at a smooth rate between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 14 Cab to Chassis Interface (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 16 Left-Hand Control Handle (55.100.DP-C.20.E.16)

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Electrical systems - FAULT CODES

5202-Left Joystick L-R Axis - Pin B Short to Power/ Short to Ground/ Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the left joystick L-R signal has failed. Diagnostic Trouble Code 5202 - Left Joystick L-R Axis - Pin B Short to Power/ Short to Ground/ Open Circuit has an error priority of Amber. Implement functions will operate in limp home mode while Diagnostic Trouble Code 5202 - Left Joystick L-R Axis Pin B Short to Power/ Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the left joystick L-R signal has failed. The fault is active while the voltage on CN2B pin 14 is less than 0.2 V or the voltage is greater than 4.8 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire. 2. An open circuit in the signal wire. 3. A failure of the left control handle. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5202 - Left Joystick L-R Axis - Pin B Short to Power/ Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the left joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the left joystick. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector CN2B. Disconnect the left joystick connector X-UJML. Turn the ignition switch ON.

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Electrical systems - FAULT CODES

Measure the voltage between X-UJML pin 8 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector CN2B. Disconnect the left joystick connector X-UJML. Measure the resistance between X-UJML pin 8 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Go to step 5. B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Fabricate a jumper wire that will connect between connector CN2B pin 14 and chassis ground. Connect the jumper wire between connector CN2B pin 14 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-UJML pin 8 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage to the sensor. Turn the ignition switch OFF. Reconnect the UCM connector. Disconnect the left joystick connector X-UJML. Turn the ignition switch ON. Measure the voltage between X-UJML pin 7 and X-UJML pin 10. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.

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Electrical systems - FAULT CODES

RAPH12SSL0346FA

(1) (2)

Connector X-UJML Joystick X-Y position sensor

Schematic legend (3) (4)

DVM set to measure voltage. Left Joystick L-R CN2B pin 14

A. The voltage is approximately 5 V. Go to step 7. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is an open circuit in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 7. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the left joystick connector X-UJML. Fabricate a breakout harness to measure the voltage output of the sensor.

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Electrical systems - FAULT CODES

RAPH12SSL0370GA

(1)

Schematic legend Dealer supplied breakout harness. (2)

DVM set to measure voltage.

Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJML. Turn the ignition switch ON. Measure the voltage between pin 8 and pin 10 on the breakout harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the L-R position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. The voltage is approximately 2.5 V in the neutral position and the voltage changes between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 14 Cab to Chassis Interface (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 16 Left-Hand Control Handle (55.100.DP-C.20.E.16)

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Electrical systems - FAULT CODES

5204-Left Joystick L-R Axis - In Range Fault WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the left joystick L-R signal has failed. Diagnostic Trouble Code 5204 - Left Joystick L-R Axis - In Range Fault has an error priority of Red. Boom functions are disabled while Diagnostic Trouble Code 5204 - Left Joystick L-R Axis - In Range Fault is active. Cause: The UCM has sensed that the left joystick L-R signal has failed. The fault is active while the voltage on CN4A pin 25 and CN2B pin 14 is less than 0.2 V or greater than 4.8 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor in the neutral position is approximately 2.5 V. Possible failure modes: 1. An open circuit in the signal wire. 2. A short circuit in the signal wire. 3. Failure of the left control handle. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5204 - Left Joystick L-R Axis - In Range Fault is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the left joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the left joystick. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connectors CN4A and CN2B. Disconnect the left joystick connector X-UJML. Turn the ignition switch ON. Measure the voltage between X-UJML pin 2 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition.

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Electrical systems - FAULT CODES

Measure the voltage between X-UJML pin 8 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector CN4A and CN2B. Disconnect the left joystick connector X-UJML. Measure the resistance of X-UJML pin 2 to chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance of X-UJML pin 8 to chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Go to step 5. B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance of the signal wire. Fabricate a jumper wire that will connect between connector CN4A pin 25 and chassis ground. Connect the jumper wire between connector CN4A pin 25 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil and paint. Measure the resistance between connector X-UJML pin 2 to chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect the jumper wire between connector CN2B pin 14 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil and paint. Measure the resistance between connector X-UJML pin 8 to chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage to the sensor. Turn the ignition switch OFF. Reconnect the UCM connectors. Disconnect the left joystick connector X-UJML. Turn the ignition switch ON. Measure the voltage between X-UJML pin 1 and X-UJML pin 4. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-UJML pin 7 and X-UJML pin 10. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.

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Electrical systems - FAULT CODES

RAPH12SSL0348FA

Schematic legend (4)

(1)

Connector X-UJML

(2)

Joystick X-Y position sensor

(3)

DVM set to measure voltage.

(5)

Left Joystick L-R CN4A pin 25 Left Joystick L-R CN2B pin 14

A. The voltage is approximately 5 V. Go to step 7. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is a problem in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 7. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the left joystick connector X-UJML. Fabricate a breakout harness to measure the voltage output of the sensor.

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Electrical systems - FAULT CODES

RAPH12SSL0371GA

(1)

Schematic legend Dealer supplied breakout harness. (2)

DVM set to measure voltage.

Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJML. Turn the ignition switch ON. Measure the voltage between pin 2 and pin 4 on the break out harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the L-R position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. Measure the voltage between pin 8 and pin 10 on the breakout harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the L-R position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. For both measurements, the voltage is approximately 2.5 V in the neutral position and the voltage changes at a smooth rate between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 47683911 27/02/2015

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Electrical systems - FAULT CODES

B. On one or both measurements, the voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 14 Cab to Chassis Interface (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 16 Left-Hand Control Handle (55.100.DP-C.20.E.16) Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

5211-Left Joystick F-B Axis - Pin A Short to Ground/ Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the left joystick F-B 5 V signal has failed. Diagnostic Trouble Code 5211 - Left Joystick F-B Axis - Pin A Short to Ground/ Open Circuit has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 5211 - Left Joystick F-B Axis - Pin A Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the left joystick F-B 5 V signal has failed low. The fault is active while the engine is ON and the voltage on CN4A pin 18 is less than 0.2 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor with the joystick in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire. 2. An open circuit in the signal wire. 3. A failure of the left control handle. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5211 - Left Joystick F-B Axis - Pin A Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the left joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the left joystick. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector CN4A. Disconnect the left joystick connector X-UJML. Measure the resistance between X-UJML pin 3 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Go to step 4. 47683911 27/02/2015

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Electrical systems - FAULT CODES

B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance through the signal wire. Fabricate a jumper wire that will connect between connector CN4A pin 18 and chassis ground. Connect the jumper wire between connector CN4A pin 18 and chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-UJML pin 3 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 5. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the voltage to the sensor. Turn the ignition switch OFF. Reconnect the UCM connectors. Disconnect the left joystick connector X-UJML. Turn the ignition switch ON. Measure the voltage between X-UJML pin 1 and X-UJML pin 4. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.

RAPH12SSL0339FA

(1) (2)

Connector X-UJML Joystick X-Y position sensor

Schematic legend (3) (4)

DVM set to measure voltage. Left joystick F-B CN4A pin 18

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Electrical systems - FAULT CODES

6. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the left joystick connector X-UJML. Fabricate a breakout harness to measure the voltage output of the sensor.

RAPH12SSL0342GA

(1)

Schematic legend Dealer supplied breakout harness. (2)

DVM set to measure voltage.

Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJML. Turn the ignition switch ON. Measure the voltage between pin 4 and pin 3 on the breakout harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the F-B position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. The voltage is approximately 2.5 V in the neutral position and the voltage changes between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 47683911 27/02/2015

55.17 [55.DTC] / 682

Electrical systems - FAULT CODES

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Electrical systems - FAULT CODES

5212-Left Joystick F-B Axis - Pin A Short to Power WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the left joystick F-B signal has failed. Diagnostic Trouble Code 5212 - Left Joystick F-B Axis - Pin A Short to Power has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 5212 - Left Joystick F-B Axis - Pin A Short to Power is active. Cause: The UCM has sensed that the left joystick F-B signal has failed. The fault is active when the voltage on CN4A pin 18 is greater than 4.8 V. Normal operating voltage of the sensor output is 0.5 V to 4.5 V. Output of the sensor with the joystick in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire to another voltage source. 2. A failure of the left control handle. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5212 - Left Joystick F-B Axis - Pin A Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the left joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the left joystick. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector CN4A. Disconnect the left joystick connector X-UJML. Turn the ignition switch ON. Measure the voltage between X-UJML pin 3 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4.

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Electrical systems - FAULT CODES

B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance through the signal wire. Turn the ignition switch OFF. Fabricate a jumper wire that will connect between connector CN4A pin 18 and chassis ground. Connect the jumper wire between connector CN4A pin 18 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-UJML pin 3 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 5. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the voltage to the sensor. Turn the ignition switch OFF. Reconnect the UCM connectors. Disconnect the left joystick connector X-UJML. Turn the ignition switch ON. Measure the voltage between X-UJML pin 1 and X-UJML pin 4. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.

RAPH12SSL0339FA

(1) (2)

Connector X-UJML Joystick X-Y position sensor

Schematic legend (3) (4)

A. The voltage is approximately 5 V. Go to step 6.

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DVM set to measure voltage. Left joystick F-B CN4A pin 18

Electrical systems - FAULT CODES

B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is an open circuit in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the left joystick connector X-UJML. Fabricate a breakout harness to measure the voltage output of the sensor.

RAPH12SSL0342GA

(1)

Schematic legend Dealer supplied breakout harness. (2)

DVM set to measure voltage.

55.17 [55.DTC] / 686

Electrical systems - FAULT CODES

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Electrical systems - FAULT CODES

5214-Left Joystick F-B Axis - Pin B Short to Ground/ Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the left joystick F-B signal has failed. Diagnostic Trouble Code 5214 - Left Joystick F-B Axis - Pin B Short to Ground/ Open Circuit has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 5214 - Left Joystick F-B Axis - Pin B Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the left joystick F-B signal has failed. The fault is active while the voltage on CN2B pin 31 is less than 0.2 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor with the joystick in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire. 2. An open circuit in the signal wire. 3. A failure of the right control handle. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5214 - Left Joystick F-B Axis - Pin B Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the left joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the left joystick. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector CN2B. Disconnect the left joystick connector X-UJML. Measure the resistance between X-UJML pin 9 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Go to step 4. 47683911 27/02/2015

55.17 [55.DTC] / 688

Electrical systems - FAULT CODES

B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance through the signal wire. Fabricate a jumper wire that will connect between connector CN2B pin 31 and chassis ground. Connect the jumper wire between connector CN2B pin 31 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-UJML pin 9 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 5. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the voltage to the sensor. Turn the ignition switch OFF. Reconnect the UCM connector. Disconnect the left joystick connector X-UJML. Turn the ignition switch ON. Measure the voltage between X-UJML pin 7 and X-UJML pin 10. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.

RAPH12SSL0346FA

(1) (2)

Connector X-UJML Joystick X-Y Position Sensor

Schematic legend (3) (4)

DVM set to measure voltage. Left Joystick F-B CN2B pin 31

A. The voltage is approximately 5 V. Go to step 6. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is an open circuit in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 47683911 27/02/2015

55.17 [55.DTC] / 689

Electrical systems - FAULT CODES

6. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the left joystick connector X-UJML. Fabricate a breakout harness to measure the voltage output of the sensor.

RAPH12SSL0347GA

(1)

Schematic legend Dealer supplied breakout harness. (2)

DVM set to measure voltage.

Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJML. Turn the ignition switch ON. Measure the voltage between pin 9 and pin 10 on the break out harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the F-B position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. The voltage is approximately 2.5 V in the neutral position and the voltage changes between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 47683911 27/02/2015

55.17 [55.DTC] / 690

Electrical systems - FAULT CODES

B. The voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 14 Cab to Chassis Interface (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 16 Left-Hand Control Handle (55.100.DP-C.20.E.16)

47683911 27/02/2015

55.17 [55.DTC] / 691

Electrical systems - FAULT CODES

5215-Left Joystick F-B Axis - Pin B Short to Power WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the left joystick F-B signal has failed. Diagnostic Trouble Code 5215 - Left Joystick F-B Axis - Pin B Short to Power has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 5215 - Left Joystick F-B Axis - Pin B Short to Power is active. Cause: The UCM has sensed that the right joystick R-L signal has failed. The fault is active when the voltage on CN2B pin 31 is greater than 4.8 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor with the joystick in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire to another voltage source. 2. A failure of the right control handle. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5215 - Left Joystick F-B Axis - Pin B Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the left joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the left joystick. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector CN2B. Disconnect the left joystick connector X-UJML. Turn the ignition switch ON. Measure the voltage between X-UJML pin 9 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4.

47683911 27/02/2015

55.17 [55.DTC] / 692

Electrical systems - FAULT CODES

B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance through the signal wire. Fabricate a jumper wire that will connect between connector CN2B pin 31 and chassis ground. Connect the jumper wire between connector CN2B pin 31 and chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-UJML pin 9 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 5. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the voltage to the sensor. Turn the ignition switch OFF. Reconnect the UCM connector. Disconnect the left joystick connector X-UJML. Turn the ignition switch ON. Measure the voltage between X-UJML pin 7 and X-UJML pin 10. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.

RAPH12SSL0346FA

(1) (2)

Connector X-UJML Joystick X-Y Position Sensor

Schematic legend (3) (4)

DVM set to measure voltage. Left Joystick F-B CN2B pin 31

A. The voltage is approximately 5 V. Go to step 6. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is an open circuit in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 47683911 27/02/2015

55.17 [55.DTC] / 693

Electrical systems - FAULT CODES

6. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the left joystick connector X-UJML. Fabricate a breakout harness to measure the voltage output of the sensor.

RAPH12SSL0347GA

(1)

Schematic legend Dealer supplied breakout harness. (2)

DVM set to measure voltage.

55.17 [55.DTC] / 694

Electrical systems - FAULT CODES

B. The voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 14 Cab to Chassis Interface (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 16 Left-Hand Control Handle (55.100.DP-C.20.E.16)

47683911 27/02/2015

55.17 [55.DTC] / 695

Electrical systems - FAULT CODES

5217-Left Joystick F-B Axis - In Range Fault WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the left joystick F-B signal has failed. Diagnostic Trouble Code 5217 - Left Joystick F-B Axis - In Range Fault has an error priority of Red. Ground drive is disabled while Diagnostic Trouble Code 5217 - Left Joystick F-B Axis - In Range Fault is active. Cause: The UCM has sensed that the left joystick F-B signal has failed. The fault is active while voltage on CN4A pin 18 and CN2B pin 31 is less than 0.2 V or greater than 4.8 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor in the neutral position is approximately 2.5 V. Possible failure modes: 1. An open circuit in the signal wire. 2. A short circuit in the signal wire. 3. Failure of the left control handle. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5217 - Left Joystick F-B Axis - In Range Fault is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the left joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the left joystick. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connectors CN4A and CN2B. Disconnect the left joystick connector X-UJML. Turn the ignition switch ON. Measure the voltage between X-UJML pin 3 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition.

47683911 27/02/2015

55.17 [55.DTC] / 696

Electrical systems - FAULT CODES

Measure the voltage between X-UJML pin 9 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector CN4A and CN2B. Disconnect the left joystick connector X-UJML. Measure the resistance of X-UJML pin 3 to chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance of X-UJML pin 9 to chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Go to step 5. B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance of the signal wire. Fabricate a jumper wire that will connect between connector CN4A pin 18 to chassis ground. Connect the jumper wire between connector CN4A pin 18 and chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-UJML pin 3 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect the jumper wire between connector CN2B pin 31 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-UJML pin 9 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage to the sensor. Turn the ignition switch OFF. Reconnect the UCM connectors. Disconnect the left joystick connector X-UJML. Turn the ignition switch ON. Measure the voltage between X-UJML pin 1 and X-UJML pin 4. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-UJML pin 7 and X-UJML pin 10. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.

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55.17 [55.DTC] / 697

Electrical systems - FAULT CODES

RAPH12SSL0348FA

Schematic legend (4)

(1)

Connector X-UJML

(2)

Joystick X-Y position sensor

(3)

DVM set to measure voltage.

(5)

Left Joystick F-B CN4A pin 18 Left Joystick F-B CN2B pin 31

A. The voltage is approximately 5 V. Go to step 7. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is a problem in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 7. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the left joystick connector X-UJML. Fabricate a breakout harness to measure the voltage output of the sensor.

47683911 27/02/2015

55.17 [55.DTC] / 698

Electrical systems - FAULT CODES

RAPH12SSL0349GA

(1)

Schematic legend Dealer supplied breakout harness. (2)

DVM set to measure voltage.

Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJML. Turn the ignition switch ON. Measure the voltage between pin 3 and pin 4 on the breakout harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the F-B position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. Measure the voltage between pin 9 and pin 10 on the break out harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the F-B position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. For both measurements, the voltage is approximately 2.5 V in the neutral position and the voltage changes at a smooth rate between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 47683911 27/02/2015

55.17 [55.DTC] / 699

Electrical systems - FAULT CODES

B. On one or both measurements, the voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the Joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 14 Cab to Chassis Interface (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 16 Left-Hand Control Handle (55.100.DP-C.20.E.16) Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19)

47683911 27/02/2015

55.17 [55.DTC] / 700

Electrical systems - FAULT CODES

5221-Loader Arm Valve (Directional) Solenoid Raise (A) Supply Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed an open circuit in the loader solenoid circuit. Diagnostic Trouble Code 5221 - Loader Arm Valve (Directional) Solenoid Raise (A) Supply Open Circuit has an error priority of Red. The boom functions are disabled while Diagnostic Trouble Code 5221 - Loader Arm Valve (Directional) Solenoid Raise (A) Supply Open Circuit is active. Cause: The UCM has sensed an open circuit in the loader solenoid circuit, CN3B pin 6. The fault is active while the hydraulics are enabled and the calculated solenoid resistance has increased over 70 %. Possible failure modes: 1. An open circuit in the solenoid circuit. 2. The loader valve extend solenoid has failed. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5221 - Loader Arm Valve (Directional) Solenoid Raise (A) Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader solenoids. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connectors CN3B and CN2B. Disconnect connector X-28. Fabricate a jumper wire that will connect between CN3B pin 6 and chassis ground. Connect the jumper wire between CN3B pin 6 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt.

47683911 27/02/2015

55.17 [55.DTC] / 701

Electrical systems - FAULT CODES

Measure the resistance between X-28 pin 1 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect the jumper wire between CN2B pin 7 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. Measure the resistance between X-28 pin 2 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 Ω. Go to step 4. B. One or both resistance measurements are greater than 10 Ω. There is an open circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the resistance through the solenoid. Measure the resistance across the loader extend solenoid terminals, X-28 pin 1 and X-28 pin 2. The resistance should be less than 1,000 Ω. A. The resistance is less than 1,000 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 1,000 Ω. There is an open circuit in the solenoid. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 702

Electrical systems - FAULT CODES

5222-Loader Arm Valve (Directional) Solenoid Raise (A) Supply Shorted To Ground C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE Electro hydraulic controls WE WE Electro hydraulic controls

Context: The UCM has sensed that the loader extend solenoid current is too high. Diagnostic Trouble Code 5222 - Loader Arm Valve (Directional) Solenoid Raise (A) Supply Shorted To Ground has an error priority of Red. The boom functions are disabled while Diagnostic Trouble Code 5222 - Loader Arm Valve (Directional) Solenoid Raise (A) Supply Shorted To Ground is active. Cause: The UCM has sensed that the loader extend solenoid current is too high. The fault is active when the hydraulics are enabled and the solenoid output current, CN3B pin 6 is greater than 3 A. Possible failure modes: 1. A short circuit in the solenoid wiring. 2. The loader valve solenoid has failed. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5222 - Loader Arm Valve (Directional) Solenoid Raise (A) Supply Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader solenoids. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Test the UCM. Turn the ignition switch OFF. Disconnect solenoid connector X-28. Turn the ignition switch ON. Use the electronic service tool and access the fault code screen. Fault code 5222 - Loader Arm Valve (Directional) Solenoid Raise (A) Supply Shorted To Ground should no longer be active. Fault code 5221 - Loader Arm Valve (Directional) Solenoid Raise (A) Supply Open Circuit is now active.

47683911 27/02/2015

55.17 [55.DTC] / 703

Electrical systems - FAULT CODES

A. Fault code 5222 - Loader Arm Valve (Directional) Solenoid Raise (A) Supply Shorted To Ground is no longer active. Fault code 5221 - Loader Arm Valve (Directional) Solenoid Raise (A) Supply Open Circuit is now active. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5222 - Loader Arm Valve (Directional) Solenoid Raise (A) Supply Shorted To Ground is active. Fault code 5221 - Loader Arm Valve (Directional) Solenoid Raise (A) Supply Open Circuit did not become active. Go to step 4. 4. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connectors CN3B and CN2B. Disconnect solenoid connector X-28. Measure the resistance between CN3B pin 6 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN2B pin 7 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN3B pin 6 and CN2B pin 7. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. One or more resistance measurements are less than 20,000 Ω. There is a short circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 704

Electrical systems - FAULT CODES

5231-Loader Arm Valve (Directional) Solenoid Lower (B) Supply Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed an open circuit in the loader solenoid circuit. Diagnostic Trouble Code 5231 - Loader Arm Valve (Directional) Solenoid Lower (B) Supply Open Circuit has an error priority of Red. The boom functions are disabled while Diagnostic Trouble Code 5231 - Loader Arm Valve (Directional) Solenoid Lower (B) Supply Open Circuit is active. Cause: The UCM has sensed an open circuit in the loader solenoid circuit, CN3A pin 22. The fault is active when the hydraulics are enabled and the calculated solenoid resistance has increased over 70 %. Possible failure modes: 1. An open circuit in the solenoid circuit. 2. The loader valve retract solenoid has failed. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5231 - Loader Arm Valve (Directional) Solenoid Lower (B) Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader solenoids. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connectors CN3A and CN2B. Disconnect connector X-27. Fabricate a jumper wire that will connect between CN3A pin 22 and chassis ground. Connect the jumper wire between CN3A pin 22 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt.

47683911 27/02/2015

55.17 [55.DTC] / 705

Electrical systems - FAULT CODES

Measure the resistance between X-27 pin 1and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect the jumper wire between CN2B pin 7 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. Measure the resistance between X-27 pin 2 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 Ω. Go to step 4. B. One or both resistance measurements are greater than 10 Ω. There is an open circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the resistance through the solenoid. Measure the resistance across the loader extend solenoid terminals, X-27 pin 1 and X-27 pin 2. The resistance should be less than 1,000 Ω. A. The resistance is less than 1,000 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 1,000 Ω. There is an open circuit in the solenoid. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 706

Electrical systems - FAULT CODES

5232-Loader Arm Valve (Directional) Solenoid Lower (B) Supply Shorted To Ground C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE Electro hydraulic controls WE WE Electro hydraulic controls

Context: The UCM has sensed that the loader retract solenoid current is too high. Diagnostic Trouble Code 5232 - Loader Arm Valve (Directional) Solenoid Lower (B) Supply Shorted To Ground has an error priority of Red. The boom functions are disabled while Diagnostic Trouble Code 5232 - Loader Arm Valve (Directional) Solenoid Lower (B) Supply Shorted To Ground is active. Cause: The UCM has sensed that the loader retract solenoid current is too high. The fault is active when hydraulics are enabled and solenoid output current, X-CN3A pin 22 is greater than 3 A. Possible failure modes: 1. A short circuit in the solenoid wiring. 2. The loader valve solenoid has failed. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5232 - Loader Arm Valve (Directional) Solenoid Lower (B) Supply Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader solenoids. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Test the UCM. Turn the ignition switch OFF. Disconnect solenoid connector X-27. Turn the ignition switch ON. Use the electronic service tool and access the fault code screen. Fault code 5232 - Loader Arm Valve (Directional) Solenoid Lower (B) Supply Shorted To Ground should no longer be active. Fault code 5231 - Loader Arm Valve (Directional) Solenoid Lower (B) Supply Open Circuit is now active.

47683911 27/02/2015

55.17 [55.DTC] / 707

Electrical systems - FAULT CODES

A. Fault code 5232 - Loader Arm Valve (Directional) Solenoid Lower (B) Supply Shorted To Ground is no longer active. Fault code 5231 - Loader Arm Valve (Directional) Solenoid Lower (B) Supply Open Circuit is now active. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5232 - Loader Arm Valve (Directional) Solenoid Lower (B) Supply Shorted To Ground is active. Fault code 5231 - Loader Arm Valve (Directional) Solenoid Lower (B) Supply Open Circuit did not become active. Go to step 4. 4. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connectors CN3A and CN2B. Disconnect solenoid connector X-27. Measure the resistance between CN3A pin 22 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN2B pin 7 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN3A pin 22 and CN2B pin 7. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. One or more resistance measurements are less than 20,000 Ω. There is a short circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 708

Electrical systems - FAULT CODES

5241-Loader Arm Valve (Directional) Loader Arm Solenoid(s) Shorted To Power C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE Electro hydraulic controls WE WE Electro hydraulic controls

Context: The UCM has sensed a higher than normal voltage on the loader solenoid lines. Fault code 5241 - Loader Arm Valve (Directional) Loader Arm Solenoid(s) Shorted To Power has an error priority of Red. Boom functions are disabled while Diagnostic Trouble Code 5241 - Loader Arm Valve (Directional) Loader Arm Solenoid(s) Shorted To Power is active. Cause: The UCM has sensed the voltage on the loader solenoid lines, CN3B pin 6, CN3A pin 22, and CN2B pin 7 is too high. The fault is active when hydraulics are disabled and the solenoid feedback voltage is greater than 5 V. Possible failure modes: 1. A short circuit in the signal wire to another voltage source. 2. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5241 - Loader Arm Valve (Directional) Loader Arm Solenoid(s) Shorted To Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader solenoids. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the signal wires. Turn the ignition switch OFF. Disconnect UCM connectors CN3A, CN2B, and CN3B. Turn the ignition switch ON. Measure the voltage between CN3B pin 6 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. Measure the voltage between CN3A pin 22 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. Measure the voltage between CN2B pin 7 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. 47683911 27/02/2015

55.17 [55.DTC] / 709

Electrical systems - FAULT CODES

A. All voltage measurements are less than 0.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. One or more of the voltage measurements are greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 710

Electrical systems - FAULT CODES

5242-Loader Arm Valve (Directional) Loader Arm Solenoid(s) Shorted To Ground WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed a lower than normal voltage on the loader solenoid lines. Fault code 5242 - Loader Arm Valve (Directional) Loader Arm Solenoid(s) Shorted To Ground has an error priority of Red. Boom functions are disabled while Diagnostic Trouble Code 5242 - Loader Arm Valve (Directional) Loader Arm Solenoid(s) Shorted To Ground is active. Cause: The UCM has sensed that the voltage on the loader solenoid lines, CN3B pin 6, CN3A pin 22, and CN2B pin 7 is too low. The fault is active when hydraulics are disabled and the solenoid feedback voltage is less than 2 V. Possible failure modes: 1. A short circuit in the signal wire to chassis ground. 2. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5242 - Loader Arm Valve (Directional) Loader Arm Solenoid(s) Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader solenoids. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connectors CN3A, CN2B, and CN3B. Disconnect solenoid connectors, X-27 and X-28. Measure the resistance between CN3B pin 6 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN3A pin 22 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN2B pin 7 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. 47683911 27/02/2015

55.17 [55.DTC] / 711

Electrical systems - FAULT CODES

Measure the resistance between CN3B pin 6 and CN2B pin 7. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN3A pin 22 and CN2B pin 7. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are greater than 20,000 Ω. Go to step 4. B. One or more resistance measurements are less than 20,000 Ω. There is a short circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the resistance through the solenoid. Disconnect connector X-27 and X-28. Measure the resistance across the loader extend solenoid terminals. The resistance should be greater than 1 Ω. Measure the resistance across the loader retract solenoid terminals. The resistance should be greater than 1 Ω. A. Both resistance measurements are greater than 1 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. One or both resistance measurements are less than 1 Ω. There is a short circuit in the solenoid. Replace the solenoid as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 712

Electrical systems - FAULT CODES

5243-Loader Arm Valve (Directional) Solenoids Return Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed an open circuit in the loader solenoid return circuit. Diagnostic Trouble Code 5243 - Loader Arm Valve (Directional) Solenoids Return Open Circuit has an error priority of Red. Boom functions are disabled while Diagnostic Trouble Code 5243 - Loader Arm Valve (Directional) Solenoids Return Open Circuit is active. Cause: The UCM has sensed an open circuit in the loader solenoid return circuit, CN2B pin 7. The fault is active when the ignition is ON and the calculated solenoid resistances have increased over 70 %. Possible failure modes: 1. An open circuit in the solenoid return wiring. 2. The loader solenoids have failed. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5243 - Loader Arm Valve (Directional) Solenoids Return Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader solenoids. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connectors CN3A, CN2B, and CN3B. Measure the resistance between CN3A pin 22 and CN2B pin 7. The resistance should be less than 100 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN3B pin 6 and CN2B pin 7. The resistance should be less than 100 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 100 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. One or both resistance are greater than 100 Ω. There is an open circuit in the wiring. Go to step 4. 47683911 27/02/2015

55.17 [55.DTC] / 713

Electrical systems - FAULT CODES

4. Measure the solenoid resistance. Measure the resistance across the extend solenoid terminals, pin 1 and pin 2. The resistance should be less than 20 Ω. Measure the resistance across the retract solenoid terminals, pin 1 and pin 2. The resistance should be less than 20 Ω. A. The resistance is less than 20 Ω. Go to step 5. B. The resistance is greater than 20 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the circuit. Leave UCM connectors CN3A, CN2B, and CN3B disconnected. Fabricate a jumper wire that will connect between X-27 pin 1 and X-27 pin 2. Connect the jumper wire between X-27 pin 1 and X-27 pin 2. Measure the resistance between CN3A pin 22 and CN2B pin 7. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Remove the jumper from X-27. Connect the jumper wire between X-28 pin 1 and X-28 pin 2. Measure the resistance between CN3B pin 6 and CN2B pin 7. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 10 Ω. There is an open circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 714

Electrical systems - FAULT CODES

5251-Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed an open circuit in the bucket solenoid circuit. Diagnostic Trouble Code 5251 - Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Open Circuit has an error priority of Red. The bucket functions are disabled while Diagnostic Trouble Code 5251 - Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Open Circuit is active. Cause: The UCM has sensed an open circuit in the bucket solenoid circuit, CN3B pin 17. The fault is active when the hydraulics are enabled and the calculated solenoid resistance has increased over 70 %. Possible failure modes: 1. An open circuit in the solenoid circuit. 2. The bucket valve retract solenoid has failed. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5251 - Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the bucket solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the bucket solenoids. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connectors CN3B and CN1A. Disconnect connector X-25. Fabricate a jumper wire that will connect between CN3B pin 17 and chassis ground. Connect the jumper wire between CN3B pin 17 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt.

47683911 27/02/2015

55.17 [55.DTC] / 715

Electrical systems - FAULT CODES

Measure the resistance between X-25 pin 1 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect the jumper wire between CN1A pin 13 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. Measure the resistance between X-25 pin 2 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 Ω. Go to step 4. B. One or both resistance measurements are greater than 10 Ω. There is an open circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the solenoid resistance. Measure the resistance across the retract solenoid terminals, pin 1 and pin 2. The resistance should be less than 20 Ω. A. The resistance is less than 20 Ω. Go to step 5. B. The resistance is greater than 20 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the circuit. Leave UCM connectors CN3B and CN1A disconnected. Fabricate a jumper wire that will connect between X-25 pin 1 and X-25 pin 2. Connect the jumper wire between X-25 pin 1 and X-25 pin 2. Measure the resistance between CN3B pin 17 and CN1A pin 13. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 10 Ω. There is an open circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 716

Electrical systems - FAULT CODES

5252-Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Shorted To Ground WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the bucket retract solenoid current is too high. Diagnostic Trouble Code 5252 - Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Shorted To Ground has an error priority of Red. Bucket functions are disabled while Diagnostic Trouble Code 5252 - Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Shorted To Ground is active. Cause: The UCM has sensed that the bucket retract solenoid current is too high. The fault is active when the hydraulics are enabled and the solenoid output current, CN3B pin 17 is greater than 3 A. Possible failure modes: 1. A short circuit in the solenoid wiring. 2. The bucket valve retract solenoid has failed. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5252 - Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the bucket solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the bucket solenoids. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Test the UCM. Turn the ignition switch OFF. Disconnect solenoid connector X-25. Turn the ignition switch ON, activate the hydraulics. Use the electronic service tool and access the fault code screen. Fault code 5252 - Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Shorted To Ground should no longer be active. Fault code 5251 Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Open Circuit is now active.

47683911 27/02/2015

55.17 [55.DTC] / 717

Electrical systems - FAULT CODES

A. Fault code 5252 - Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Shorted To Ground is no longer active. Fault code 5251 - Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Open Circuit is now active. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5252 - Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Shorted To Ground is active. Fault code 5251 - Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Open Circuit did not become active. Go to step 4. 4. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. Leave solenoid connector X-25 disconnected. Disconnect UCM connectors CN3B and CN1A. Measure the resistance between CN3B pin 17 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN1A pin 13 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN3B pin 17 and CN1A pin 13. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 20,000 Ω. There is a short circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 718

Electrical systems - FAULT CODES

5261-Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed an open circuit in the bucket solenoid circuit. Diagnostic Trouble Code 5261 - Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Open Circuit has an error priority of Red. The bucket functions are disabled while Diagnostic Trouble Code 5261 - Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Open Circuit is active. Cause: The UCM has sensed an open circuit in the bucket solenoid circuit, CN4A pin 19. The fault is active when the hydraulics are enabled and the calculated solenoid resistance has increased over 70 %. Possible failure modes: 1. An open circuit in the solenoid circuit. 2. The bucket valve extend solenoid has failed. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5261 - Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the bucket solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the bucket solenoids. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connectors CN4A and CN1A. Disconnect connector X-26. Fabricate a jumper wire that will connect between CN4A pin 19 and chassis ground. Connect the jumper wire between CN4A pin 19 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt.

47683911 27/02/2015

55.17 [55.DTC] / 719

Electrical systems - FAULT CODES

Measure the resistance between X-26 pin 1and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect the jumper wire between CN1A pin 13 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. Measure the resistance between X-26 pin 2 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 Ω. Go to step 4. B. One or both resistance measurements are greater than 10 Ω. There is an open circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the solenoid resistance. Measure the resistance across the extend solenoid terminals, pin 1 and pin 2. The resistance should be less than 20 Ω. A. The resistance is less than 20 Ω. Go to step 5. B. The resistance is greater than 20 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the circuit. Leave UCM connectors CN4A and CN1A disconnected. Fabricate a jumper wire that will connect between X-26 pin 1 and X-26 pin 2. Connect the jumper wire between X-26 pin 1 and X-26 pin 2. Measure the resistance between CN4A pin 19 and CN1A pin 13. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 10 Ω. There is an open circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 720

Electrical systems - FAULT CODES

5262-Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Shorted To Ground WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the bucket extend solenoid current is too high. Diagnostic Trouble Code 5262 - Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Shorted To Ground has an error priority of Red. Bucket functions are disabled while Diagnostic Trouble Code 5262 - Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Shorted To Ground is active. Cause: The UCM has sensed that the bucket extend solenoid current is too high. The fault is active when hydraulics are enabled and solenoid output current, CN4A pin 19 is greater than 3 A. Possible failure modes: 1. A short circuit in the solenoid wiring. 2. The bucket valve solenoid has failed. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5262 - Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the bucket solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the bucket solenoids. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Test the UCM. Turn the ignition switch OFF. Disconnect solenoid connector X-26. Turn the ignition switch ON, activate the hydraulics. Use the electronic service tool and access the fault code screen. Fault code 5262 - Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Shorted To Ground should no longer be active. Fault code 5261 - Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Open Circuit is now active.

47683911 27/02/2015

55.17 [55.DTC] / 721

Electrical systems - FAULT CODES

A. Fault code 5262 - Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Shorted To Ground is no longer active. Fault code 5261 - Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Open Circuit is now active. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5262 - Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Shorted To Ground is active. Fault code 5261 - Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Open Circuit did not become active. Go to step 4. 4. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. Leave solenoid connector X-26 disconnected. Disconnect UCM connectors CN4A and CN1A. Measure the resistance between CN4A pin 19 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN1A pin 13 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN4A pin 19 and CN1A pin 13. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 20,000 Ω. There is a short circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 722

Electrical systems - FAULT CODES

5271-Loader Bucket Valve (Directional) Loader Bucket Solenoid(s) Shorted To Power C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE Electro hydraulic controls WE WE Electro hydraulic controls

Context: The UCM has sensed higher than normal voltage on the bucket solenoid lines. Fault code 5271 - Loader Bucket Valve (Directional) Loader Bucket Solenoid(s) Shorted To Power has an error priority of Red. Bucket functions are disabled while Diagnostic Trouble Code 5271 - Loader Bucket Valve (Directional) Loader Bucket Solenoid(s) Shorted To Power is active. Cause: The UCM has sensed higher than normal voltage on the bucket solenoid lines, CN3B pin 17, CN4A pin 19, and CN1A pin 13. The fault is active when hydraulics are disabled and the solenoid voltage feedback is greater than 5 V. Possible failure modes: 1. A short circuit in the signal wire to another voltage source. 2. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5271 - Loader Bucket Valve (Directional) Loader Bucket Solenoid(s) Shorted To Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the bucket solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the bucket solenoids. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the signal wires. Turn the ignition switch OFF. Disconnect UCM connectors CN3B, CN1A, and CN4A. Turn the ignition switch ON. Measure the voltage between CN3B pin 17 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. Measure the voltage between CN1A pin 13 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. Measure the voltage between CN4A pin 19 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. 47683911 27/02/2015

55.17 [55.DTC] / 723

Electrical systems - FAULT CODES

A. All measured voltages are less than 0.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. One or more of the voltage measurements are greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 724

Electrical systems - FAULT CODES

5272-Loader Bucket Valve (Directional) Loader Bucket Solenoid(s) Shorted To Ground WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed a lower than normal voltage on the bucket solenoid lines. Fault code 5272 - Loader Bucket Valve (Directional) Loader Bucket Solenoid(s) Shorted To Ground has an error priority of Red. Bucket functions are disabled while Diagnostic Trouble Code 5272 - Loader Bucket Valve (Directional) Loader Bucket Solenoid(s) Shorted To Ground is active. Cause: The UCM has sensed that the voltage on the loader solenoid lines, CN3B pin 17, CN4A pin 19, and CN1A pin 13 is too low. The fault is active when hydraulics are disabled and the solenoid feedback voltage is less than 2 V. Possible failure modes: 1. A short circuit in the signal wire to chassis ground. 2. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5272 - Loader Bucket Valve (Directional) Loader Bucket Solenoid(s) Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the bucket solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the bucket solenoids. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connectors CN3B, CN4A, and CN1A. Disconnect solenoid connectors, X-25 and X-26. Measure the resistance between CN3B pin 17 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN4A pin 19 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN1A pin 13 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. 47683911 27/02/2015

55.17 [55.DTC] / 725

Electrical systems - FAULT CODES

Measure the resistance between CN3B pin 17 and CN1A pin 13. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN4A pin 19 and CN1A pin 13. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are greater than 20,000 Ω. Go to step 4. B. One or more resistance measurements are less than 20,000 Ω. There is a short circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the resistance through the solenoid. Disconnect connector X-25 and X-26. Measure the resistance across the bucket extend solenoid terminals. The resistance should be greater than 1 Ω. Measure the resistance across the bucket retract solenoid terminals. The resistance should be greater than 1 Ω. A. Both resistance measurements are greater than 1 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. One or both resistance measurements are less than 1 Ω. There is a short circuit in the solenoid. Replace the solenoid as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 726

Electrical systems - FAULT CODES

5273-Loader Bucket Valve (Directional) Solenoids Return Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed an open circuit in the bucket solenoid return circuit. Diagnostic Trouble Code 5273 - Loader Bucket Valve (Directional) Solenoids Return Open Circuit has an error priority of Red. The bucket functions are disabled while Diagnostic Trouble Code 5273 - Loader Bucket Valve (Directional) Solenoids Return Open Circuit is active. Cause: The UCM has sensed an open circuit in the loader solenoid return circuit, CN1A pin 13. The fault is active when the ignition is ON and the calculated solenoid resistances have increased over 70 %. Possible failure modes: 1. An open circuit in the solenoid return wiring. 2. The bucket solenoids have failed. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5273 - Loader Bucket Valve (Directional) Solenoids Return Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the bucket solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the bucket solenoids. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connectors CN3B, CN1A, and CN4A. Measure the resistance between CN3B pin 17 and CN1A pin 13. The resistance should be less than 100 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN4A pin 19 and CN1A pin 13. The resistance should be less than 100 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 100 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 47683911 27/02/2015

55.17 [55.DTC] / 727

Electrical systems - FAULT CODES

B. One or both resistance are greater than 100 Ω. There is an open circuit in the wiring. Go to step 4. 4. Measure the solenoid resistance. Measure the resistance across the extend solenoid terminals, pin 1 and pin 2. The resistance should be less than 20 Ω. Measure the resistance across the retract solenoid terminals, pin 1 and pin 2. The resistance should be less than 20 Ω. A. The resistance is less than 20 Ω. Go to step 5. B. The resistance is greater than 20 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the circuit. Leave UCM connectors CN3B, CN1A, and CN4A disconnected. Fabricate a jumper wire that will connect between X-25 pin 1 and X-25 pin 2. Connect the jumper wire between X-25 pin 1 and X-25 pin 2. Measure the resistance between CN3B pin 17 and CN1A pin 13. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Remove the jumper from X-25. Connect the jumper wire between X-26 pin 1 and X-26 pin 2. Measure the resistance between CN4A pin 19 and CN1A pin 13. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 10 Ω. There is an open circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 728

Electrical systems - FAULT CODES

5281-Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed an open circuit in the proportional aux extend solenoid circuit. Diagnostic Trouble Code 5281 - Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Open Circuit has an error priority of White. Auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5281 - Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Open Circuit is active. Cause: The UCM has sensed an open circuit in the proportional aux extend solenoid circuit, CN1B pin 33 and CN1A pin 22. The fault is active when the ignition is ON and the calculated solenoid resistance has increased over 70 %. Possible failure modes: 1. An open circuit in the wiring. 2. The proportional aux extend solenoid has failed. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5281 - Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the proportional aux solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the proportional aux solenoids. Verify that the harness is free of damage, corrosion, abrasion, and incorrect, attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connector CN1A. Disconnect UCM connector CN1B. Measure the resistance between CN1B pin 33 and CN1A pin 22. The resistance should be less than 100 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 100 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault.

47683911 27/02/2015

55.17 [55.DTC] / 729

Electrical systems - FAULT CODES

B. The resistance is greater than 100 Ω. There is an open circuit. Go to step 4. 4. Measure the solenoid resistance. Measure the resistance across the solenoid terminals pin 1 and pin 2. The resistance should be less than 100 Ω. A. The resistance is less than 100 Ω. Go to step 5. B. The resistance is greater than 100 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the circuit. Leave UCM connectors CN1A and CN1B disconnected. Fabricate a jumper wire that will connect between X-24 pin 1 and pin 2. Connect the jumper wire between X-24 pin 1 and pin 2. Measure the resistance between CN1B pin 33 and CN1A pin 22. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 10 Ω. There is an open circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 730

Electrical systems - FAULT CODES

5282-Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Shorted To Ground WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the proportional aux extend solenoid current is too high. Diagnostic Trouble Code 5282 - Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Shorted To Ground has an error priority of White. Auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5282 - Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Shorted To Ground is active. Cause: The UCM has sensed that the proportional aux extend solenoid current is too high. The fault is active when the hydraulics are enabled and the solenoid output current, CN1B pin 33 is greater than 3 A. Possible failure modes: 1. A short circuit in the solenoid wiring. 2. A failure of the proportional aux extend solenoid. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5282 - Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the proportional aux solenoid connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the proportional aux solenoids. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Test the UCM. Turn the ignition switch OFF. Disconnect solenoid connector X-24. Turn the ignition switch ON. Use the electronic service tool and access the fault code screen. Fault code 5282 - Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Shorted To Ground should no longer be active. Fault code 5281 Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Open Circuit is now active.

47683911 27/02/2015

55.17 [55.DTC] / 731

Electrical systems - FAULT CODES

A. Fault code 5282 - Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Shorted To Ground is no longer active. Fault code 5281 - Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Open Circuit is now active. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5282 - Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Shorted To Ground is active. Fault code 5281 - Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Open Circuit did not become active. Go to step 4. 4. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector CN1A. Disconnect UCM connector CN1B. Measure the resistance between CN1B pin 33 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN1A pin 22 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN1B pin 33 and CN1A pin 22. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 20,000 Ω. There is a short circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 732

Electrical systems - FAULT CODES

5291-Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed an open circuit in the proportional aux retract solenoid circuit. Diagnostic Trouble Code 5291 Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Open Circuit has an error priority of White. Auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5291 - Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Open Circuit is active. Cause: The UCM has sensed an open circuit in the proportional aux retract solenoid circuit, CN1A pin 24 and CN1A pin 22. The fault is active when the ignition is ON and the calculated solenoid resistance has increased over 70 %. Possible failure modes: 1. An open circuit in the wiring. 2. The proportional aux retract solenoid has failed. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5291 - Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the proportional aux solenoid connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the proportional aux solenoids. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connector CN1A. Measure the resistance between CN1A pin 24 and CN1A pin 22. The resistance should be less than 100 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 100 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 100 Ω. There is an open circuit. Go to step 4. 4. Measure the solenoid resistance. 47683911 27/02/2015

55.17 [55.DTC] / 733

Electrical systems - FAULT CODES

Measure the resistance across the solenoid terminals pin 1 and pin 2. The resistance should be less than 100 Ω. A. The resistance is less than 100 Ω. Go to step 5. B. The resistance is greater than 100 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the circuit. Leave UCM connector CN1A disconnected. Fabricate a jumper wire that will connect between X-29 pin 1 and X-29 pin 2. Connect the jumper wire between X-29 pin 1 and X-29 pin 2. Measure the resistance between CN1A pin 24 and CN1A pin 22. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 10 Ω. There is an open circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 734

Electrical systems - FAULT CODES

5292-Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Shorted To Ground WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the proportional aux valve retract solenoid current is too high. Diagnostic Trouble Code 5292 - Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Shorted To Ground has an error priority of White. Auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5292 - Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Shorted To Ground is active. Cause: The UCM has sensed that the proportional aux valve retract solenoid current is too high. The fault is active when hydraulics are enabled and solenoid output current, CN1A pin 24 is greater than 3 A. Possible failure modes: 1. A short circuit in the solenoid wiring. 2. A failure of the proportional aux retract solenoid. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5292 - Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the proportional aux solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the proportional aux solenoids. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Test the UCM. Turn the ignition switch OFF. Disconnect solenoid connector X-29. Turn the ignition switch ON. Use the electronic service tool to access the fault code screen. Fault code 5292 - Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Shorted To Ground should no longer be active. Fault code 5291 - Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Open Circuit is now active.

47683911 27/02/2015

55.17 [55.DTC] / 735

Electrical systems - FAULT CODES

A. Fault code 5292 - Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Shorted To Ground is no longer active. Fault code 5291 - Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Open Circuit is now active. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5292 - Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Shorted To Ground is active. Fault code 5291 - Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Open Circuit did not become active. Go to step 4. 4. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN1A. Disconnect solenoid connector X-29. Measure the resistance between CN1A pin 24 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN1A pin 22 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN1A pin 24 and CN1A pin 22. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 20,000 Ω. There is a short circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 736

Electrical systems - FAULT CODES

5309-Float Button - Float Button Timeout (30 sec) WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: UCM has sensed that the float switch signal has been ON for more than 30 s. Diagnostic Trouble Code 5309 - Float Button - Float Button Timeout (30 sec) has an error priority of White. Loader float feature is disabled while Diagnostic Trouble Code 5309 - Float Button - Float Button Timeout (30 sec) is active. Cause: The UCM has sensed that the float switch input signal, CN2B pin 27 has been high for more than 30 s. Possible failure modes: 1. A short circuit to another voltage source. 2. A failure of the float switch. 3. A failure of the UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5309 - Float Button - Float Button Timeout (30 sec) is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the float switch connections on the right joystick. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the float switch on the right joystick. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the float switch. Turn the ignition switch OFF. Disconnect connector X-403 from the right joystick. Measure the resistance between X-403 pin 13 and X-403 pin 14. The resistance should be greater than 20,000 Ω. Actuate the float switch while measuring the resistance between X-403 pin 13 and X-403 pin 14. The resistance should be less than 10 Ω while the float switch is activated. A. The resistance is greater than 20,000 Ω when the switch is in the open (not actuated) position and the resistance is less than 10 Ω while the float switch is actuated. Go to step 4. B. The resistance is less than 10 Ω when the switch is in the open (not actuated) position and the resistance is less than 10 Ω while the float switch is actuated. There is a short circuit in the float switch, temporarily replace the right joystick and retest. Return to step 1 to confirm elimination of the fault.

47683911 27/02/2015

55.17 [55.DTC] / 737

Electrical systems - FAULT CODES

4. Measure the voltage on the signal wire. Turn the ignition switch OFF. Disconnect UCM connector CN2B. Reconnect the right joystick connector X-403. Turn the ignition switch ON. Measure the voltage between CN2B pin 27 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 13 Cab to Chassis Interface (55.100.DP-C.20.E.13) Wiring harnesses - Electrical schematic sheet 17 Right-Hand Control Handle (55.100.DP-C.20.E.17)

47683911 27/02/2015

55.17 [55.DTC] / 738

Electrical systems - FAULT CODES

5313-EHF Enable Switch STP WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed the voltage on the EHF enable input, CN3B pin 11, is greater than 3.5 V. Diagnostic Trouble Code 5313 - EHF Enable Switch STP has an error priority of White. The EHF functions are disabled while Diagnostic Trouble Code 5313 - EHF Enable Switch STP is active. Cause: The UCM has sensed the voltage on the EHF enable input, CN3B pin 11 is greater than 3.5 V. Possible failure modes: 1. A short circuit in the wiring. 2. A faulty EHF switch. 3. The UCM has internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5313 - EHF Enable Switch STP is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the EHF switch connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the EHF switch. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the switch inputs to the UCM. Turn the ignition switch OFF. Remove the EHF switch from the left-hand post. Disconnect connector X-303 from the EHF switch. Disconnect UCM connector CN3B. Turn the ignition switch ON. Measure the voltage between X-303 pin A and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair as required. Return to step 1 to confirm elimination of fault. 47683911 27/02/2015

55.17 [55.DTC] / 739

Electrical systems - FAULT CODES

4. Measure the resistance through the signal wire. Fabricate a jumper wire that will connect between connector CN3B pin 11 and chassis ground. Connect the jumper wire between connector CN3B pin 11 and chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-303 pin A and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 5. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Test the UCM. Turn the ignition switch OFF. Remove the jumper wire that is connected between connector CN3B pin 11 and chassis ground. Reconnect UCM connector CN3B. Fabricate a jumper wire that will connect between connector X-303 pin A and positive battery. Connect the jumper wire between connector X-303 pin A and positive battery. Turn the ignition switch ON. Use the Electronic Service Tool to monitor the switch status. The switch status should read that the EHF switch is ON. The switch status should read ON while the jumper wire is connected and OFF when it is disconnected. A. The switch status reads ON while the jumper wire is connected and OFF when it is disconnected. Replace the EHF switch and retest. Return to step 1 to confirm elimination of fault. B. The EHF switch status reads OFF when the jumper wire is connected. The EHF switch status reads OFF when the jumper wire is not connected. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 14 Cab to Chassis Interface (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 15 Cab Console Switches (55.100.DP-C.20.E.15)

47683911 27/02/2015

55.17 [55.DTC] / 740

Electrical systems - FAULT CODES

5323-EHF Fwd/Rev Switch STP WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed the voltage on the switch input of the 2nd aux hydraulic, CN3B pin 29 and CN3B pin 31 is greater than 3.5 V. Diagnostic Trouble Code 5323 - EHF Fwd/Rev Switch STP has an error priority of White. The EHF functions are disabled while Diagnostic Trouble Code 5323 - EHF Fwd/Rev Switch STP is active. Cause: The UCM has sensed the voltage on the switch input of the 2nd aux hydraulic, CN3B pin 29 and CN3B pin 31 is greater than 3.5 V. Possible failure modes: 1. A short circuit in the wiring. 2. A faulty 2nd aux hydraulic switch. 3. The UCM has internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5323 - EHF Fwd/Rev Switch STP is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the 2nd aux hydraulic switch connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the 2nd aux hydraulic switch. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the switch inputs to the UCM. Turn the ignition switch OFF. Disconnect connector X-408 from the left control handle. Disconnect UCM connector CN3B. Disconnect the 2nd aux connector X-AUX_RET and X-AUX_EXT. Turn the ignition switch ON. Measure the voltage between X-408 pin 2 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-408 pin 3 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition.

47683911 27/02/2015

55.17 [55.DTC] / 741

Electrical systems - FAULT CODES

Measure the voltage between X-AUX_RET pin 1 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-AUX_EXT pin 1 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance through the signal wire. Fabricate a jumper wire that will connect between connector CN3B pin 29 and CN3B pin 31. Connect the jumper wire between connector CN3B pin 29 and CN3B pin 31. Measure the resistance between connector X-408 pin 2 and X-408 pin 3. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-AUX_RET pin 1 and X-AUX_EXT pin 1. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 5. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Test the UCM. Turn the ignition switch OFF. Remove the jumper wire that is connected between connector CN3B pin 29 and CN3B pin 31. Reconnect UCM connector CN3B. Fabricate a jumper wire that will connect between connector X-408 pin 2 and positive battery. Connect the jumper wire between connector X-408 pin 2 and positive battery. Turn the ignition switch ON. Use the Electronic Service Tool to monitor the switch status. The switch status for the extend solenoid of the 2nd aux hydraulics should read ON. The switch status for the extend solenoid of the 2nd aux hydraulics should read ON while the jumper wire is connected and OFF when it is disconnected. Turn the ignition switch OFF. Connect the jumper wire between connector X-408 pin 3 and positive battery. Turn the ignition switch ON. Use the Electronic Service Tool to monitor the switch status. The switch status for the retract solenoid of the 2nd aux hydraulics should read ON. The switch status for the retract solenoid of the 2nd aux hydraulics should read ON while the jumper wire is connected and OFF when it is disconnected. A. The switch status reads ON while the jumper wire is connected and OFF when it is disconnected. Replace the left joystick module and retest. Return to step 1 to confirm elimination of fault. B. The 2nd aux switch status reads OFF when the jumper wire is connected. The 2nd aux switch status reads OFF when the jumper wire is not connected. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. 47683911 27/02/2015

55.17 [55.DTC] / 742

Electrical systems - FAULT CODES

Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 14 Cab to Chassis Interface (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 15 Cab Console Switches (55.100.DP-C.20.E.15)

47683911 27/02/2015

55.17 [55.DTC] / 743

Electrical systems - FAULT CODES

5371-EHF Forward Solenoid (A) Supply STG WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed a short circuit in the EHF forward solenoid circuit. Diagnostic Trouble Code 5371 - EHF Forward Solenoid (A) Supply STG has an error priority of White. The EHF function is disabled while Diagnostic Trouble Code 5371 - EHF Forward Solenoid (A) Supply STG is active. Cause: The UCM has sensed a short circuit condition in the EHF forward solenoid, CN3A pin 19. The fault is active when the EHF function is active, the hydraulics are enabled, and the solenoid current is below normal. Possible failure modes: 1. A short circuit in the wiring. 2. A failure of the EHF forward solenoid. 3. A faulty UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5371 - EHF Forward Solenoid (A) Supply STG is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the EHF forward solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the EHF forward solenoid. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the harness. Turn the ignition switch OFF. Disconnect UCM connectors CN3A and CN2B. Disconnect connector X-19. Measure the resistance between CN3A pin 19 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN2B pin 8 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN3A pin 19 and CN2B pin 8. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are less than 10 Ω. Go to step 4. 47683911 27/02/2015

55.17 [55.DTC] / 744

Electrical systems - FAULT CODES

B. One or more resistance measurements are greater than 10 Ω. There is a short circuit in the harness. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Reconnect UCM connectors CN3A and CN2B. Disconnect connector X-19. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 5371 - EHF Forward Solenoid (A) Supply STG should no longer be active. Fault code 5372 - EHF Pump Control PRV's (Directional) - Forward Solenoid (A) Supply Short to Ground should become active. A. Fault code 5372 - EHF Pump Control PRV's (Directional) - Forward Solenoid (A) Supply Short to Ground is active and fault code 5371 - EHF Forward Solenoid (A) Supply STG is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5371 - EHF Forward Solenoid (A) Supply STG is still active. Fault code 5372 - EHF Pump Control PRV's (Directional) - Forward Solenoid (A) Supply Short to Ground did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 32 Enhanced High Flow (55.100.DP-C.20.E.32) Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19)

47683911 27/02/2015

55.17 [55.DTC] / 745

Electrical systems - FAULT CODES

5372-EHF Forward Solenoid (A) Supply OC WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed an open circuit condition for the EHF forward solenoid. Diagnostic Trouble Code 5372 - EHF Forward Solenoid (A) Supply OC has an error priority of White. The EHF functions are disabled while Diagnostic Trouble Code 5372 - EHF Forward Solenoid (A) Supply OC is active. Cause: The UCM has sensed an open circuit condition for the EHF forward solenoid, CN3A pin 19. The fault is active when the EHF setting is active, the hydraulics are enabled, and the solenoid current is greater than 3 A. Possible failure modes: 1. An open circuit in the wiring. 2. A failure of the EHF forward solenoid. 3. A faulty UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5372 - EHF Forward Solenoid (A) Supply OC is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the EHF forward solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the EHF forward solenoid. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the solenoid wires to chassis ground Turn the ignition switch OFF. Disconnect UCM connectors CN3A and CN2B. Disconnect solenoid connector X-19. Fabricate a jumper wire that will connect between X-19 pin 1 and X-19 pin 2. Connect the jumper wire between X-19 pin 1 and X-19 pin 2. Measure the resistance between CN3A pin 19 and CN2B pin 8. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is less than 10 Ω. Go to step 4.

47683911 27/02/2015

55.17 [55.DTC] / 746

Electrical systems - FAULT CODES

B. The resistance measurement is greater than 10 Ω. There is an open circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM Turn the ignition switch OFF. Reconnect UCM connectors CN3A and CN2B. Leave the jumper wire connected between X-19 pin 1 and X-19 pin 2. Turn the ignition switch ON. Activate the EHF hydraulics while monitoring the fault code screen. Fault code 5372 - EHF Forward Solenoid (A) Supply OC should no longer be active. Fault code 5371 - EHF Pump Control PRV's (Directional) - Forward Solenoid (A) Supply Open Circuit should become active. A. Fault code 5371 - EHF Pump Control PRV's (Directional) - Forward Solenoid (A) Supply Open Circuit is active and fault code 5372 - EHF Forward Solenoid (A) Supply OC is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5372 - EHF Forward Solenoid (A) Supply OC is still active. Fault code 5371 - EHF Pump Control PRV's (Directional) - Forward Solenoid (A) Supply Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 32 Enhanced High Flow (55.100.DP-C.20.E.32) Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19)

47683911 27/02/2015

55.17 [55.DTC] / 747

Electrical systems - FAULT CODES

5381-EHF Reverse Solenoid (B) Supply STG WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed a short circuit in the EHF reverse solenoid circuit. Diagnostic Trouble Code 5381 - EHF Reverse Solenoid (B) Supply STG has an error priority of White. The EHF function is disabled while Diagnostic Trouble Code 5381 - EHF Reverse Solenoid (B) Supply STG is active. Cause: The UCM has sensed a short circuit condition in the EHF reverse solenoid, CN3A pin 6. The fault is active when the EHF function is active, the hydraulics are enabled, and the solenoid current is below normal. Possible failure modes: 1. A short circuit in the wiring. 2. A failure of the EHF reverse solenoid. 3. A faulty UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5381 - EHF Reverse Solenoid (B) Supply STG is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the EHF reverse solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the EHF reverse solenoid. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the harness. Turn the ignition switch OFF. Disconnect UCM connectors CN3A and CN2B. Disconnect connector X-40. Measure the resistance between CN3A pin 6 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN2B pin 8 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN3A pin 6 and CN2B pin 8. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are less than 10 Ω. Go to step 4. 47683911 27/02/2015

55.17 [55.DTC] / 748

Electrical systems - FAULT CODES

B. One or more resistance measurements are greater than 10 Ω. There is a short circuit in the harness. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Reconnect UCM connectors CN3A and CN2B. Disconnect connector X-40. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 5381 - EHF Reverse Solenoid (B) Supply STG should no longer be active. Fault code 5382 - EHF Pump Control PRV's (Directional) - Reverse Solenoid (B) Supply Short to Ground should become active. A. Fault code 5382 - EHF Pump Control PRV's (Directional) - Reverse Solenoid (B) Supply Short to Ground is active and fault code 5381 - EHF Reverse Solenoid (B) Supply STG is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5381 - EHF Reverse Solenoid (B) Supply STG is still active. Fault code 5382 - EHF Pump Control PRV's (Directional) - Reverse Solenoid (B) Supply Short to Ground did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 32 Enhanced High Flow (55.100.DP-C.20.E.32) Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19)

47683911 27/02/2015

55.17 [55.DTC] / 749

Electrical systems - FAULT CODES

5382-EHF Reverse Solenoid (B) Supply OC WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed an open circuit condition for the EHF reverse solenoid. Diagnostic Trouble Code 5382 - EHF Reverse Solenoid (B) Supply OC has an error priority of White. The EHF functions are disabled while Diagnostic Trouble Code 5382 - EHF Reverse Solenoid (B) Supply OC is active. Cause: The UCM has sensed an open circuit condition for the EHF reverse solenoid, CN3A pin 6. The fault is active when the EHF setting is active, the hydraulics are enabled, and the solenoid current is greater than 3 A. Possible failure modes: 1. An open circuit in the wiring. 2. A failure of the EHF reverse solenoid. 3. A faulty UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5382 - EHF Reverse Solenoid (B) Supply OC is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the EHF reverse solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the EHF reverse solenoid. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the solenoid wires to chassis ground Turn the ignition switch OFF. Disconnect UCM connectors CN3A and CN2B. Disconnect solenoid connector X-40. Fabricate a jumper wire that will connect between X-40 pin 1 and X-40 pin 2. Connect the jumper wire between X-40 pin 1 and X-40 pin 2. Measure the resistance between CN3A pin 6 and CN2B pin 8. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is less than 10 Ω. Go to step 4.

47683911 27/02/2015

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Electrical systems - FAULT CODES

B. The resistance measurement is greater than 10 Ω. There is an open circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM Turn the ignition switch OFF. Reconnect UCM connectors CN3A and CN2B. Leave the jumper wire connected between X-40 pin 1 and X-40 pin 2. Turn the ignition switch ON. Activate the EHF hydraulics while monitoring the fault code screen. Fault code 5382 - EHF Reverse Solenoid (B) Supply OC should no longer be active. Fault code 5381 - EHF Pump Control PRV's (Directional) - Reverse Solenoid (B) Supply Open Circuit should become active. A. Fault code 5381 - EHF Pump Control PRV's (Directional) - Reverse Solenoid (B) Supply Open Circuit is active and fault code 5382 - EHF Reverse Solenoid (B) Supply OC is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5382 - EHF Reverse Solenoid (B) Supply OC is still active. Fault code 5381 - EHF Pump Control PRV's (Directional) - Reverse Solenoid (B) Supply Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 32 Enhanced High Flow (55.100.DP-C.20.E.32) Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19)

47683911 27/02/2015

55.17 [55.DTC] / 751

Electrical systems - FAULT CODES

5391-EHF Solenoids Return OC WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed an open circuit condition in the EHF solenoid return line. Diagnostic Trouble Code 5391 - EHF Solenoids Return OC has an error priority of White. The EHF functions are disabled while Diagnostic Trouble Code 5391 - EHF Solenoids Return OC is active. Cause: The UCM has sensed an open circuit condition in the EHF solenoid return line, CN2B pin 8. The fault is active while the EHF setting is active, the hydraulics are enabled, and the extend solenoid and the retract solenoid current is incorrect. Possible failure modes: 1. An open circuit in the solenoid return line. 2. A failure of the EHF extend solenoid and the EHF retract solenoid. 3. A faulty UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5391 - EHF Solenoids Return OC is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the EHF forward solenoid, and the EHF reverse solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to both EHF solenoids. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the harness. Fabricate a jumper wire that will connect between the EHF extend solenoid connector X-19 pin 1 and X-19 pin 2. Turn the ignition switch OFF. Disconnect UCM connectors CN3A and CN2B. Disconnect solenoid connectors X-19 and X-40. Connect jumper wire between X-19 pin 1 to X-19 pin 2. Measure the resistance between CN3A pin 19 and CN2B pin 8. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Remove the jumper wire from connector X-19.

47683911 27/02/2015

55.17 [55.DTC] / 752

Electrical systems - FAULT CODES

Connect the jumper wire between X-40 pin 1 to X-40 pin 2. Measure the resistance between CN3A pin 6 and CN2B pin 8. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 Ω. Go to step 4. B. One or both resistance measurement is greater than 10 Ω. There is an open circuit in the wiring. Check splice SP-193. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the resistance of the solenoids. Disconnect connectors X-19 and X-40. Measure the resistance between X-19 pin 1 and X-19 pin 2. The resistance should be less than 1,000 Ω. Measure the resistance between X-40 pin 1 and X-40 pin 2. The resistance should be less than 1,000 Ω. A. Both resistance measurements are less than 1,000 Ω. Replace the solenoids. Return to step 1 to confirm elimination of the fault. B. One or both resistance measurement is greater than 1,000 Ω. There is an open circuit in the solenoid. Check splice SP-193. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 32 Enhanced High Flow (55.100.DP-C.20.E.32) Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19)

47683911 27/02/2015

55.17 [55.DTC] / 753

Electrical systems - FAULT CODES

5392-EHF Pump Solenoid(s) STG WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed a short to ground condition for the EHF pump solenoids. Diagnostic Trouble Code 5392 - EHF Pump Solenoid(s) STG has an error priority of White. The EHF functions are disabled while Diagnostic Trouble Code 5392 - EHF Pump Solenoid(s) STG is active. Cause: The UCM has sensed a short to ground condition for the EHF pump solenoids. The fault is active when the EHF setting is active, the hydraulics are disabled, and the solenoid return voltage is low. Possible failure modes: 1. A short circuit in the wiring. 2. A failure of EHF Pump solenoid. 3. A faulty UCM Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5392 - EHF Pump Solenoid(s) STG is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the EHF forward solenoid, and the EHF reverse solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to both EHF solenoids. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the solenoid wires to chassis ground Turn the ignition switch OFF. Disconnect UCM connectors CN3A and CN2B. Disconnect solenoid connectors X-19 and X-40. Measure the resistance between X-19 pin 1 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-19 pin 2 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-40 pin 1 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition.

47683911 27/02/2015

55.17 [55.DTC] / 754

Electrical systems - FAULT CODES

Measure the resistance between X-40 pin 2 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN3A pin 19 and CN2B pin 8. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN3A pin 6 and CN2B pin 8. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are greater than 20,000 Ω. Go to step 4. B. One or more resistance measurements is less than 20,000 Ω. There is a short circuit to chassis ground in the harness. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connectors CN3A and CN2B. Leave connectors X-19 and X-40 disconnected. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 5392 - EHF Pump Solenoid(s) STG should no longer be active. Fault code 5391 - EHF Pump Control PRV's (Directional) - Solenoids Return Open Circuit should become active. A. Fault code 5391 - EHF Pump Control PRV's (Directional) - Solenoids Return Open Circuit is active and fault code 5392 - EHF Pump Solenoid(s) STG is no longer active. Temporarily replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5392 - EHF Pump Solenoid(s) STG is still active. Fault code 5391 - EHF Pump Control PRV's (Directional) - Solenoids Return Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 32 Enhanced High Flow (55.100.DP-C.20.E.32) Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19)

47683911 27/02/2015

55.17 [55.DTC] / 755

Electrical systems - FAULT CODES

5393-EHF Pump Solenoid(s) STP WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed a short circuit to another voltage source in the EHF Pump solenoid circuit. Diagnostic Trouble Code 5393 - EHF Pump Solenoid(s) STP has an error priority of White. The EHF function is disabled while Diagnostic Trouble Code 5393 - EHF Pump Solenoid(s) STP is active. Cause: The UCM has sensed a short circuit to another voltage source in the EHF Pump solenoid circuit. The fault is active when the EHF setting is active, the hydraulics are disabled, and the solenoid voltage feedback is greater than 5 V. Possible failure modes: 1. A short circuit to another voltage source in the wiring. 2. A faulty UCM Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5393 - EHF Pump Solenoid(s) STP is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the EHF forward solenoid, and the EHF reverse solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to both EHF solenoids. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the solenoid wires. Turn the ignition switch OFF. Disconnect UCM connectors CN3A and CN2B. Disconnect solenoid connector X-19 and X-40. Turn the ignition switch ON. Measure the voltage between X-19 pin 1 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-19 pin 2 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-40 pin 1 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition.

47683911 27/02/2015

55.17 [55.DTC] / 756

Electrical systems - FAULT CODES

Measure the voltage between X-40 pin 2 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. All voltage measurements are less than 0.5 V. Go to step 4. B. One or more voltage measurements are greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM Turn the ignition switch OFF. Reconnect UCM connectors CN3A and CN2B. Leave connectors X-19 and X-40 disconnected. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 5393 - EHF Pump Solenoid(s) STP should no longer be active. Fault code 5391 - EHF Pump Control PRV's (Directional) - Solenoids Return Open Circuit should become active. A. Fault code 5391 - EHF Pump Control PRV's (Directional) - Solenoids Return Open Circuit is active and fault code 5393 - EHF Pump Solenoid(s) STP is no longer active. Temporarily replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5393 - EHF Pump Solenoid(s) STP is still active. Fault code 5391 - EHF Pump Control PRV's (Directional) - Solenoids Return Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 32 Enhanced High Flow (55.100.DP-C.20.E.32) Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19)

47683911 27/02/2015

55.17 [55.DTC] / 757

Electrical systems - FAULT CODES

5409-Aux Override Disabled Due To Aux Override Button Timeout (30 Seconds) WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed an error with the aux override button status. Diagnostic Trouble Code 5409 - Aux Override Disabled Due To Aux Override Button Timeout (30 Seconds) has an error priority of White. The aux override is disabled while Diagnostic Trouble Code 5409 - Aux Override Disabled Due To Aux Override Button Timeout (30 Seconds) is active. Cause: The UCM has sensed an error with the aux override Button status. The fault is active when ignition is on and CAN message from the instrument cluster is high for more than 30 s. Possible failure modes: 1. A failure of the instrument cluster. Solution: 1. Use the EST to verify fault code 5409 - Aux Override Disabled Due To Aux Override Button Timeout (30 Seconds) is active. A. If the fault is active, erase the fault with the EST. 2. If the fault persists, this is an indication of an instrument cluster failure. Replace the instrument cluster and retest.

47683911 27/02/2015

55.17 [55.DTC] / 758

Electrical systems - FAULT CODES

5501-Loader Arm Spool Sensor Open or Shorted To Ground WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the loader position sensor signal has failed. Diagnostic Trouble Code 5501 - Loader Arm Spool Sensor Open or Shorted To Ground has an error priority of White. The loader function will operate in limp home mode while Diagnostic Trouble Code 5501 - Loader Arm Spool Sensor Open or Shorted To Ground is active. Cause: The UCM has sensed that the loader position sensor signal, CN3B pin 13 has failed. The fault is active when the engine is ON and the loader position sensor signal is less than 0.2 V. Possible failure modes: 1. A short circuit in the wiring. 2. An open circuit in the wiring. 3. The boom spool position sensor has failed. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5501 - Loader Arm Spool Sensor Open or Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the loader solenoid, and loader position sensor connection. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader solenoids and loader position sensor. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the sensor. Disconnect the boom spool position sensor. Turn the ignition switch ON. Measure the voltage between X-22 pin 1 and X-22 pin 3. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 5 V. Go to step 4. B. The voltage is less the 4.5 V. There is a problem in the supply voltage to the sensor. Check UCM connector X-CN1A pin 8. Verify the chassis ground connection from X-10 is secure. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the resistance of the signal wire to chassis ground. 47683911 27/02/2015

55.17 [55.DTC] / 759

Electrical systems - FAULT CODES

Turn the ignition switch OFF. Disconnect UCM connector CN3B. Disconnect the boom spool position sensor from the harness. Measure the resistance between CN3B pin 13 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Go to step 5. B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Turn the ignition switch OFF. Fabricate a jumper wire that will connect between connector CN3B pin 13 and chassis ground. Connect the jumper wire between connector CN3B pin 13 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-22 pin 4 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 6. Test the UCM. Reconnect UCM connector CN3B. Fabricate a jumper wire that will connect between X-22 pin 1 and X-22 pin 4. Connect the jumper wire between X-22 pin 1 and X-22 pin 4. Turn the ignition switch ON and monitor the active fault screen. Fault code 5502 - Loader Arm Spool Sensor Shorted To Power should become active. Fault code 5501 - Loader Arm Spool Sensor Open or Shorted To Ground should no longer be active. A. Fault code 5502 - Loader Arm Spool Sensor Shorted To Power is active and fault code 5501 - Loader Arm Spool Sensor Open or Shorted To Ground is no longer active. Temporarily replace the boom spool position sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5501 - Loader Arm Spool Sensor Open or Shorted To Ground is still active. Fault code 5502 Loader Arm Spool Sensor Shorted To Power is not active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 760

Electrical systems - FAULT CODES

5502-Loader Arm Spool Sensor Shorted To Power WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed a higher than normal voltage on the boom spool position sensor input. Diagnostic Trouble Code 5502 - Loader Arm Spool Sensor Shorted To Power has an error priority of Amber. The loader function will operate in limp home mode while Diagnostic Trouble Code 5502 - Loader Arm Spool Sensor Shorted To Power is active. Cause: The UCM has sensed a higher than normal voltage on the loader valve spool input, CN3B pin 13. The fault is active while the ignition is ON and the loader position sensor voltage is greater than 4.8 V. Possible failure modes: 1. The signal wire is shorted to another voltage source. 2. A faulty boom spool position sensor. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5502 - Loader Arm Spool Sensor Shorted To Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the boom spool position sensor connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the boom spool position sensor. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the sensor. Disconnect the boom spool position sensor. Turn the ignition switch ON. Measure the voltage between X-22 pin 1 and X-22 pin 3. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 5 V. Go to step 4. B. The voltage is less the 4.5 V. There is a problem in the supply voltage to the sensor. Check UCM connector CN1A pin 8. Verify the chassis ground connection from connector X-10 is secure. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the voltage of the signal wire.

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55.17 [55.DTC] / 761

Electrical systems - FAULT CODES

Disconnect UCM connector CN3B. Disconnect the boom spool position sensor from the harness. Turn the ignition switch ON. Measure the voltage between CN3B pin 13 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 5. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the signal wire. Turn the ignition switch OFF. Fabricate a jumper wire that will connect between CN3B pin 13 and chassis ground. Connect the jumper wire between CN3B pin 13 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-22 pin 4 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 6. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connector CN3B. Turn the ignition switch ON and monitor the active fault screen. Fault code 5501 - Loader Arm Spool Sensor Open or Shorted To Ground should become active. Fault code 5502 - Loader Arm Spool Sensor Shorted To Power should no longer be active. A. Fault code 5501 - Loader Arm Spool Sensor Open or Shorted To Ground is active. Fault code 5502 Loader Arm Spool Sensor Shorted To Power is no longer active. Temporarily replace the boom spool position sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5502 - Loader Arm Spool Sensor Shorted To Power is still active. Fault code 5501 - Loader Arm Spool Sensor Open or Shorted To Ground is not active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 762

Electrical systems - FAULT CODES

5503-Electro-Hydraulic Aux Output Shorted To Power WE Mechanical hydraulic controls WE WE Mechanical hydraulic controls

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The instrument cluster has sensed a short circuit to another voltage source in the EH aux power output circuit, X-C23 pin 26. Diagnostic Trouble Code 5503 has an error priority of Red. The vehicle is disabled while Diagnostic Trouble Code 5503 is active. Cause: The instrument cluster has sensed a short circuit to another voltage source in the EH aux power output circuit. The fault is active while the ignition is ON, the Aux output is low, and the EH aux output is still energized. Possible failure modes: 1. Faulty wiring or connectors. 2. A faulty Instrument Cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5503 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the instrument cluster connector X-C23 and the EH Aux PWM controller connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the instrument cluster to the EH Aux PWM controller. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the power wire. Turn the ignition switch OFF. Disconnect the instrument cluster connector X-C23. Disconnect EH Aux PWM connector X-430. Turn the ignition switch ON. Measure the voltage between the instrument cluster connector X-C23 pin 26 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm the elimination of the fault. B. The voltage is greater than 0.5 V. The EH Aux power wire is shorted to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 Instrument Cluster (55.100.DP-C.20.E.21) 47683911 27/02/2015

55.17 [55.DTC] / 763

Electrical systems - FAULT CODES

Wiring harnesses - Electrical schematic sheet 10 Cab to Chassis Interface (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 15 Std Aux Hydraulics (55.100.DP-C.20.E.15)

47683911 27/02/2015

55.17 [55.DTC] / 764

Electrical systems - FAULT CODES

5504-Bucket Valve Spool Sensor Open Or Shorted To Ground WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the bucket spool position sensor signal has failed. Diagnostic Trouble Code 5504 - Bucket Valve Spool Sensor Open Or Shorted To Ground has an error priority of Amber. Bucket functions will operate in limp home mode while Diagnostic Trouble Code 5504 - Bucket Valve Spool Sensor Open Or Shorted To Ground is active. Cause: The UCM has sensed that the bucket spool position sensor signal, CN3B pin 12 has failed. The fault is active when the engine is ON and the loader position sensor signal is less than 0.2 V. Possible failure modes: 1. The spool is sticking inside the valve body. 2. Improper wiring in the circuit. Connector X-25 is swapped with connector X-26. 3. A failure of the bucket spool position sensor. 4. A faulty UCM. Solution: 1. Verify that the spool is not stuck in the valve. Turn the ignition switch OFF. Remove the bucket spool position sensor from the valve body. Turn the ignition switch ON. Access EST and monitor the spool position. Move the pintle arm while monitoring the valve position sensor signal. The value should change linearly and not become erratic. A. The sensor values change in a linear fashion. The problem is in the valve body. Repair or replace the valve or spool as required. B. The fault sensor values did not change in a linear fashion. The problem is in the sensor circuit. Go to step 2. 2. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5504 - Bucket Valve Spool Sensor Open Or Shorted To Ground is recorded again. Go to step 3. 3. Verify that the wiring and connectors are free of damage. Inspect the UCM and the bucket spool position sensor connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the bucket spool position sensor. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 4.

47683911 27/02/2015

55.17 [55.DTC] / 765

Electrical systems - FAULT CODES

B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 2 to confirm elimination of fault. 4. Measure the voltage at the sensor. Disconnect the bucket spool position sensor. Turn the ignition switch ON. Measure the voltage between X-22 pin 1 and X-22 pin 3. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 5 V. Go to step 5. B. The voltage is less the 4.5 V. There is a problem in the supply voltage to the sensor. Check UCM connector CN1A pin 8. Verify the chassis ground connection from connector X-10 is tight and secure. Repair or replace the harness as required. Return to step 2 to confirm elimination of fault. 5. Test the UCM. Turn the ignition switch OFF. Disconnect the bucket spool position sensor from the harness. Fabricate a jumper wire that will connect between X-22 pin 1 and X-22 pin 4. Connect the jumper between X-22 pin 1 and X-22 pin 4. Turn the ignition switch ON. Monitor the EST fault code screen. Fault code 5505 - Bucket Valve Spool Sensor Shorted To Power should be active. A. Fault code 5504 - Bucket Valve Spool Sensor Open Or Shorted To Ground is active while the sensor is disconnected. Fault code 5505 - Bucket Valve Spool Sensor Shorted To Power is active while the jumper wire is installed. Temporarily replace the bucket spool position sensor and retest. Return to step 2 to confirm elimination of the fault. B. Fault code 5505 - Bucket Valve Spool Sensor Shorted To Power is not active while the jumper wire is installed. Fault code 5504 - Bucket Valve Spool Sensor Open Or Shorted To Ground is still active. Temporarily replace the UCM and retest. Return to step 2 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 766

Electrical systems - FAULT CODES

5505-Bucket Valve Spool Sensor Shorted To Power WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed a higher than normal voltage on the bucket spool position sensor. Diagnostic Trouble Code 5505 - Bucket Valve Spool Sensor Shorted To Power has an error priority of Amber. Implement functions will operate in limp home mode while Diagnostic Trouble Code 5505 - Bucket Valve Spool Sensor Shorted To Power is active. Cause: The UCM has sensed a higher than normal voltage on the bucket spool position sensor. The fault is active when the ignition is ON and the bucket spool position sensor voltage is high. Possible failure modes: 1. A short circuit in the wiring. 2. A failure of the bucket spool position sensor. 3. The UCM has internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5505 - Bucket Valve Spool Sensor Shorted To Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and bucket spool position sensor connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the bucket spool position sensor. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the sensor. Disconnect the bucket spool position sensor. Turn the ignition switch ON. Measure the voltage between X-21 pin 1 and X-21 pin 3. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 5 V. Go to step 4. B. The voltage is less the 4.5 V. There is a problem in the supply voltage to the sensor. Check UCM connector CN1A pin 8. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the voltage of the signal wire. Disconnect UCM connector CN3B. 47683911 27/02/2015

55.17 [55.DTC] / 767

Electrical systems - FAULT CODES

Disconnect the bucket spool position sensor from the harness. Turn the ignition switch ON. Measure the voltage between CN3B pin 12 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 5. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance of the signal wire. Turn the ignition switch OFF. Fabricate a jumper wire that will connect between connector CN3B pin 12 and chassis ground. Connect the jumper wire between connector CN3B pin 12 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-21 pin 4 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 6. Test the UCM. Reconnect UCM connector CN3B. Fabricate a jumper wire that will connect between X-21 pin 3 and X-21 pin 4. Connect the jumper wire between connector X-21 pin 3 and X-21 pin 4. Turn the ignition switch ON and monitor the active fault screen. Fault code 5504 - Bucket Valve Spool Sensor Open Or Shorted To Ground should become active. Fault code 5505 - Bucket Valve Spool Sensor Shorted To Power should no longer be active. A. Fault code 5504 - Bucket Valve Spool Sensor Open Or Shorted To Ground is active and fault code 5505 - Bucket Valve Spool Sensor Shorted To Power is no longer active. Temporarily replace the bucket spool position sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5505 - Bucket Valve Spool Sensor Shorted To Power is still active. Fault code 5504 - Bucket Valve Spool Sensor Open Or Shorted To Ground is not active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 768

Electrical systems - FAULT CODES

5507-Auxiliary Valve Spool Sensor Open Or Shorted To Ground WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the auxiliary spool position sensor signal has failed low. Diagnostic Trouble Code 5507 Auxiliary Valve Spool Sensor Open Or Shorted To Ground has an error priority of White. The auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5507 - Auxiliary Valve Spool Sensor Open Or Shorted To Ground is active. Cause: The UCM has sensed that the auxiliary spool position sensor signal, CN3B pin 14 has failed low. The fault is active while the engine is ON and the auxiliary spool position sensor signal is less than 0.2 V. Possible failure modes: 1. A short circuit in the wiring. 2. An open circuit in the wiring. 3. The auxiliary spool position sensor has failed. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5507 - Auxiliary Valve Spool Sensor Open Or Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the auxiliary spool position sensor connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the auxiliary spool position sensor. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of the fault. 3. Measure the voltage at the sensor. Disconnect the auxiliary spool position sensor. Turn the ignition switch ON. Measure the voltage between X-23 pin 1 and X-23 pin 3. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 5 V. Go to step 4. B. The voltage is less the 4.5 V. There is a problem in the supply voltage to the sensor. Check UCM connector CN1A pin 8. Verify the chassis ground connection from X-10 is secure. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 47683911 27/02/2015

55.17 [55.DTC] / 769

Electrical systems - FAULT CODES

4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector CN3B. Disconnect the auxiliary spool position sensor from the harness. Measure the resistance between CN3B pin 14 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Go to step 5. B. The resistance is less than 20,000 Ω. There is a short circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Turn the ignition switch OFF. Fabricate a jumper wire that will connect between CN3B pin 14 and chassis ground. Connect the jumper wire between CN3B pin 14 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-23 pin 4 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 6. Test the UCM. Reconnect UCM connector CN3B. Fabricate a jumper wire that will connect between X-23 pin 1 and X-23 pin 4. Connect the jumper wire between X-23 pin 1 and X-23 pin 4. Turn the ignition switch ON and monitor the active fault screen. Fault code 5508 - Auxiliary Valve Spool Sensor Shorted To Power should become active. Fault code 5507 - Auxiliary Valve Spool Sensor Open Or Shorted To Ground should no longer be active. A. Fault code 5508 - Auxiliary Valve Spool Sensor Shorted To Power is active. Fault code 5507 - Auxiliary Valve Spool Sensor Open Or Shorted To Ground is no longer active. Temporarily replace the auxiliary spool position sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5507 - Auxiliary Valve Spool Sensor Open Or Shorted To Ground is still active. Fault code 5508 - Auxiliary Valve Spool Sensor Shorted To Power is not active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 770

Electrical systems - FAULT CODES

5508-Auxiliary Valve Spool Sensor Shorted To Power WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed a higher than normal voltage on the auxiliary spool position sensor input. Diagnostic Trouble Code 5508 - Auxiliary Valve Spool Sensor Shorted To Power has an error priority of White. The auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5508 - Auxiliary Valve Spool Sensor Shorted To Power is active. Cause: The UCM has sensed a higher than normal voltage on the auxiliary valve spool input, CN3B pin 14. The fault is active while the ignition is ON and the auxiliary position sensor signal is greater than 4.8 V. Possible failure modes: 1. The signal wire is shorted to another voltage source. 2. A failure of the auxiliary spool position sensor. 3. The UCM has internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5508 - Auxiliary Valve Spool Sensor Shorted To Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the auxiliary spool position sensor connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the auxiliary spool position sensor. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of the fault. 3. Measure the voltage at the sensor. Disconnect the auxiliary spool position sensor. Turn the ignition switch ON. Measure the voltage between X-23 pin 1 and X-23 pin 3. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 5 V. Go to step 4. B. The voltage is less the 4.5 V. There is a problem in the supply voltage to the sensor. Check UCM connector CN1A pin 8. Verify the chassis ground connection from connector X-10 is secure. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the voltage on the signal wire.

47683911 27/02/2015

55.17 [55.DTC] / 771

Electrical systems - FAULT CODES

Disconnect UCM connector CN3B. Disconnect the auxiliary spool position sensor from the harness. Turn the ignition switch ON. Measure the voltage between CN3B pin 14 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 5. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the signal wire. Turn the ignition switch OFF. Fabricate a jumper wire that will connect between connector CN3B pin 14 and chassis ground. Connect the jumper wire between connector CN3B pin 14 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-23 pin 4 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 6. Test the UCM. Reconnect UCM connector CN3B. Fabricate a jumper wire that will connect between X-23 pin 3 and X-23 pin 4. Connect the jumper wire between X-23 pin 3 and X-23 pin 4. Turn the ignition switch ON and monitor the active fault screen. Fault code 5507 - Auxiliary Valve Spool Sensor Open Or Shorted To Ground should become active. Fault code 5508 - Auxiliary Valve Spool Sensor Shorted To Power should no longer be active. A. Fault code 5507 - Auxiliary Valve Spool Sensor Open Or Shorted To Ground is active. Fault code 5508 Auxiliary Valve Spool Sensor Shorted To Power is no longer active. Temporarily replace the auxiliary spool position sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5508 - Auxiliary Valve Spool Sensor Shorted To Power is still active. Fault code 5507 - Auxiliary Valve Spool Sensor Open Or Shorted To Ground is not active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 772

Electrical systems - FAULT CODES

5511-Implausible Loader Arm Sensor State Vs Loader Arm Command - Stuck Spool Or PRV WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the loader arm position sensor does not agree with the direction of travel for the loader arm the command. Diagnostic Trouble Code 5511 - Implausible Loader Arm Sensor State Vs Loader Arm Command - Stuck Spool Or PRV has an error priority of Red. The loader hydraulics are disabled while Diagnostic Trouble Code 5511 - Implausible Loader Arm Sensor State Vs Loader Arm Command - Stuck Spool Or PRV is active. Cause: The UCM has sensed that the loader arm position sensor does not agree with the direction of travel for the loader arm the command. The fault is active while the engine is ON and the loader arm position sensor senses the loader arm movement but the solenoids are not energized or the loader arm movement is opposite of the energized solenoid. Possible failure modes: 1. Improper wiring in the circuit. Connector X-28 is swapped with connector X-27. 2. The spool is sticking inside the valve body. 3. A failure of the boom spool position sensor. 4. A faulty UCM. Solution: 1. Verify that the spool is not stuck in the valve. Turn the ignition switch OFF. Remove the boom spool position sensor from the valve body. Turn the ignition switch ON. Access EST and monitor the spool position. Move the pintle arm while monitoring the valve position sensor signal. The value should change linearly and not become erratic. A. The sensor value changes in a linear fashion. The problem is in the valve body. Repair or replace the valve or the spool as required. Return to step 2 to confirm elimination of the fault. B. The sensor values did not change in a linear fashion. The problem is in the sensor circuit. Go to step 2. 2. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5511 - Implausible Loader Arm Sensor State Vs Loader Arm Command - Stuck Spool Or PRV is recorded again. Go to step 3. 3. Verify that the wiring and connectors are free of damage. Inspect the UCM, the loader valve solenoids, and the boom spool position sensor connections. All connections should be secure, tight, free of corrosion, abrasion, and damage.

47683911 27/02/2015

55.17 [55.DTC] / 773

Electrical systems - FAULT CODES

Inspect the harness from the UCM to the loader valve solenoids, and the boom spool position sensor connections. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment.

20111502

Legend (1) (2)

Boom / Loader Extend Boom / Loader Retract

(3)

Boom / Loader Position Sensor

A. The connectors are secure and the harness is free of damage. Go to step 4. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 2 to confirm elimination of fault. 4. Measure the voltage at the sensor. Disconnect the boom spool position sensor. Turn the ignition switch ON. Measure the voltage between X-22 pin 1 and X-22 pin 3. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 5 V. Go to step 5. B. The voltage is less the 4.5 V. There is a problem in the supply voltage to the sensor. Check UCM connector CN1A pin 8. Verify the chassis ground connection from connector X-10 is tight and secure. Repair or replace the harness as required. Return to step 2 to confirm elimination of fault. 5. Test the UCM. Turn the ignition switch OFF. Disconnect the boom spool position sensor from the harness. Turn the ignition switch ON. Monitor the EST fault code screen. Fault code 5511 - Implausible Loader Arm Sensor State Vs Loader Arm Command - Stuck Spool Or PRV should be active. Use a jumper wire to short X-22 pin 1 to X-22 pin 4. Fault code 5502 - Loader Arm Spool Sensor Shorted To Power should be active. Fault code 5511 - Implausible Loader Arm Sensor State Vs Loader Arm Command - Stuck Spool Or PRV should no longer be active. A. Fault code 5511 - Implausible Loader Arm Sensor State Vs Loader Arm Command - Stuck Spool Or PRV is active while the sensor is disconnected and fault code 5502 - Loader Arm Spool Sensor Shorted To Power is active while the X-22 pin 1 is shorted to X-22 pin 4. Temporarily replace the boom spool position sensor and retest. Return to step 2 to confirm elimination of the fault. B. Fault code 5502 - Loader Arm Spool Sensor Shorted To Power is not active while X-22 pin 1 is shorted to X-22 pin 4. Temporarily replace the UCM and retest. Return to step 2 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 774

Electrical systems - FAULT CODES

5512-Implausible Bucket Sensor State Vs Loader Bucket Command - Stuck Spool Or PRV WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the bucket spool position sensor does not agree with the direction of bucket travel. Diagnostic Trouble Code 5512 - Implausible Bucket Sensor State Vs Loader Bucket Command - Stuck Spool Or PRV has an error priority of Red. The loader hydraulics are disabled while Diagnostic Trouble Code 5512 - Implausible Bucket Sensor State Vs Loader Bucket Command - Stuck Spool Or PRV. Cause: The UCM has sensed that the bucket spool position sensor does not agree with the direction of bucket travel. The fault is active while the engine is ON and the bucket spool position sensor senses the bucket movement but the solenoids are not energized or bucket movement is opposite of the energized solenoid. Possible failure modes: 1. Improper wiring in circuit. Connector X-25 swapped with connector X-26. 2. The spool is sticking inside the valve body. 3. A failure of bucket spool position sensor. 4. A faulty UCM. Solution: 1. Verify that the spool is not stuck in the valve. Turn the ignition switch OFF. Remove the bucket spool position sensor from the valve body. Turn the ignition switch ON. Access EST and monitor the spool position. Move the pintle arm while monitoring the valve position sensor signal. The value should change linearly and not become erratic. A. The sensor value changes in a linear fashion. The problem is in the valve body. Repair or replace the valve or spool as required. Return to step 2 to confirm elimination of the fault. B. The sensor values did not change in a linear fashion. The problem is in the sensor circuit. Go to step 2. 2. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5512 - Implausible Bucket Sensor State Vs Loader Bucket Command - Stuck Spool Or PRV is recorded again. Go to step 3. 3. Verify that the wiring and connectors are free of damage. Inspect the UCM, the bucket valve solenoids, and the bucket spool position sensor connections. All connections should be secure, tight, free of corrosion, abrasion, and damage.

47683911 27/02/2015

55.17 [55.DTC] / 775

Electrical systems - FAULT CODES

Inspect the harness from the UCM to the bucket valve solenoids, and the bucket spool position sensor connections. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment.

20111502

Legend (1) (2)

Bucket Position Sensor Bucket Valve Retract

(3) (4)

Boom Position Sensor Aux Position Sensor

A. The connectors are secure and the harness is free of damage. The bucket Valve Spools are connected properly. Go to step 4. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 2 to confirm elimination of fault. 4. Measure the voltage at the sensor. Disconnect the bucket spool position sensor. Turn the ignition switch ON. Measure the voltage between X-21 pin 1 and X-21 pin 3. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 5 V. Go to step 5. B. The voltage is less the 4.5 V. There is a problem in the supply voltage to the sensor. Check UCM connector CN1A pin 8. Repair or replace the harness as required. Return to step 2 to confirm elimination of fault. 5. Test the UCM. Turn the ignition switch OFF. Disconnect the bucket spool position sensor from the harness. Turn the ignition switch ON. Monitor the EST fault code screen. Fault code 5512 - Implausible Bucket Sensor State Vs Loader Bucket Command - Stuck Spool Or PRV should be active. Use a jumper wire to connect X-21 pin 1 to X-21 pin 4. Fault code 5505 - Bucket Valve Spool Sensor Shorted To Power should be active. A. Fault code 5512 - Implausible Bucket Sensor State Vs Loader Bucket Command - Stuck Spool Or PRV is active while the sensor is disconnected and fault code 5505 - Bucket Valve Spool Sensor Shorted To Power is active while the X-21 pin 1 is shorted to X-21 pin 4. Temporarily replace the bucket spool position sensor and retest. Return to step 2 to confirm elimination of the fault. B. Fault code 5512 - Implausible Bucket Sensor State Vs Loader Bucket Command - Stuck Spool Or PRV is not active while the X-21 pin 1 is shorted to X-21 pin 4. Temporarily replace the UCM and retest. Return to step 2 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 776

Electrical systems - FAULT CODES

5513-Implausible Auxiliary Sensor State Vs Auxiliary Command Stuck Spool Or PRV WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the auxiliary position sensor does not agree with the direction of travel for the auxiliary valve command. Diagnostic Trouble Code 5513 - Implausible Auxiliary Sensor State Vs Auxiliary Command Stuck Spool Or PRV has an error priority of Red. The loader hydraulics are disabled while Diagnostic Trouble Code 5513 - Implausible Auxiliary Sensor State Vs Auxiliary Command - Stuck Spool Or PRV is active. Cause: The UCM has sensed that the auxiliary spool position sensor does not agree with the direction of travel for the auxiliary valve command. The fault is active when the engine is ON and the auxiliary spool position sensor senses movement but the solenoids are not energized or the auxiliary spool movement is opposite of the energized solenoid. Possible failure modes: 1. Improper wiring in the circuit. Connector X-29 is swapped with connector X-24. 2. The spool is sticking inside the valve body. 3. A failure of the auxiliary spool position sensor. 4. A faulty UCM. Solution: 1. Verify that the spool is not stuck in the valve. Turn the ignition switch OFF. Remove the auxiliary spool position sensor from the valve body. Turn the ignition switch ON. Access EST and monitor the spool position. Move the pintle arm while monitoring the valve position sensor signal. The value should change linearly and not become erratic. A. The sensor values change in a linear fashion. The problem is in the valve body. Repair or replace the valve or the spool as required. Return to step 2 to confirm elimination of the fault. B. The sensor values did not change in a linear fashion. The problem is in the sensor circuit. Go to step 2. 2. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5513 - Implausible Auxiliary Sensor State Vs Auxiliary Command - Stuck Spool Or PRV is recorded again. Go to step 3. 3. Verify that the wiring and connectors are free of damage. Inspect the UCM, the proportional aux solenoid connections, and the auxiliary spool position sensor connections. All connections should be secure, tight, free of corrosion, abrasion, and damage.

47683911 27/02/2015

55.17 [55.DTC] / 777

Electrical systems - FAULT CODES

Inspect the harness from the UCM to the proportional aux solenoids, and the auxiliary spool position sensor. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment.

20111502

Legend (1) (2)

Aux Valve Retract Aux Position Sensor

(3) (4)

Bucket Position Sensor Boom Position Sensor

A. The connectors are secure and the harness is free of damage. Go to step 4. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 2 to confirm elimination of fault. 4. Measure the voltage at the sensor. Disconnect the auxiliary spool position sensor. Turn the ignition switch ON. Measure the voltage between X-23 pin 1 and X-23 pin 3. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 5 V. Go to step 5. B. The voltage is less the 4.5 V. There is a problem in the supply voltage to the sensor. Check UCM connector X-CN1A pin 8. Verify the chassis ground connection from connector X-10 is tight and secure. Repair or replace the harness as required. Return to step 2 to confirm elimination of fault. 5. Test the UCM. Turn the ignition switch OFF. Disconnect the auxiliary spool position sensor from the harness. Turn the ignition switch ON. Monitor the EST fault code screen. Fault code 5513 - Implausible Auxiliary Sensor State Vs Auxiliary Command - Stuck Spool Or PRV should be active. Use a jumper wire to short X-23 pin 1 to X-23 pin 4. Fault code 5508 - Auxiliary Valve Spool Sensor Shorted To Power should be active. A. Fault code 5513 - Implausible Auxiliary Sensor State Vs Auxiliary Command - Stuck Spool Or PRV is active while the sensor is disconnected and fault code 5508 - Auxiliary Valve Spool Sensor Shorted To Power is active while the X-23 pin 1 is shorted to X-23 pin 4. Temporarily replace the auxiliary spool position sensor and retest. Return to step 2 to confirm elimination of the fault. B. Fault code 5508 - Auxiliary Valve Spool Sensor Shorted To Power is not active while the X-23 pin 1 is shorted to X-23 pin 4. Temporarily replace the UCM and retest. Return to step 2 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 778

Electrical systems - FAULT CODES

5601-Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Power WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed a higher than normal voltage on the proportional aux solenoid lines. Fault code 5601 - Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Power has an error priority of White. The auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5601 - Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Power is active. Cause: The UCM has sensed a higher than normal voltage on the proportional aux solenoid lines, CN1A pin 24 or CN1B pin 33. The fault is active while the ignition is on, the hydraulics are disabled, and the solenoid voltage feedback is greater than 5 V. Possible failure modes: 1. A shorted wire in the circuit. 2. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5601 - Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the proportional aux solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the proportional aux solenoids. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the signal wires. Turn the ignition switch OFF. Disconnect UCM connectors CN1A and CN1B. Turn the ignition switch ON. Measure the voltage between CN1A pin 24 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. Measure the voltage between CN1A pin 22 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition.

47683911 27/02/2015

55.17 [55.DTC] / 779

Electrical systems - FAULT CODES

Measure the voltage between CN1B pin 33 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. A. All measured voltages are less than 0.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. One or more of the voltage measurements are greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 780

Electrical systems - FAULT CODES

5602-Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Ground WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the solenoid voltages are too low. Fault code 5602 - Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Ground has an error priority of White. Auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5602 - Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Ground is active. Cause: The UCM has sensed that the solenoid voltages are too low. The fault is active while the hydraulics are disabled and the solenoid voltages on pin CN1A pin 22 and CN1A pin 24 are less than 2 V. Possible failure modes: 1. A short circuit in the wiring. 2. Faulty proportional auxiliary valves. 3. A failure of the UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5602 - Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the proportional aux solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the proportional aux solenoids. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Test the UCM. Turn the ignition switch OFF. Disconnect solenoid connectors X-29 and X-24. Turn the ignition switch ON. Use the electronic service tool to access the fault code screen. Fault code 5602 - Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Ground should no longer be active. Fault code 5603 - Loader Auxiliary Valve (Directional) Solenoids Return Open Circuit is now active.

47683911 27/02/2015

55.17 [55.DTC] / 781

Electrical systems - FAULT CODES

A. Fault code 5602 - Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Ground is no longer active. Fault code 5603 - Loader Auxiliary Valve (Directional) Solenoids Return Open Circuit is now active. Replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5602 - Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Ground is active. Fault code 5603 - Loader Auxiliary Valve (Directional) Solenoids Return Open Circuit did not become active. Go to step 4. 4. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector CN1A and both solenoid connectors, X-29 and X-24. Measure the resistance between CN1A pin 24 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN1A pin 22 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN1A pin 24 and CN1A pin 22. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Leave UCM connector CN1A disconnected. Disconnect UCM connector CN1B. Measure the resistance between CN1B pin 33 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN1B pin 33 and CN1A pin 22. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN1B pin 33 and CN1A pin 24. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are greater than 20,000 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. One or more resistance measurements are less than 20,000 Ω. There is a short circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 782

Electrical systems - FAULT CODES

5603-Loader Auxiliary Valve (Directional) Solenoids Return Open Circuit WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed an open circuit in the proportional aux solenoid return circuit. Diagnostic Trouble Code 5603 Loader Auxiliary Valve (Directional) Solenoids Return Open Circuit has an error priority of White. The auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5603 - Loader Auxiliary Valve (Directional) Solenoids Return Open Circuit is active. Cause: The UCM has sensed an open circuit in the proportional aux solenoid return circuit, CN1A pin 22. The fault is active while the ignition is ON and the calculated solenoid resistances have increased over 70 %. Possible failure modes: 1. An open circuit in the solenoid wiring. 2. The proportional aux solenoids have failed. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5603 - Loader Auxiliary Valve (Directional) Solenoids Return Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the proportional aux solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the proportional aux solenoids. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connectors CN1A and CN1B. Measure the resistance between CN1A pin 24 and CN1A pin 22. The resistance should be less than 1,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN1B pin 33 and CN1A pin 22. The resistance should be less than 1,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 1,000 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 47683911 27/02/2015

55.17 [55.DTC] / 783

Electrical systems - FAULT CODES

B. One or both resistance are greater than 1,000 Ω. There is an open circuit in the wiring. Go to step 4. 4. Measure the solenoid resistance. Measure the resistance across the extend solenoid terminals, pin 1 and pin 2. The resistance should be less than 1,000 Ω. Measure the resistance across the retract solenoid terminals, pin 1 and pin 2. The resistance should be less than 1,000 Ω. A. The resistance is less than 1,000 Ω. Go to step 5. B. The resistance is greater than 1,000 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the circuit. Leave UCM connectors CN1A and CN1B disconnected. Fabricate a jumper wire that will connect between X-29 pin 1 and pin 2. Connect the jumper wire between X-29 pin 1 and X-29 pin 2. Measure the resistance between CN1A pin 24 and CN1A pin 22. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Remove the jumper from X-29. Connect the jumper wire between X-24 pin 1 and X-24 pin 2. Measure the resistance between CN1B pin 33 and CN1A pin 22. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 10 Ω. There is an open circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 11 Loader Valve and Sensors (55.100.DP-C.20.E.11)

47683911 27/02/2015

55.17 [55.DTC] / 784

Electrical systems - FAULT CODES

5701-Pattern Switch Open Or Shorted To Ground WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed the voltage at CN1B pin 15, CN2B pin 20, and CN2B pin 21 is less than 1.5 V. Diagnostic Trouble Code 5701 - Pattern Switch Open Or Shorted To Ground has an error priority of White. The selected joystick pattern is locked and cannot be changed while Diagnostic Trouble Code 5701 - Pattern Switch Open Or Shorted To Ground is active. Cause: The UCM has sensed the voltage at CN1B pin 15, CN2B pin 20, and CN2B pin 21 is less than 1.5 V. Possible failure modes: 1. A short circuit in the wiring 2. An open circuit in the wiring. 3. A faulty drive pattern select switch. 4. The UCM has internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5701 - Pattern Switch Open Or Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the drive pattern selector switch connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the drive pattern selector switch. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the switch. Turn the ignition switch OFF. Remove the drive pattern switch (ISO/ H pattern) from the right hand post. Turn the ignition switch ON. Measure the voltage between X-95 pin 5 and chassis ground. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 12 V. Go to step 4. B. The voltage is less than 10 V. There is a problem in the battery supply to the switch. Repair as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. 47683911 27/02/2015

55.17 [55.DTC] / 785

Electrical systems - FAULT CODES

Turn the ignition switch OFF. Disconnect UCM connectors CN1B and CN2B. Disconnect the drive pattern (ISO/ H Pattern) selector switch. Measure the resistance between X-95 pin 1 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-95 pin 3 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-95 pin 6 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Go to step 5. B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance of the signal wire. Fabricate a jumper wire the will connect between connector CN2B pin 20 and chassis ground. Connect the jumper wire between connector CN2B pin 20 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-95 pin 1 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect the jumper wire between connector CN2B pin 21 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-95 pin 6 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect the jumper wire between connector CN1B pin 15 and the chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-95 pin 3 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 6. Test the drive pattern (ISO/ H pattern) switch. Turn the ignition switch OFF. Remove the drive pattern (ISO/ H pattern) switch from the right hand post. Measure the resistance between pin 5 and pin 3 on the drive pattern (ISO/ H pattern) switch. The resistance should be less than 10 Ω. Actuate the switch to another function. The resistance should be greater than 20,000 Ω. A. The resistance is less than 10 Ω in the neutral state and the resistance changed to a value greater than 20,000 Ω when the switch was actuated. Go to step 7. B. The resistance is not less than 10 Ω in the neutral state or the resistance did not change to a value greater than 20,000 Ω when the switch was actuated. Temporarily replace the drive pattern (ISO/ H pattern) switch and retest. Return to step 1 to confirm elimination of fault. 7. Test the drive pattern (ISO/ H pattern) switch.

47683911 27/02/2015

55.17 [55.DTC] / 786

Electrical systems - FAULT CODES

Measure the resistance between pin 5 and pin 1 on the drive pattern (ISO/ H pattern) switch. The resistance should be greater than 20,000 Ω. Actuate the switch to the H pattern. The resistance should be less than 10 Ω. Measure the resistance between pin 5 and pin 6 on the drive pattern (ISO/ H pattern) switch. The resistance should be greater than 20,000 Ω. Actuate the switch to the ISO Pattern. The resistance should be less than 10 Ω. A. The resistance is greater than 20,000 Ω when the switch is in the neutral state and the resistance changed to a value less than 10 Ω when the switch was actuated. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 20,000 Ω while the switch is in the neutral state or the resistance did not change to a value less than 10 Ω when the switch was actuated. Temporarily replace the drive pattern (ISO/ H pattern) switch and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 13 Cab to Chassis Interface (55.100.DP-C.20.E.13) Wiring harnesses - Electrical schematic sheet 15 Cab Console Switches (55.100.DP-C.20.E.15)

47683911 27/02/2015

55.17 [55.DTC] / 787

Electrical systems - FAULT CODES

5703-Pattern Switch Shorted To Power WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed the voltage at two or more drive pattern selector (ISO/ H pattern) switch pins, CN1B pin 15, CN2B pin 20, or CN2B pin 21 is greater than 3.5 V. Diagnostic Trouble Code 5703 - Pattern Switch Shorted To Power has an error priority of White. The selected joystick pattern is locked and cannot be changed while Diagnostic Trouble Code 5703 - Pattern Switch Shorted To Power is active. Cause: The UCM has sensed the voltage at two or more drive pattern selector (ISO/ H pattern) switch pins, CN1B pin 15, CN2B pin 20, or CN2B pin 21 is greater than 3.5 V. Possible failure modes: 1. A short circuit in the wiring. 2. A faulty drive pattern selector (ISO/ H pattern) switch. 3. The UCM has internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5703 - Pattern Switch Shorted To Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the drive pattern selector switch connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the drive pattern selector switch. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the switch inputs to the UCM. Turn the ignition switch OFF. Remove the drive pattern switch (ISO/ H pattern) from the right-hand post. Disconnect connector X-95 from the drive pattern selector switch. Disconnect UCM connectors CN1B and CN2B from the UCM. Turn the ignition switch ON. Measure the voltage between X-95 pin 1 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition.

47683911 27/02/2015

55.17 [55.DTC] / 788

Electrical systems - FAULT CODES

Measure the voltage between X-95 pin 3 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-95 pin 6 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V, there is a short circuit to another voltage source. Check for a short to battery supply on X-95 pin 5. Repair as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire. Fabricate a jumper wire that will connect between connector CN2B pin 20 and chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-95 pin 1 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect one end of the jumper wire to connector CN2B pin 21 and the other end to chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-95 pin 6 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect one end the jumper wire between connector CN1B pin 15 and chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-95 pin 3 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 5. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Test the drive pattern (ISO/ H pattern) switch. Turn the ignition switch OFF. Remove the drive pattern (ISO/ H pattern) switch from the right-hand post. Use a pair of jumper wires with alligator clips to connect the DVM to the switch. Measure the resistance between pin 5 and pin 3 on the drive pattern (ISO/ H pattern) switch. The resistance should be less than 10 Ω. Actuate the switch to the other function. The resistance should change to a value greater than 20,000 Ω. A. The resistance is less than 10 Ω in the neutral state and the resistance changed to a value greater than 20,000 Ω when the switch was actuated. Go to step 6. B. The resistance is not less than 10 Ω in the neutral state or the resistance did not change to a value greater than 20,000 Ω when the switch was actuated. Temporarily replace the drive pattern (ISO/ H pattern) switch and retest. Return to step 1 to confirm elimination of fault. 6. Test the drive pattern (ISO/ H pattern) switch. Use a pair of jumper wires with alligator clips to connect the DVM to the switch. Measure the resistance between pin 5 and pin 1 on the drive pattern (ISO/ H pattern) switch. The resistance should be greater than 20,000 Ω. Actuate the switch to the H Pattern. The resistance should change to a value less than 10 Ω. Measure the resistance between pin 5 and pin 6 on the drive pattern (ISO/ H pattern) switch. The resistance should be greater than 20,000 Ω. 47683911 27/02/2015

55.17 [55.DTC] / 789

Electrical systems - FAULT CODES

Actuate the switch to the ISO Pattern. The resistance should change to a value less than 10 Ω. A. The resistance is greater than 20,000 Ω when the switch is in the neutral state and the resistance changed to a value less than 10 Ω when the switch was actuated. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 20,000 Ω while the switch is in the neutral state or the resistance did not change to a value less than 10 Ω when the switch was actuated. Temporarily replace the drive pattern (ISO/ H pattern) switch and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 13 Cab to Chassis Interface (55.100.DP-C.20.E.13) Wiring harnesses - Electrical schematic sheet 15 Cab Console Switches (55.100.DP-C.20.E.15)

47683911 27/02/2015

55.17 [55.DTC] / 790

Electrical systems - FAULT CODES

5811-Loader Port Lock Switch Is In An Implausible State WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed an implausible state of the loader lockout switch. Diagnostic Trouble Code 5811 - Loader Port Lock Switch Is In An Implausible State has an error priority of Amber. There are no restrictions while Diagnostic Trouble Code 5811 - Loader Port Lock Switch Is In An Implausible State is active. Cause: The UCM has sensed an implausible state on the loader lockout switch. The fault is active when the engine is running and both UCM inputs CN2B pin 23 and CN3B pin 19, are less than 1.5 V or greater than 3.5 V. Possible failure modes: 1. Faulty wiring or connectors. 2. A faulty loader lockout switch. 3. A faulty UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5811 - Loader Port Lock Switch Is In An Implausible State is recorded again. Go to step 2. 2. Verify the harness and connectors are not damaged. Inspect the UCM and loader lockout switch connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader lockout switch. Verify that the harness is free of damage, corrosion, abrasion, or incorrect attachment. A. The wiring is free of corrosion, damage, abrasion, and incorrect attachment. Go to step 3. B. The wiring is not free of corrosion, damage, abrasion, or incorrect attachment. Repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 3. Measure the voltage at the switch. Turn the ignition switch OFF. Disconnect the loader lockout switch connector X-306. Turn the ignition switch ON. Measure the voltage between X-306 pin B and chassis ground. The voltage should be approximately 12 V. Wiggle the harness to reveal an intermittent condition. A. The voltage is approximately 12 V. Go to step 3. B. The voltage is less than 10 V. There is a problem with the battery supply to the switch. Check the fuses. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. 47683911 27/02/2015

55.17 [55.DTC] / 791

Electrical systems - FAULT CODES

Turn the ignition switch OFF. Disconnect the loader lockout switch. Fabricate a jumper with that will connect between X-306 pin B and X-306 pin A. Connect the jumper between X-306 pin B and X-306 pin A. Turn the ignition switch ON. Monitor the fault code screen. Fault code 5811 - Loader Port Lock Switch Is In An Implausible State should no longer be active. Use the EST to monitor the loader lockout switch status. The switch status should change from OFF to ON. Turn the ignition switch OFF. Connect the jumper between X-306 pin B and X-306 pin C. Turn the ignition switch ON. Monitor the fault code screen. Fault code 5811 - Loader Port Lock Switch Is In An Implausible State should no longer be active. Use the EST to monitor the loader lockout switch status. The switch status should change from ON to OFF. A. The switch status displayed ON when the jumper was connected between X-306 pin B and X-306 pin A. The switch status displayed OFF when the jumper was not connected between X-306 pin B and X-306 pin C. Replace the loader lockout switch and retest. Return to step 1 to confirm elimination of the fault. B. The switch status did not change or fault code 5811 - Loader Port Lock Switch Is In An Implausible State remained active. Go to step 5. 5. Measure the resistance through the signal wires. Turn the ignition switch OFF. Use the jumper wire to connect X-306 pin A to X-306 pin C. Disconnect UCM connectors CN2B and CN3B. Measure the resistance between CN2B pin 23 and CN3B pin 19. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The measured resistance is less than 10 Ω. Go to step 6. B. The measured resistance is greater than 10 Ω. There is an open circuit in the wiring. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of the fault. 6. Measure the voltage on the signal wires. Remove the jumper wire connected between X-306 pin A and X-306 pin C. Turn the ignition switch ON. Measure the voltage between CN2B pin 23 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. Measure the voltage between CN3B pin 19 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. A. Both measured voltages are less than 0.5 V. Temporarily replace the UCM and retest. Return to step 6. B. One or both voltage measurements are greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) 47683911 27/02/2015

55.17 [55.DTC] / 792

Electrical systems - FAULT CODES

Wiring harnesses - Electrical schematic sheet 20 Unit Control Module (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 13 Cab to Chassis Interface (55.100.DP-C.20.E.13) Wiring harnesses - Electrical schematic sheet 15 Cab Console Switches (55.100.DP-C.20.E.15)

47683911 27/02/2015

55.17 [55.DTC] / 793

Electrical systems - FAULT CODES

9004-Memory Error - Triple Redundant - Hour Meter Location 1 Corrupt WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Cause: 1. An internal failure within the instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 9004 - Memory Error - Triple Redundant - Hour Meter Location 1 Corrupt is recorded again. Replace the instrument cluster. Return to step 1 to confirm elimination of the fault. B. The fault code is not recorded again. OK to return the machine to service.

47683911 27/02/2015

55.17 [55.DTC] / 794

Electrical systems - FAULT CODES

9005-Memory Error - Triple Redundant - Hour Meter Location 2 Corrupt WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: Diagnostic Trouble Code 9005 has an error priority of White. There are no restrictions with Diagnostic Trouble Code 9005. Cause: 1. Internal failure within the instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 9005 - Memory Error - Triple Redundant - Hour Meter Location 2 Corrupt is recorded again. Replace the instrument cluster. Return to step 1 to confirm elimination of the fault. B. The fault code is not recorded again. OK to return the machine to service.

47683911 27/02/2015

55.17 [55.DTC] / 795

Electrical systems - FAULT CODES

9006-Memory Error - Triple Redundant - Hour Meter Location 3 Corrupt WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: Diagnostic Trouble Code 9006 has an error priority of White. There are no restrictions with Diagnostic Trouble Code 9006. Cause: 1. Internal failure within the instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 9006 - Memory Error - Triple Redundant: Hour Meter - Location 3 Corrupt is recorded again. Replace the instrument cluster. Return to step 1 to confirm elimination of the fault. B. The fault code is not recorded again. OK to return the machine to service.

47683911 27/02/2015

55.17 [55.DTC] / 796

Electrical systems - FAULT CODES

9151-Bus-Warn at CAN-Bus No.1 WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: CAN bus communications between the modules on the data link have been lost. This fault code may be displayed with other CAN bus fault code messages. Cause: CAN bus communications between the modules on the data link have been lost. Possible failure modes: 1. An open circuit in the CAN data link wiring. 2. A short circuit in the CAN data link wiring. 3. A faulty device on the CAN data link. 4. A faulty instrument cluster. 5. A faulty ECU. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 9151 - Bus-Warn at CAN-Bus No.1 is not recorded again. Go to step 2. B. Fault code 9151 - Bus-Warn at CAN-Bus No.1 is recorded again. There are one or two other CAN bus fault codes associated with 9151 - Bus-Warn at CAN-Bus No.1. Go to step 2. C. Fault code 9151 - Bus-Warn at CAN-Bus No.1 is recorded along with multiple CAN data link faults such as 1051 - Timeout of CAN message EEC1 - 1063 - Timeout of CAN message EEC2, and/or 3096 - CAN A Bus off failure, 3179 - CAN communication failure between vehicle controller and ECU - BC2ECU2 message and 3180 - CAN communication error between vehicle controller to ECU. Go to 1051-No CAN Communication With Engine Controller (55.640) step 3. 2. Verify that the CAN bus circuit is functioning properly. Connect the Electronic Service Tool to the service tool connector. Turn the ignition switch ON. Verify the connections to the ECU, the instrument cluster, the diagnostic connector, the UCM (if installed), and the optional Telematics unit are tight and secure. Check for CAN bus fault codes while wiggling the harness. Turn the ignition switch OFF. Disconnect the instrument cluster connector X-C23-EH. Measure the resistance between X-C23-EH pin 5 and X-C23-EH pin 6 on the instrument cluster. The resistance should be between 108 Ω and 132 Ω. Disconnect the ECU connector X-012. Measure the resistance between X-012 pin 24 and X-012 pin 25 on the ECU. The resistance should be between 108 Ω and 132 Ω. A. All connections are secure. Both resistance measurements are within the specified range. OK to return the machine to service. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of the fault. 47683911 27/02/2015

55.17 [55.DTC] / 797

Electrical systems - FAULT CODES

C. One or both resistance measurements are less than 108 Ω or greater than 132 Ω. Replace the control module that has the bad resistance value. Return to step 1 to confirm elimination of fault.

47683911 27/02/2015

55.17 [55.DTC] / 798

Electrical systems - FAULT CODES

9152-Bus-Warn at CAN-Bus No.1 WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: CAN bus communications between the modules on the data link have been lost. This fault code may be displayed with other CAN bus fault code messages. Cause: CAN bus communications between the modules on the data link have been lost. Possible failure modes: 1. An open circuit in the CAN data link wiring. 2. A short circuit in the CAN data link wiring. 3. A faulty device on the CAN data link. 4. A faulty instrument cluster. 5. A faulty ECU. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 9152 - Bus-Warn at CAN-Bus No.1 is not recorded again. Go to step 2. B. Fault code 9152 - Bus-Warn at CAN-Bus No.1 is recorded again. There are one or two other CAN bus fault codes associated with 9151 - Bus-Warn at CAN-Bus No.1. Go to step 2. C. Fault code 9152 - Bus-Warn at CAN-Bus No.1 is recorded along with multiple CAN data link faults such as 1051 - Timeout of CAN message EEC1 - 1063 - Timeout of CAN message EEC2, and/or 3096 - CAN A Bus off failure, 3179 - CAN communication failure between vehicle controller and ECU - BC2ECU2 message and 3180 - CAN communication error between vehicle controller to ECU. Go to 1051-No CAN Communication With Engine Controller (55.640) step 3. 2. Verify that the CAN bus circuit is functioning properly. Connect the Electronic Service Tool to the service tool connector. Turn the ignition switch ON. Verify the connections to the ECU, the instrument cluster, the diagnostic connector, the UCM (if installed), and the optional Telematics unit are tight and secure. Check for CAN bus fault codes while wiggling the harness. Turn the ignition switch OFF. Disconnect the instrument cluster connector X-C23-EH. Measure the resistance between X-C23-EH pin 5 and X-C23-EH pin 6 on the instrument cluster. The resistance should be between 108 Ω and 132 Ω. Disconnect the ECU connector X-012. Measure the resistance between X-012 pin 24 and X-012 pin 25 on the ECU. The resistance should be between 108 Ω and 132 Ω. A. All connections are secure. Both resistance measurements are within the specified range. OK to return the machine to service. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of the fault. 47683911 27/02/2015

55.17 [55.DTC] / 799

Electrical systems - FAULT CODES

C. One or both resistance measurements are less than 108 Ω or greater than 132 Ω. Replace the control module that has the bad resistance value. Return to step 1 to confirm elimination of fault.

47683911 27/02/2015

55.17 [55.DTC] / 800

Electrical systems - FAULT CODES

9153-Timeout of CAN Message EEC1 WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: CAN bus communications between the modules on the data link have been lost. This fault code may be displayed with other CAN bus fault code messages. Cause: CAN bus communications between the modules on the data link have been lost. Possible failure modes: 1. A failed main relay. 2. An open circuit in the CAN data link wiring. 3. A short circuit in the CAN data link wiring. 4. A faulty device on the CAN data link. 5. A faulty instrument cluster. 6. A faulty ECU. Solution: 1. Check the main relay. Remove the main relay from the panel. Check the main relay for water intrusion. A. There are no signs of water intrusion in the main relay. Go to step 2. B. The main relay shows signs of water intrusion such as corrosion or water inside the relay. Replace the relay and retest. Return to step 3 to confirm elimination of the fault. 2. Use the EST to verify the controller status. Connect the EST to the service tool connector. Turn the ignition switch ON. Verify that the all of the controllers are ONLINE. A. The ECU status is OFFLINE and fault codes 9153 - Timeout of CAN Message EEC1 and 1051 - Timeout of CAN message EEC1 are active. Check the 2 A relay ground fuses. Replace the fuses as required. Verify that the fault codes are no longer active. If the fault code is still active, refer to 1051-No CAN Communication With Engine Controller (55.640). B. The ECU status is ONLINE. Go to step 3. 3. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 9153 - Timeout of CAN Message EEC1 is not recorded again. Go to step 4. B. Fault code 9153 - Timeout of CAN Message EEC1 is recorded again. There are one or two other CAN bus fault codes associated with 9151 - Bus-Warn at CAN-Bus No.1. Go to step 4. C. Fault code 9153 - Timeout of CAN Message EEC1 is recorded along with multiple CAN data link faults such as 1051 - Timeout of CAN message EEC1 - 1063 - Timeout of CAN message EEC2, and/or 3096 - CAN 47683911 27/02/2015

55.17 [55.DTC] / 801

Electrical systems - FAULT CODES

A Bus off failure, 3179 - CAN communication failure between vehicle controller and ECU - BC2ECU2 message and 3180 - CAN communication error between vehicle controller to ECU. Go to 1051-No CAN Communication With Engine Controller (55.640) step 3. 4. Verify that the CAN bus circuit is functioning properly. Connect the Electronic Service Tool to the service tool connector. Turn the ignition switch ON. Verify the connections to the ECU, the instrument cluster, the diagnostic connector, the UCM (if installed), and the optional Telematics unit are tight and secure. Check for CAN bus fault codes while wiggling the harness. Turn the ignition switch OFF. Disconnect the instrument cluster connector X-C23-EH. Measure the resistance between X-C23-EH pin 5 and X-C23-EH pin 6 on the instrument cluster. The resistance should be between 108 Ω and 132 Ω. Disconnect the ECU connector X-012. Measure the resistance between X-012 pin 24 and X-012 pin 25 on the ECU. The resistance should be between 108 Ω and 132 Ω. A. All connections are secure. Both resistance measurements are within the specified range. OK to return the machine to service. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 3 to confirm elimination of the fault. C. One or both resistance measurements are less than 108 Ω or greater than 132 Ω. Replace the control module that has the bad resistance value. Return to step 3 to confirm elimination of fault.

47683911 27/02/2015

55.17 [55.DTC] / 802

Electrical systems - FAULT CODES

9154-Timeout of CAN Message TSC1 WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: CAN bus communications between the modules on the data link have been lost. This fault code may be displayed with other CAN bus fault code messages. Cause: CAN bus communications between the modules on the data link have been lost. Possible failure modes: 1. An open circuit in the CAN data link wiring. 2. A short circuit in the CAN data link wiring. 3. A faulty device on the CAN data link. 4. A faulty instrument cluster. 5. A faulty ECU. Solution: 1. Use the EST to verify the controller status. Connect the EST to the service tool connector. Turn the ignition switch ON. Verify that the all of the controllers are ONLINE. A. The ECU status is OFFLINE and fault codes 9153 - Timeout of CAN Message EEC1 and 1051 - Timeout of CAN message EEC1 are active. Check the 2 A relay ground fuses. Replace the fuses as required. Verify that the fault codes are no longer active. If the fault code is still active, refer to 1051-No CAN Communication With Engine Controller (55.640) B. The ECU status is ONLINE. Go to step 2. 2. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 9154 - Timeout of CAN Message TSC1 is not recorded again. Go to step 3. B. Fault code 9154 - Timeout of CAN Message TSC1 is recorded again. There are one or two other CAN bus fault codes associated with 9154 - Timeout of CAN Message TSC1. Go to step 3. C. Fault code 9154 - Timeout of CAN Message TSC1 is recorded along with multiple CAN data link faults such as 1051 - Timeout of CAN message EEC1 - 1063 - Timeout of CAN message EEC2, and/or 3096 - CAN A Bus off failure, 3179 - Timeout of CAN Message BC2EDC2 and 3180 - Timeout of CAN Message VCM2EDC. Go to 1051-No CAN Communication With Engine Controller (55.640) step 3. 3. Verify that the CAN bus circuit is functioning properly. Connect the Electronic Service Tool to the service tool connector. Turn the ignition switch ON. Verify the connections to the ECU, the instrument cluster, the diagnostic connector, the UCM (if installed), and the optional Telematics unit are tight and secure. Check for CAN bus fault codes while wiggling the harness.

47683911 27/02/2015

55.17 [55.DTC] / 803

Electrical systems - FAULT CODES

Turn the ignition switch OFF. Disconnect the instrument cluster connector X-C23-EH. Measure the resistance between X-C23-EH pin 5 and X-C23-EH pin 6 on the instrument cluster. The resistance should be between 108 Ω and 132 Ω. Disconnect the ECU connector X-012. Measure the resistance between X-012 pin 24 and X-012 pin 25 on the ECU. The resistance should be between 108 Ω and 132 Ω. A. All connections are secure. Both resistance measurements are within the specified range. OK to return the machine to service. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 2 to confirm elimination of the fault. C. One or both resistance measurements are less than 108 Ω or greater than 132 Ω. Replace the control module that has the bad resistance value. Return to step 2 to confirm elimination of fault.

47683911 27/02/2015

55.17 [55.DTC] / 804

Electrical systems - FAULT CODES

9156-Hydraulic Enable Button Error From AIC WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: Diagnostic Trouble Code 9156 - Hydraulic Enable Button Error From AIC has an error priority of amber. Loader limp home and ground drive limp home operating modes are enabled while Diagnostic Trouble Code 9156 Hydraulic Enable Button Error From AIC is active. Cause: The UCM is receiving conflicting information about the hydraulic enable button. The fault is active when the ignition is on and hydraulic enable pin voltage is opposite of value transmitted from instrument cluster. Possible failure modes: 1. A short circuit in the wiring. 2. An open circuit in the wiring. 3. A failure of the instrument cluster. 4. A failure of the UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault code: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 9156 - Hydraulic Enable Button Error From AIC is recorded again. Go to 1350-Hyd Enable Switch - Implausible State (Hardwire vs CAN) (55.640).

47683911 27/02/2015

55.17 [55.DTC] / 805

Electrical systems - FAULT CODES

9158-H Pattern Indicator Shorted To Ground C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE Electro hydraulic controls WE WE Electro hydraulic controls

Context: The UCM has sensed that the H pattern indicator voltage signal has failed low. Diagnostic Trouble Code 9158 - H Pattern Indicator Shorted To Ground has an error priority of White. The ISO pattern will remain active while Diagnostic Trouble Code 9158 - H Pattern Indicator Shorted To Ground is active. Cause: The UCM has sensed that the H pattern indicator voltage signal has failed low. The fault is active while the H pattern indicator voltage, CN2A pin 23 is less than 5 V. Possible failure modes: 1. A short circuit to ground in the signal wire. 2. A faulty pattern select switch. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 9158 - H Pattern Indicator Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the drive pattern switch connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the drive pattern switch. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the switch. Turn the ignition switch OFF. Remove the pattern select switch from the right side column. Disconnect connector X-95. Turn the ignition switch ON. Measure the voltage between X-95 pin 5 and chassis ground. The voltage should be approximately 12 V. Wiggle the harness to reveal an intermittent condition. Measure the voltage between X-95 pin 7 and chassis ground. The voltage should be approximately 12 V. Wiggle the harness to reveal an intermittent condition. Measure the voltage between X-95 pin 10 and chassis ground. The voltage should be approximately 12 V. Wiggle the harness to reveal an intermittent condition.

47683911 27/02/2015

55.17 [55.DTC] / 806

Electrical systems - FAULT CODES

A. All voltage measurements are approximately 12 V. Go to step 4. B. One or more voltage measurements are less than 10 V. There is a problem with the voltage supply to the switch. Check fuses and splices. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the indicator wire to other circuits. Turn the ignition switch OFF. Disconnect connector X-95. Disconnect UCM connectors CN2A and CN2B. Measure the resistance between connector X-95 pin 8 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-95 pin 8 and X-95 pin 9. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are greater than 20,000 Ω. Go to step 5. B. One or more resistance measurements are less than 20,000 Ω. There is a short circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Test the switch. Leave the switch in the neutral position. Measure the resistance between pin 8 and pin 9. The resistance should be greater than 20,000 Ω. A. The resistance is greater than 20,000 Ω. Temporarily replace the UCM and retest. Return to step 1. B. The resistance is less than 20,000 Ω. There is a short circuit in the switch. Temporarily replace the switch and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 13 Cab to Chassis Interface (55.100.DP-C.20.E.13) Wiring harnesses - Electrical schematic sheet 15 Cab Console Switches (55.100.DP-C.20.E.15)

47683911 27/02/2015

55.17 [55.DTC] / 807

Electrical systems - FAULT CODES

9159-ISO Pattern Indicator Shorted To Ground WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the ISO pattern indicator voltage signal has failed. Diagnostic Trouble Code 9159 - ISO Pattern Indicator Shorted To Ground has an error priority of White. The H pattern will remain active while Diagnostic Trouble Code 9159 - ISO Pattern Indicator Shorted To Ground is active. Cause: The UCM has sensed that the ISO pattern indicator voltage signal has failed. The fault is active while the ISO pattern indicator voltage, CN2B pin 2 is less than 5 V. Possible failure modes: 1. The signal wire is shorted to chassis ground. 2. A faulty pattern select switch. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 9159 - ISO Pattern Indicator Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the drive pattern switch connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the drive pattern switch. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the switch. Turn the ignition switch OFF. Remove the pattern select switch from the right side column. Disconnect connector X-95. Turn the ignition switch ON. Measure the voltage between X-95 pin 5 and chassis ground. The voltage should be approximately 12 V. Wiggle the harness to reveal an intermittent condition. Measure the voltage between X-95 pin 7 and chassis ground. The voltage should be approximately 12 V. Wiggle the harness to reveal an intermittent condition. Measure the voltage between X-95 pin 10 and chassis ground. The voltage should be approximately 12 V. Wiggle the harness to reveal an intermittent condition.

47683911 27/02/2015

55.17 [55.DTC] / 808

Electrical systems - FAULT CODES

A. All voltage measurements are approximately 12 V. Go to step 4. B. One or more voltage measurements are less than 10 V. There is a problem with the voltage supply to the switch. Check the fuses and the splices. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the indicator wire to other circuits. Turn the ignition switch OFF. Disconnect connector X-95. Disconnect UCM connectors CN2A and CN2B. Measure the resistance between connector X-95 pin 9 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-95 pin 8 and X-95 pin 9. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are greater than 20,000 Ω. Go to step 5. B. One or more resistance measurements are less than 20,000 Ω. The signal wire has a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Test the switch. Leave the switch in the neutral position. Measure the resistance between pin 8 and pin 9. The resistance should be greater than 20,000 Ω. A. The resistance is greater than 20,000 Ω. Temporarily replace the UCM and retest. Return to step 1. B. The resistance is less than 20,000 Ω. There is a short circuit in the switch. Temporarily replace the switch and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 13 Cab to Chassis Interface (55.100.DP-C.20.E.13) Wiring harnesses - Electrical schematic sheet 15 Cab Console Switches (55.100.DP-C.20.E.15)

47683911 27/02/2015

55.17 [55.DTC] / 809

Electrical systems - FAULT CODES

9160-H Pattern Indicator Shorted To Power WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the H pattern indicator voltage signal has failed. Diagnostic Trouble Code 9160 - H Pattern Indicator Shorted To Power has an error priority of White. The ISO pattern will remain active while Diagnostic Trouble Code 9160 - H Pattern Indicator Shorted To Power is active. Cause: The UCM has sensed that the H pattern indicator voltage signal has failed. The fault is active while the H pattern indicator voltage, CN2A pin 23 is greater than 8 V. Possible failure modes: 1. The signal wire is shorted to another voltage source. 2. A faulty pattern select switch. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 9160 - H Pattern Indicator Shorted To Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the drive pattern switch connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the drive pattern switch. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the switch. Turn the ignition switch OFF. Remove the pattern select switch from the right side column. Disconnect connector X-95. Disconnect UCM connector CN2A. Turn the ignition switch ON. Measure the voltage between X-95 pin 8 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 47683911 27/02/2015

55.17 [55.DTC] / 810

Electrical systems - FAULT CODES

4. Measure the resistance of the signal wire to other circuits. Turn the ignition switch OFF. Disconnect UCM connector CN2A and CN2B. Measure the resistance between connector X-95 pin 8 and X-95 pin 10. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-95 pin 8 and X-95 pin 9. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-95 pin 8 and X-95 pin 7. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-95 pin 8 and X-95 pin 6. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-95 pin 8 and X-95 pin 5. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-95 pin 8 and X-95 pin 3. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-95 pin 8 and X-95 pin 1. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are greater than 20,000 Ω. Go to step 5. B. One or more resistance measurements are less than 20,000 Ω. The signal wire has a short circuit to another circuit. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Test the switch. Leave the switch in the neutral position. Measure the resistance between pin 5 and pin 3. The resistance should be less than 10 Ω. Measure the resistance between pin 8 and pin 10. The resistance should be greater than 20,000 Ω. Measure the resistance between pin 8 and pin 9. The resistance should be greater than 20,000 Ω. Measure the resistance between pin 8 and pin 6. The resistance should be greater than 20,000 Ω. Measure the resistance between pin 8 and pin 5. The resistance should be greater than 20,000 Ω. Measure the resistance between pin 8 and pin 3. The resistance should be greater than 20,000 Ω. Measure the resistance between pin 8 and pin 1. The resistance should be greater than 20,000 Ω. A. All resistance measurements are correct. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. One or more resistance measurements are incorrect. Temporarily replace the switch and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 13 Cab to Chassis Interface (55.100.DP-C.20.E.13) Wiring harnesses - Electrical schematic sheet 15 Cab Console Switches (55.100.DP-C.20.E.15)

47683911 27/02/2015

55.17 [55.DTC] / 811

Electrical systems - FAULT CODES

9161-ISO Pattern Indicator Shorted To Power WE Electro hydraulic controls WE WE Electro hydraulic controls

C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The UCM has sensed that the ISO pattern indicator voltage signal has failed. Diagnostic Trouble Code 9161 - ISO Pattern Indicator Shorted To Power has an error priority of White. The H pattern will remain active while Diagnostic Trouble Code 9161 - ISO Pattern Indicator Shorted To Power is active. Cause: The UCM has sensed that the ISO pattern indicator voltage signal has failed. The fault is active while the ISO pattern indicator voltage, CN2B pin 2 is greater than 8 V. Possible failure modes: 1. The signal wire is shorted to another voltage source. 2. A faulty pattern select switch. 3. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 9161 - ISO Pattern Indicator Shorted To Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the drive pattern switch connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the drive pattern switch. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the switch. Turn the ignition switch OFF. Remove the pattern select switch from the right side column. Disconnect connector X-95. Disconnect UCM connector CN2B. Turn the ignition switch ON. Measure the voltage between X-95 pin 9 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 47683911 27/02/2015

55.17 [55.DTC] / 812

Electrical systems - FAULT CODES

4. Measure the resistance of the signal wire to other circuits. Turn the ignition switch OFF. Disconnect UCM connector CN2A and CN2B. Measure the resistance between connector X-95 pin 9 and X-95 pin 10. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-95 pin 9 and X-95 pin 8. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-95 pin 9 and X-95 pin 7. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-95 pin 9 and X-95 pin 6. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-95 pin 9 and X-95 pin 5. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-95 pin 9 and X-95 pin 3. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-95 pin 9 and X-95 pin 1. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are greater than 20,000 Ω. Go to step 5. B. One or more resistance measurements are less than 20,000 Ω. The signal wire has a short circuit to another circuit. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Test the switch. Leave the switch in the neutral position. Measure the resistance between pin 5 and pin 3. The resistance should be less than 10 Ω. Measure the resistance between pin 9 and pin 8. The resistance should be greater than 20,000 Ω. Measure the resistance between pin 9 and pin 7. The resistance should be greater than 20,000 Ω. Measure the resistance between pin 9 and pin 6. The resistance should be greater than 20,000 Ω. Measure the resistance between pin 9 and pin 5. The resistance should be greater than 20,000 Ω. Measure the resistance between pin 9 and pin 3. The resistance should be greater than 20,000 Ω. Measure the resistance between pin 9 and pin 1. The resistance should be greater than 20,000 Ω. A. All resistance measurements are correct. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. One or more resistance measurements are incorrect. Temporarily replace the switch and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 13 Cab to Chassis Interface (55.100.DP-C.20.E.13) Wiring harnesses - Electrical schematic sheet 15 Cab Console Switches (55.100.DP-C.20.E.15)

47683911 27/02/2015

55.17 [55.DTC] / 813

Electrical systems - FAULT CODES

9401-Memory Error - Double Redundant Memory - Corruption Detected And Repaired WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: Diagnostic Trouble Code 9401 has an error priority of White. There are no restrictions while Diagnostic Trouble Code 9401 is active. Cause: 1. An internal failure within the instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 9401 - Memory Error - Double Redundant Memory - Corruption Detected And Repaired is recorded again. Replace the instrument cluster. Return to step 1 to confirm elimination of the fault. B. The fault code is not recorded again. OK to return the machine to service.

47683911 27/02/2015

55.17 [55.DTC] / 814

Electrical systems - FAULT CODES

9403-Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: Diagnostic Trouble Code 9403 has an error priority of White. There are no restrictions while Diagnostic Trouble Code 9403 is active. Cause: 1. An internal failure within the instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 9403 - Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable is recorded again. Replace the instrument cluster. Return to step 1 to confirm elimination of the fault. B. The fault code is not recorded again. OK to return the machine to service.

47683911 27/02/2015

55.17 [55.DTC] / 815

Electrical systems - FAULT CODES

9404-Memory Error - Triple Redundant - Hour Meter Failure WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: Diagnostic Trouble Code 9404 has an error priority of White. There are no restrictions while Diagnostic Trouble Code 9404 is active. Cause: 1. An internal failure within the instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 9404 - Memory Error - Triple Redundant - Hour Meter Failure is recorded again. Replace the instrument cluster. Return to step 1 to confirm elimination of the fault. B. The fault code is not recorded again. OK to return the machine to service.

47683911 27/02/2015

55.17 [55.DTC] / 816

Electrical systems - FAULT CODES

9405-Loss Of DM1 Message From VCM C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE Electro hydraulic controls WE WE Electro hydraulic controls

Context: CAN bus communications between modules on the data link have been lost. This fault code may be displayed with other CAN bus fault code messages. Cause: CAN bus communications between modules on the data link have been lost. Possible failure modes: 1. CAN data link wiring or circuits open. 2. CAN data link wiring or circuits shorted. 3. Faulty CAN Data Link device. 4. Faulty instrument cluster. 5. Faulty ECU. Solution: 1. Verify that the fault code is active. Use the Electronic Service Tool to verify that the CAN data link faults are ACTIVE. To check for fault codes: Start and operate the machine. Wiggle the harness to reveal an intermittent condition. If three or more fault codes are active, such as 1051 through 1059 or 3096, 3334, 3339 or 3358, this is an indication of a problem in the CAN bus circuit, continue with this procedure. If one or two CAN bus fault codes are active, this is an indication of an intermittent connection in the CAN circuit. Check the wiring and connectors to verify they are secure and free of damage, corrosion, abrasion or incorrect attachment. A. CAN bus fault codes are not recorded again and are no longer ACTIVE. OK to return the machine to service. B. CAN bus fault codes are present and ACTIVE. Refer to 1051-No CAN Communication With Engine Controller (55.408).

47683911 27/02/2015

55.17 [55.DTC] / 817

Electrical systems - FAULT CODES

9406-No CAN Communication From VCM C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE Electro hydraulic controls WE WE Electro hydraulic controls

47683911 27/02/2015

55.17 [55.DTC] / 818

Electrical systems - FAULT CODES

9407-Memory Error - Unrecoverable Hardware ID WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: Diagnostic Trouble Code 9407 has an error priority of Red. The vehicle is immediately disabled with Diagnostic Trouble Code 9407. Cause: The instrument cluster has sensed an internal failure. Possible failure modes: 1. A failure of the instrument cluster. Solution: 1. Use the machine to recreate conditions for error. Use the EST to verify fault code 9407 - Memory Error - Unrecoverable Hardware ID is active. A. If the fault is active, the instrument cluster has failed. Replace the instrument cluster. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 2. 2. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

47683911 27/02/2015

55.17 [55.DTC] / 819

Electrical systems - FAULT CODES

9408-Memory Error - Unrecoverable Panel ID WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: Diagnostic Trouble Code 9408 has an error priority of Red. The vehicle is immediately disabled with Diagnostic Trouble Code 9408. Cause: The instrument cluster has sensed an internal failure. Possible failure modes: 1. A failure of the instrument cluster. Solution: 1. Use the machine to recreate conditions for error. Use the EST to verify fault code 9408 - Memory Error - Unrecoverable Panel ID is active. A. If the fault is active, the instrument cluster has failed. Replace the instrument cluster. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 2. 2. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

47683911 27/02/2015

55.17 [55.DTC] / 820

Electrical systems - FAULT CODES

9410-Loss Of EGR Inducement Status Message From EDC C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

47683911 27/02/2015

55.17 [55.DTC] / 821

Electrical systems - FAULT CODES

17105-Turbo protection cold start detection C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: This fault is for information purposes only and does not require any action. The recognition of a cold start condition is provided by the turbocharger protection speed limitation module. The Engine Control Unit (ECU) A-9000 will limit the number of engine revolutions until the engine oil pressure has reached a calibrated threshold.

47683911 27/02/2015

55.17 [55.DTC] / 822

Electrical systems - FAULT CODES

17513-PMCat inlet temperature sensor physical range check high WE WE WE

C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

Context: The Engine Control Unit (ECU) A-9000 monitors the Particulate Matter (PM) catalytic converter inlet temperature sensor B-9126. If the ECU A-9000 detects a temperature greater than 1000 °C (1832 °F) from the PM catalytic converter inlet temperature sensor B-9126, this fault will occur. Other active faults may have caused this fault to occur. Cause: The ECU A-9000 has detected a temperature too high from the PM catalytic converter inlet temperature sensor B-9126. Possible failure modes: 1. PM catalytic converter temperature too high. 2. Faulty PM catalytic converter inlet temperature sensor B-9126. 3. Faulty ECU A-9000, software.

47683911 27/02/2015

55.17 [55.DTC] / 823

Electrical systems - FAULT CODES

17514-Timeout Error of CAN-Receive-Frame CM1BC C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228

WE WE WE

Context: The Engine Control Unit (ECU) monitors Controller Area Network (CAN) communication by performing a CAN bus data check. If the ECU A-9000 detects a failure during this check, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.

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55.17 [55.DTC] / 824

Index Electrical systems - 55 FAULT CODES - DTC 1002-Engine Coolant Temperature Is Above Normal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1004-Hydraulic Filter Restriction Switch - Hydraulic Filter Restricted (*) . . . . . . . . . . . . . . . . . . . . . . .

1009-Hydraulic Oil Temperature Is Above Normal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1014-Cluster System Voltage Above Normal (>16.5V) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1015-Cluster System Voltage Below Normal (<11.5V) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1025-Foot Throttle Sensor Is Above Range - Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . .

1026-Hand Throttle Sensor Is Above Range - Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . .

1030-Foot Throttle Sensor Is Below Range - Open Or Shorted To Ground (*) . . . . . . . . . . . . . . . . . .

1031-Hand Throttle Sensor Is Below Range - Open Or Shorted To Ground (*) . . . . . . . . . . . . . . . . .

1040-RPM Monitoring Over Speed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1041-RPM Monitoring Over Speed Max (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1044-Fuel level sensor below 2.0 ohm for 5 seconds, shorted low (*) . . . . . . . . . . . . . . . . . . . . . . . . .

1045-Fuel Level Sensor Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1051-No CAN Communication With Engine Controller (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1053-Timeout of CAN Message CM1BC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1054-Timeout of CAN Message ET1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1056-Timeout of CAN Message DPFC1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1058-Timeout of CAN Message EDC2BC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1059-Timeout of CAN Message DM1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1201-Hydraulic oil filter switch open circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1205-Hydraulic Enable (EH Machines) - Hydraulic Enable Output, Short to Power (*) . . . . . . . . . . .

1206-CAN Connection: Configuration Response Timeout (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1207-Memory Parameters - Invalid Configuration Between IC and UCM (*) . . . . . . . . . . . . . . . . . . . .

1208-Seat Switch Plausibility Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1211-Calibration Functions - Joystick Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . .

1212-Calibration Functions - Ground Drive Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . . . .

1213-Calibration Functions - Loader Valve Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . . . .

1215-Saturation Function not complete - Forward Pumps (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1216-Saturation Function not complete - Reverse Pumps (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1221-VCM Temperature / Current Draw Over Limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1222-VCM Sustained Over Temperature Limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1223-VCM Sustained Over Current Limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1224-VCM Internal Memory or Core Monitoring Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

55.17 [55.DTC] / 825

1225-VCM EEPROM Memory Checksum Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1350-Hyd Enable Switch - Implausible State (Hardwire vs CAN) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . .

1532-Backup Alarm - Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1533-Backup Alarm - Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17105-Turbo protection cold start detection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

822

17513-PMCat inlet temperature sensor physical range check high (*) . . . . . . . . . . . . . . . . . . . . . . . . .

823

17514-Timeout Error of CAN-Receive-Frame CM1BC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

824

1900-VCM Ground Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1901-VCM - VCM Supply Voltage High (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1902-VCM - VCM Supply Voltage Low (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1903-VCM - VCM Supply Voltage Below Operational Limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1904-VCM - Rail 12VB - 5V Regulators Supply Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . .

1905-VCM - 5Vref1 Sensor Supply Voltage Out Of Range (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1906-VCM - 5Vref3 Sensor Supply Voltage Out Of Range (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1907-VCM - Rail 12VF1 - Aux Retract Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1908-VCM - Rail 12VF2 - Bucket Extend Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1909-VCM - Rail 12VF3 - Boom Raise/Lower Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100

1910-VCM - Rail 12VH - Loader Pilot Interlock And Port Lock Input Power Off (*) . . . . . . . . . . . . . . .

102

1911-VCM - Rail 12VH1 - Left And Right Pump Reverse Input Power Off (*) . . . . . . . . . . . . . . . . . . .

104

1912-VCM - Rail 12VM - Left And Right Brake Lights And Aux Extend Input Power Off (*) . . . . . . .

106

1913-VCM - Rail 12VS1 - Bucket Curl Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

108

1914-VCM - Rail 12VS2 - Backup Alarm Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

110

1915-VCM - Rail 12VT1 - Two Speed Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

112

1916-VCM - Rail 12VU1 - Right And Left Pumps Forward Input Power Off (*) . . . . . . . . . . . . . . . . . .

114

1917-UCM - Rail 12VU2: Park Brake Solenoid Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

116

3007-Engine coolant temperature sensor voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . .

118

3008-Engine coolant temperature sensor voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . .

120

3010-Intake manifold temperature sensor voltage is higher than expected (*) . . . . . . . . . . . . . . . . . .

122

3011-Intake manifold temperature sensor voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . .

125

3015-Fuel temperature sensor voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

127

3016-Fuel temperature sensor voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

130

3019-Intake manifold pressure sensor voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . . . .

132

3024-ECU internal failure - Ambient pressure sensor voltage is higher than expected (*) . . . . . . . .

135

3025-ECU internal failure - Ambient pressure sensor voltage is lower than expected (*) . . . . . . . . .

136

3027-Oil pressure switch active with engine off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

137

3037-Intake manifold pressure sensor voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . .

139

3051-Battery voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

141

3052-Battery voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

142

3059-Main relay stuck error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

144

3061-Cylinder1 - Short circuit Low/High (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

146

(*) See content for specific models 47683911 27/02/2015

55.17 [55.DTC] / 826

3063-Short circuit error of injector in cylinder 1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

148

3069-Cylinder3 - Short circuit Low/High (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

151

3071-Short circuit error of injector in cylinder 3 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

153

3077-Cylinder2 - Short circuit Low/High (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

156

3079-Short circuit error of injector in cylinder 2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

158

3081-Cylinder4 - Short circuit Low/High (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

161

3083-Short circuit error of injector in cylinder 4 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

163

3088-Crankshaft speed sensor values are not plausible (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

166

3089-Crankshaft speed sensor pattern is not plausible (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

169

3090-Camshaft speed sensor values are not plausible (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

172

3091-Camshaft speed sensor pattern is not plausible (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

175

3093-Compared camshaft and crankshaft speed sensor values are not plausible (*) . . . . . . . . . . . .

177

3096-CAN A Bus off failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

178

3102-Fuel rail pressure sensor voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180

3104-Fuel pressure relief valve is open (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

182

3105-Fuel pressure relief valve is forced to open, perform pressure increase (*) . . . . . . . . . . . . . . . .

184

3106-Fuel pressure relief valve reached maximum allowed opening count (*) . . . . . . . . . . . . . . . . . .

185

3107-Fuel metering unit is shorted to battery voltage at the low side (*) . . . . . . . . . . . . . . . . . . . . . . .

186

3108-Fuel metering unit is shorted to ground at the low side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

188

3110-Rail pressure sensor value is above maximum offset (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190

3111-Rail pressure sensor value is below minimum offset (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

191

3112-Fuel rail pressure sensor voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192

3137-Fuel metering unit has an open load error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

195

3141-Fuel pump pressure has exceeded desired pressure limits (*) . . . . . . . . . . . . . . . . . . . . . . . . . . .

197

3146-Water in fuel detected or water in fuel circuit failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

198

3157-ECM Not Detected On CAN Bus - The Engine Dataset Registration Information Was Not Available From The Engine Within The Time Required. (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 3158-The Engine Dataset Installed Does Not Match The Dataset Registered For This Machine. Register The New Dataset If The Dataset Has Just Been Updated (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 3166-Fuel filter heater actuator is shorted to battery voltage (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

202

3167-Fuel filter heater actuator is shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

204

3168-Fuel filter heater actuator has an open load error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

206

3169-Fuel filter heater ECU driver has an over temperature error (*) . . . . . . . . . . . . . . . . . . . . . . . . . .

208

3176-High pressure pump fuel delivery quantity in over run exceeds a maximum threshold (*) . . .

210

3177-Engine over speed condition detected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

211

3179-CAN communication failure between vehicle controller and ECU - BC2ECU2 message (*) . .

212

3180-CAN communication error between vehicle controller to ECU (*) . . . . . . . . . . . . . . . . . . . . . . . .

214

3188-Open load error of injector in cylinder 1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

216

3192-Open load error of injector in cylinder 2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

218

3196-Open load error of injector in cylinder 3 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

220

3200-Open load error of injector in cylinder 4 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

222

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3210-Injection bank 1 short circuit failure (all injectors of the same bank can be affected) (*) . . . . .

224

3218-Injection bank 2 short circuit failure (all injectors of the same bank can be affected) (*) . . . . .

226

3230-ECU internal failure - Injector CY33x component (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

228

3235-Exceeded the number of injections for a given engine speed (*) . . . . . . . . . . . . . . . . . . . . . . . . .

229

3236-Number of injections is limited by system (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

230

3237-Number of desired injections exceeds threshold (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

231

3238-ECU internal failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

233

3239-ECU internal failure - EEPROM read error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

234

3240-ECU internal failure - EEPROM write error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

235

3241-ECU internal failure - EEPROM write/read error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

236

3242-ECU internal failure - Software resets in DSM 0 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

237

3243-ECU internal failure - Software resets in DSM 1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

238

3244-ECU internal failure - Software resets in DSM 2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

239

3245-ECU internal failure - Query/response communication errors (*) . . . . . . . . . . . . . . . . . . . . . . . . .

240

3252-ECU internal failure - SPI communication error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

241

3253-ECU internal failure - Voltage ratio in ADC monitoring (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

242

3255-ECU internal failure - ADC test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

243

3256-ECU internal failure - NTP error in ADC monitoring (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

244

3258-Starter relay high side driver circuit shorted to battery (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

245

3259-Starter relay high side driver circuit shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

247

3260-Starter relay low side driver circuit open failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

249

3261-Starter relay low side driver circuit shorted to battery (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

251

3262-Starter relay low side driver circuit shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

253

3265-Fuel injection requested during overrun (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

255

3266-ECU internal failure - Calculated engine speed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

256

3283-ECU 5 volt sensor supply 2 out of range (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

257

3285-ECU 5 volt sensor supply 3 out of range (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

259

3293-Fuel rail pressure has exceeded maximum positive deviation limits (*) . . . . . . . . . . . . . . . . . . .

261

3301-Fuel rail pressure has exceeded maximum negative deviation limits (*) . . . . . . . . . . . . . . . . . .

262

3305-Fuel rail pressure has dropped below the minimum limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

263

3309-Fuel rail pressure has exceeded maximum limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

264

3334-CAN communication failure between vehicle controller and ECU controller - TSC1_PE message (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265 3335-CAN-Receive-Frame Torque / Speed control from ABS / ASR to ECU through TSC1_PR Message active (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 3338-CAN communication failure between vehicle controller and ECU controller - TSC1_VE message (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269 3339-CAN communication failure between vehicle controller and ECU controller - TSC1_VE message (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 3350-Engine cranked for too long or key switch failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

273

3358-CAN transmit error - EEC1 message (Electronic Engine Control 1 message - Torque, accelerator pedal, engine speed, and other signals) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

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3361-ECU internal failure - EEPROM erase error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

277

3362-ECU internal failure - Fuel calibration (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

278

3368-Torque limitation caused by performance limiter (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

279

3369-Torque limitation caused by smoke limitation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

280

3370-Strong torque limitation from engine protection active (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

281

3371-Strong torque limitation from injection system active (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

282

3374-Injection quantity adjustment failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

283

3390-Air Filter Restriction Switch Short To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

284

3402-Maximum rail pressure exceeded (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

286

3403-Starter relay low side ECU driver circuit over temperature (*) . . . . . . . . . . . . . . . . . . . . . . . . . . .

287

3405-Wastegate pressure modulator control circuit open (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

289

3406-Wastegate pressure modulator control circuit over temperature (*) . . . . . . . . . . . . . . . . . . . . . . .

291

3409-Low oil pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

293

3410-Throttle valve actuator will not open to commanded position (*) . . . . . . . . . . . . . . . . . . . . . . . . .

296

3411-Throttle valve actuator will not close to commanded position (*) . . . . . . . . . . . . . . . . . . . . . . . . .

297

3414-Glow plug 1 control circuit shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

298

3415-Glow plug 3 control circuit shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

300

3416-Glow plug 4 control circuit shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

302

3417-Glow plug 2 control circuit shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

304

3418-Wastegate pressure modulator control circuit shorted to battery (*) . . . . . . . . . . . . . . . . . . . . . .

306

3419-Wastegate pressure modulator control circuit shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . .

308

3425-Turbocharger boost pressure is higher than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

310

3430-EGR Failure - Moderate Inducement (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

311

3431-EGR Failure - Severe Inducement (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

312

3432-EGR Failure - Mild Inducement (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

313

3433-DPF - Moderate Inducement (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

314

3434-DPF - Severe Inducement (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

315

3435-DPF - Mild Inducement (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

316

3436-Inducement system is locked due to 3 detections in 40 hours. The system must be reset using the dealer service tool screen "Engine Restart Counter Reset" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 3517-Ambient temperature sensor voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . . . . . . .

318

3518-Ambient temperature sensor voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . .

320

3616-Torque limitation caused by turbo charger protection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

322

3650-Battery voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

323

3651-Battery voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

324

3652-CAN A Bus off passive failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

326

3655-Torque limitation active (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

328

3656-Torque limitation caused by particulate filter (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

329

3657-CAN Bus Received frames : Timeout Error of CAN-Receive-Frame CM1BC (*) . . . . . . . . . . .

330

3665-EGR valve will not open to commanded position (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

332

3666-EGR valve will not close to commanded position (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

333

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3667-EGR valve control circuit open (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

334

3668-EGR valve control circuit over current (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

336

3669-EGR valve control circuit high side shorted to battery (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

338

3670-EGR valve control circuit low side shorted to battery (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

340

3671-EGR valve control circuit high side shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

342

3672-EGR valve control circuit low side shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

344

3673-EGR valve control circuit over load (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

346

3674-EGR valve control circuit supply voltage too low (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

349

3675-EGR valve is blocked in closed position (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

350

3676-EGR valve position sensor voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . .

351

3677-EGR valve position sensor voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . .

353

3680-Engine speed limitation via fuel injection cut off is active (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

355

3684-Exhaust manifold temperature too high (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

356

3688-Water in fuel sensor or sensor circuit failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

357

3689-Glow Control Unit (GCU) data error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

359

3691-Glow plug control circuits open (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

361

3692-Glow plug control circuits shorted (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

363

3693-Glow plug control circuits shorted to battery (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

365

3694-Glow plug control circuits shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

367

3699-ECU internal failure - EEPROM memory failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

369

3703-The minimum rail pressure value necessary to allow fuel injection has not been reached (*)

370

3704-Missing adjustment value programming for injector in cylinder 2 (*) . . . . . . . . . . . . . . . . . . . . . .

371

3705-Missing adjustment value programming for injector in cylinder 3 (*) . . . . . . . . . . . . . . . . . . . . . .

372

3706-Missing adjustment value programming for injector in cylinder 4 (*) . . . . . . . . . . . . . . . . . . . . . .

373

3707-Lambda sensor nernst cell open circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

374

3708-Lambda sensor pump current open circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

376

3709-Lambda sensor virtual ground open circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

378

3711-Lambda sensor heater power stage short circuit to battery (*) . . . . . . . . . . . . . . . . . . . . . . . . . . .

380

3712-Lambda sensor heater power stage short circuit to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . .

382

3713-Lambda sensor heater power stage open circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

384

3714-Lambda sensor O2 calibrator too high error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

386

3715-Lambda sensor O2 calibrator too low error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

387

3716-Lambda sensor O2 value above maximum threshold (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

388

3720-Lambda sensor heater battery voltage too low (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

390

3721-ECU internal failure - SPI chip error configuration (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

391

3722-Lambda sensor estimated temperature higher than threshold (*) . . . . . . . . . . . . . . . . . . . . . . . .

392

3723-Lambda sensor estimated temperature lower than threshold (*) . . . . . . . . . . . . . . . . . . . . . . . . .

394

3724-Lambda sensor cell circuits short circuit to battery (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

396

3725-Lambda sensor cell circuits short circuit to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

398

3727-Low oil viscosity (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

400

(*) See content for specific models 47683911 27/02/2015

55.17 [55.DTC] / 830

3728-Too low oil viscosity (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

401

3735-Fuel metering unit has an over-temperature error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

402

3738-ECU internal failure - ROM error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

404

3739-ECU internal failure - Loss of synchronization to MM from CPU (*) . . . . . . . . . . . . . . . . . . . . . .

405

3740-ECU internal failure - ECU shutdown test failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

406

3741-ECU internal failure - Wrong set response time (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

407

3742-ECU internal failure - SPI errors during MoCSOP execution (*) . . . . . . . . . . . . . . . . . . . . . . . . . .

408

3743-ECU internal failure - Undervoltage monitoring error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

409

3744-ECU internal failure - Overvoltage monitoring error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

410

3745-ECU internal failure - WDA is not working correctly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

411

3746-ECU internal failure - Alarm task period error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

412

3747-ECU internal failure - Positive test failed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

413

3748-ECU internal failure - Timeout in the shut off path test error (*) . . . . . . . . . . . . . . . . . . . . . . . . . .

414

3750-ECU internal failure - Fuel injection energizing time not plausible (*) . . . . . . . . . . . . . . . . . . . . .

415

3751-ECU internal failure - Fuel injection energizing phase is not plausible (*) . . . . . . . . . . . . . . . . .

416

3752-Fuel injection correction has exceeded a minimum limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

417

3753-ECU internal failure - Injection quality correction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

418

3754-ECU internal failure - SPI errors during MoCSOP execution (*) . . . . . . . . . . . . . . . . . . . . . . . . . .

419

3755-ECU internal failure - Torque request comparison (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

420

3756-ECU internal failure - Post injection quality (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

421

3757-ECU internal failure - Post injection shut-off failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

422

3758-ECU internal failure - Post injection efficiency failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

423

3759-ECU internal failure - Torque request due to fuel pressure exceeds maximum torque limit (*)

424

3760-ECU internal failure - Torque request due to air control exceeds maximum torque limit (*) . .

425

3761-ECU internal failure - Torque request exceeds maximum torque limit (*) . . . . . . . . . . . . . . . . . .

426

3762-ECU 5 volt supply voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

427

3763-ECU 5 volt supply voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

428

3764-ECU after run power interruption (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

429

3766-Diesel particulate filter pressure sensor: Fault check for the pressure sensor plausibility (*) .

432

3767-ECU internal failure - 'WDA active' reported due to errors in query/response communication (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433 3768-ECU internal failure - 'ABE active' reported due to undervoltage detection (*) . . . . . . . . . . . . .

434

3769-ECU internal failure - 'ABE active' report due to overvoltage detection (*) . . . . . . . . . . . . . . . . .

435

3770-ECU internal failure - 'WDA/ABE active' reported (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

436

3773-Turbocharger boost pressure is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

437

3786-Diesel particulate filter signal range check is high (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

438

3787-Diesel particulate filter signal range check flow resistance of the particulate filter - very high (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439 3789-Regeneration duration check exceeds maximum allowed duration (*) . . . . . . . . . . . . . . . . . . . .

440

3794-Intake manifold pressure sensor drifted high (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

441

3795-Intake manifold pressure sensor drifted low (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

442

(*) See content for specific models 47683911 27/02/2015

55.17 [55.DTC] / 831

3796-Diesel particulate filter pressure sensor hose line error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

443

3797-DPF differential pressure sensor is higher than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

444

3798-DPF differential pressure sensor is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

446

3799-Fuel pressure relief valve is forced open, perform pressure shock (*) . . . . . . . . . . . . . . . . . . . .

448

3800-Quantity balance check if a successful PRV opening is ensured (*) . . . . . . . . . . . . . . . . . . . . . .

449

3801-Exhaust gas pressure sensor voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . . . . . . .

450

3802-Exhaust gas pressure sensor voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . . . . .

452

3803-ECU internal failure - Error on R2S2 module (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

454

3808-High pressure pump fuel delivery quantity at low idle is too high (*) . . . . . . . . . . . . . . . . . . . . . .

455

3810-Rail pressure raw value is intermittent (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

456

3811-ECU 5 volt sensor supply 1 out of range (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

458

3812-Physical range check high for ECU temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

464

3813-Physical range check low for ECU temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

465

3814-Engine Controller Internal Temperature Out Of Range (SPI Error - LM71) (*) . . . . . . . . . . . . . .

466

3818-Throttle valve actuator control circuit open (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

467

3819-Throttle valve actuator control circuit over current (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

469

3820-Throttle valve actuator control circuit over temperature (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

471

3821-Throttle valve actuator control circuit high side shorted to battery (*) . . . . . . . . . . . . . . . . . . . . .

473

3823-Throttle valve actuator control circuit high side shorted to ground (*) . . . . . . . . . . . . . . . . . . . . .

475

3824-Throttle valve actuator control circuit low side shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . .

477

3825-Throttle valve actuator control circuit over load (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

479

3827-Throttle valve actuator control circuit supply voltage too low (*) . . . . . . . . . . . . . . . . . . . . . . . . . .

481

3834-Throttle valve actuator position sensor voltage is higher than expected (*) . . . . . . . . . . . . . . . .

482

3835-Throttle valve actuator position sensor voltage is lower than expected (*) . . . . . . . . . . . . . . . . .

484

3838-DOC inlet temperature sensor voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . . . . . .

486

3839-DOC inlet temperature sensor voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . . . .

488

3840-PMCat inlet temperature sensor voltage is higher than expected (*) . . . . . . . . . . . . . . . . . . . . .

490

3841-PMCat inlet temperature sensor voltage is lower than expected (*) . . . . . . . . . . . . . . . . . . . . . .

492

3842-Exhaust manifold temperature sensor voltage is higher than expected (*) . . . . . . . . . . . . . . . .

494

3843-Exhaust manifold temperature sensor voltage is lower than expected (*) . . . . . . . . . . . . . . . . .

497

3844-Error in comparing energizing time to maximum value for injector in cylinder 1 (*) . . . . . . . . .

499

3845-Error in comparing energizing time to maximum value for injector in cylinder 2 (*) . . . . . . . . .

500

3846-Error in comparing energizing time to maximum value for injector in cylinder 3 (*) . . . . . . . . .

501

3847-Error in comparing energizing time to maximum value for injector in cylinder 4 (*) . . . . . . . . .

502

3848-Error in comparing energizing time to minimum value for injector in cylinder 1 (*) . . . . . . . . . .

503

3849-Error in comparing energizing time to minimum value for injector in cylinder 2 (*) . . . . . . . . . .

504

3850-Error in comparing energizing time to minimum value for injector in cylinder 3 (*) . . . . . . . . . .

505

3851-Error in comparing energizing time to minimum value for injector in cylinder 4 (*) . . . . . . . . . .

506

3899-Engine coolant temperature has exceeded the pre-warning threshold (*) . . . . . . . . . . . . . . . . .

507

3900-Engine coolant temperature has exceeded the warning threshold (*) . . . . . . . . . . . . . . . . . . . . .

508

(*) See content for specific models 47683911 27/02/2015

55.17 [55.DTC] / 832

3906-Number of injections is limited by quantity balance of high pressure pump (*) . . . . . . . . . . . . .

509

3910-Fuel metering unit intermittent electrical connection failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . .

510

3915-Averaged rail pressure is outside the expected tolerance range (*) . . . . . . . . . . . . . . . . . . . . . .

512

3916-Fuel pressure relief valve has reached maximum allowed open time (*) . . . . . . . . . . . . . . . . . .

513

3978-PM Catalyst load high (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

514

3979-PM Catalyst load very high (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

515

3993-EGR valve will not close during after run (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

516

3995-Cold start bypass valve has an over-temperature error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

517

3996-Cold start bypass valve is shorted to battery voltage (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

519

3997-Cold start bypass valve is shorted to ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

521

4043-Hydraulic Oil Temperature Sensor Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

523

4044-Hydraulic Oil Temperature Sensor Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

525

4055-Park Brake Valve (On/Off) - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . .

527

4056-Park Brake Valve (On/Off) - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . .

529

4057-Park Brake Valve (On/Off) - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . .

531

4061-Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit (*) . . . .

533

4062-Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground (*) .

535

4071-Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit (*) . . . . .

537

4072-Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground (*) . .

539

4081-Forward Pump Control Valves (Directional) - Common Solenoid Return Short to Power (*) .

541

4082-Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground (*)

543

4083-Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit (*) . . . .

545

4309-Park Brake Button - Park Brake Button Timeout (30 sec) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

547

4361-Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit (*) . . . .

549

4362-Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground (*)

551

4371-Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit (*) . . . . .

553

4372-Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground (*) . .

555

4381-Reverse Pump Control Valves (Directional) - Common Solenoid Return Short to Power (*) .

557

4382-Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground (*)

559

4383-Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit (*) . . .

561

4401-Park Brake (Mechanical Machines) Solenoid Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . .

563

4402-Park Brake (Mechanical Machines) Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

565

4431-Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) (*) .

567

4731-Right Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . .

570

4732-Right Swash Plate Angle Sensor - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

573

4734-Right Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . .

575

4735-Right Swash Plate Angle Sensor - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

578

4737-Right Swash Plate Angle Sensor - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

580

4741-Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . .

583

4742-Left Swash Plate Angle Sensor - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

586

(*) See content for specific models 47683911 27/02/2015

55.17 [55.DTC] / 833

4744-Left Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . .

588

4745-Left Swash Plate Angle Sensor - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

591

4747-Left Swash Plate Angle Sensor - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

593

4752-Left Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596 4754-Right Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598 4781-Solenoid Valve - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

600

4782-Solenoid Valve - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

602

4783-Solenoid Valve - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

604

4951-Hydraulic Interlock Solenoid Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

606

4952-Hydraulic Interlock Solenoid Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

608

5051-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . .

610

5052-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . .

612

5053-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . .

614

5061-Port Lock Valve (On/Off) - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

616

5062-Port Lock Valve (On/Off) - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . .

618

5063-Port Lock Valve (On/Off) - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . .

620

5121-Right Joystick F-B Axis - Pin A Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . .

622

5122-Right Joystick F-B Axis - Pin B Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . .

626

5124-Right Joystick F-B Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

630

5131-Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . .

635

5132-Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . .

639

5134-Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . .

643

5135-Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . .

647

5137-Right Joystick R-L Axis (ISO/H Pattern) - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

651

5141-Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . .

656

5142-Aux Thumbwheel Axis - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

658

5144-Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . .

660

5145-Aux Thumbwheel Axis - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

662

5147-Aux Thumbwheel Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

664

5201-Left Joystick L-R Axis - Pin A Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . .

667

5202-Left Joystick L-R Axis - Pin B Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . .

671

5204-Left Joystick L-R Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

675

5211-Left Joystick F-B Axis - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . .

680

5212-Left Joystick F-B Axis - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

684

5214-Left Joystick F-B Axis - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . .

688

5215-Left Joystick F-B Axis - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

692

5217-Left Joystick F-B Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

696

5221-Loader Arm Valve (Directional) Solenoid Raise (A) Supply Open Circuit (*) . . . . . . . . . . . . . . .

701

5222-Loader Arm Valve (Directional) Solenoid Raise (A) Supply Shorted To Ground (*) . . . . . . . . .

703

(*) See content for specific models 47683911 27/02/2015

55.17 [55.DTC] / 834

5231-Loader Arm Valve (Directional) Solenoid Lower (B) Supply Open Circuit (*) . . . . . . . . . . . . . . .

705

5232-Loader Arm Valve (Directional) Solenoid Lower (B) Supply Shorted To Ground (*) . . . . . . . . .

707

5241-Loader Arm Valve (Directional) Loader Arm Solenoid(s) Shorted To Power (*) . . . . . . . . . . . . .

709

5242-Loader Arm Valve (Directional) Loader Arm Solenoid(s) Shorted To Ground (*) . . . . . . . . . . . .

711

5243-Loader Arm Valve (Directional) Solenoids Return Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . .

713

5251-Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Open Circuit (*) . . . . . . . . . .

715

5252-Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Shorted To Ground (*) . . . .

717

5261-Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Open Circuit (*) . . . . . . . . . . . .

719

5262-Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Shorted To Ground (*) . . . . . . .

721

5271-Loader Bucket Valve (Directional) Loader Bucket Solenoid(s) Shorted To Power (*) . . . . . . . .

723

5272-Loader Bucket Valve (Directional) Loader Bucket Solenoid(s) Shorted To Ground (*) . . . . . . .

725

5273-Loader Bucket Valve (Directional) Solenoids Return Open Circuit (*) . . . . . . . . . . . . . . . . . . . . .

727

5281-Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Open Circuit (*) . . . . . . . . .

729

5282-Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Shorted To Ground (*) . . .

731

5291-Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Open Circuit (*) . . . . . . . . .

733

5292-Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Shorted To Ground (*) . . .

735

5309-Float Button - Float Button Timeout (30 sec) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

737

5313-EHF Enable Switch STP (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

739

5323-EHF Fwd/Rev Switch STP (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

741

5371-EHF Forward Solenoid (A) Supply STG (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

744

5372-EHF Forward Solenoid (A) Supply OC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

746

5381-EHF Reverse Solenoid (B) Supply STG (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

748

5382-EHF Reverse Solenoid (B) Supply OC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

750

5391-EHF Solenoids Return OC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

752

5392-EHF Pump Solenoid(s) STG (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

754

5393-EHF Pump Solenoid(s) STP (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

756

5409-Aux Override Disabled Due To Aux Override Button Timeout (30 Seconds) (*) . . . . . . . . . . . .

758

5501-Loader Arm Spool Sensor Open or Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

759

5502-Loader Arm Spool Sensor Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

761

5503-Electro-Hydraulic Aux Output Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

763

5504-Bucket Valve Spool Sensor Open Or Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

765

5505-Bucket Valve Spool Sensor Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

767

5507-Auxiliary Valve Spool Sensor Open Or Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . .

769

5508-Auxiliary Valve Spool Sensor Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

771

5511-Implausible Loader Arm Sensor State Vs Loader Arm Command - Stuck Spool Or PRV (*) .

773

5512-Implausible Bucket Sensor State Vs Loader Bucket Command - Stuck Spool Or PRV (*) . . .

775

5513-Implausible Auxiliary Sensor State Vs Auxiliary Command - Stuck Spool Or PRV (*) . . . . . . .

777

5601-Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Power (*) . . . . .

779

5602-Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Ground (*) . . . .

781

5603-Loader Auxiliary Valve (Directional) Solenoids Return Open Circuit (*) . . . . . . . . . . . . . . . . . . .

783

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5701-Pattern Switch Open Or Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

785

5703-Pattern Switch Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

788

5811-Loader Port Lock Switch Is In An Implausible State (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

791

9004-Memory Error - Triple Redundant - Hour Meter Location 1 Corrupt (*) . . . . . . . . . . . . . . . . . . . .

794

9005-Memory Error - Triple Redundant - Hour Meter Location 2 Corrupt (*) . . . . . . . . . . . . . . . . . . . .

795

9006-Memory Error - Triple Redundant - Hour Meter Location 3 Corrupt (*) . . . . . . . . . . . . . . . . . . . .

796

9151-Bus-Warn at CAN-Bus No.1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

797

9152-Bus-Warn at CAN-Bus No.1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

799

9153-Timeout of CAN Message EEC1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

801

9154-Timeout of CAN Message TSC1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

803

9156-Hydraulic Enable Button Error From AIC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

805

9158-H Pattern Indicator Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

806

9159-ISO Pattern Indicator Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

808

9160-H Pattern Indicator Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

810

9161-ISO Pattern Indicator Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

812

9401-Memory Error - Double Redundant Memory - Corruption Detected And Repaired (*) . . . . . . .

814

9403-Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable (*)

815

9404-Memory Error - Triple Redundant - Hour Meter Failure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

816

9405-Loss Of DM1 Message From VCM (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

817

9406-No CAN Communication From VCM (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

818

9407-Memory Error - Unrecoverable Hardware ID (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

819

9408-Memory Error - Unrecoverable Panel ID (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

820

9410-Loss Of EGR Inducement Status Message From EDC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

821

(*) See content for specific models 47683911 27/02/2015

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

47683911 27/02/2015 EN

SERVICE MANUAL Front loader and bucket C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Front loader and bucket - 82

[82.100] Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.1 [82.300] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.2

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Front loader and bucket - 82 Arm - 100

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Front loader and bucket - 82 Arm - 100

SERVICE Arm Repair (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

(*) See content for specific models 47683911 27/02/2015

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Front loader and bucket - Arm

Arm - Repair WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

When the pivot pins fail or the retaining hardware for the bucket release device or the bucket cylinders is loose for an extended period of time, the tapered hole in the bosses become damaged and requires replacement. In this procedure, you will find directions for replacing the upper and lower bosses on the loader arm. Bosses are to be replaced only one at a time. Do not attempt to replace more than one boss at the same time. You will not be able to use the boss alignment tool, part number 380100288, which is required for this procedure if you attempt to replace more than one boss at a time. All welding procedures are to be performed by a certified welder. Protect your work area from moisture, low temperatures, and excessive wind when repairing the bosses on the loader arm. Prior operation: Bucket release device - Remove (82.300) Prior operation: Remove the bucket cylinders.

Upper boss repair 1. Attach a magnetic hole drill to the loader arm.

RAIL14SSL0303BA

RAIL14SSL0304BA

2. Cut the welds that attach the boss to the loader arm.

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Front loader and bucket - Arm

3. Remove the worn boss.

4. Install the boss 380100288.

alignment

tool,

part

RAIL14SSL0305BA

RAIL12SSL0494AA

RAIL12SSL0493AA

number

NOTE: The rods center the tool with the existing bosses and the tube helps to position the new boss to the loader frame. NOTE: Identify which way the rectangular tube assembly mounts on the rods. The lower rectangular section has the longer portion to the front, and the rod goes through the hole that is almost in the center line of the long rectangular tube.

5. Install the boss 380100288.

alignment

tool,

part

number

NOTE: The rods center the tool with the existing bosses and the tube helps to position the new boss to the loader frame. NOTE: The tool is installed with the short rectangular tube welded on the lower portion and is positioned toward the rear of the unit. The lower rod goes through the hole that is furthest from the center line of the long tube.

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6. To position the new boss horizontally, you must measure the distance from the new boss to the other pivot pin boss that is welded to the loader arm. To achieve the correct measurement of 787 mm (31 in) ± 2 mm (5/64 in), slide the new boss, short tapered pin, and alignment tool on the upper rod, and adjust the equipment as necessary.

RAPH14SSL0327BA

RAIL14SSL0306BA

RAPH14SSL0328BA

7. Disconnect the battery negative cable and positive cable. 8. Tack weld (1) the boss to the inner side and outer side of the loader arm. NOTE: A certified welder must complete the welding procedure when replacing one boss or both upper bosses.

9. Remove the boss alignment tool. 10. Weld the boss to the loader arm. *No stop/start welds NOTE: For a description of the 2x weld, please see image 9.

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Weld specifications and locations 1.

Loader arm

10 mm (25/64 in)

15 mm (19/32 in)

Upper boss

NOTE: Triple pass weld requirement.

RAPH14SSL0330BA

11. Inspect the new weld, and paint the loader arm.

RAIL14SSL0307BA

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Lower boss repair 1. Remove the front portion of the lower boss as shown in image 11. NOTE: Remove all material up to the plates of the loader frame.

RAIL12SSL0501AA

RAIL12SSL0500AA

RAIL12SSL0502AA

RAIL12SSL0503AA

2. Cut through the circular weld (1) next to the boss.

3. Use a disc grinder and a chisel to cut the upper and lower welds between the boss and the loader arm. 4. Remove the original boss.

5. Use a grinder to remove the weld material on the sides and upper plate and lower plate of the loader arm. Do not remove the base material of the loader arm. You will use the base material for positioning and rewelding when installing the new boss.

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6. Use a drum grinder to clean the surfaces on the loader arm.

7. Install the boss 380100288.

alignment

tool,

part

RAIL12SSL0504AA

RAIL12SSL0494AA

RAIL12SSL0493AA

RAIL12SSL0507AA

number

8. Install the boss 380100288.

alignment

tool,

part

number

9. Install the short tapered pin (2) (included with the boss alignment tool, part number 380100288) in the new pivot boss (3), and slide this assembly onto the lower rod and against the alignment tool (1) on the loader arm (4).

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10. To position the new boss horizontally, you must measure the distance from the new boss to the other pivot pin boss that is welded to the loader arm. To achieve the correct measurement of 822 mm (32 23/64 in) ± 2 mm (5/64 in) (1), slide the new boss, short tapered pin, and alignment tool on the lower rod, and adjust the equipment as necessary.

RAIL12SSL0570AA

RAIL12SSL0508AA

11. Disconnect the battery negative cable and positive cable. 12. Tack weld (1) the new pin boss into position. NOTE: A certified welder must complete the welding procedure when replacing one boss or both lower bosses.

13. Remove the boss alignment tool. 14. Install a new tapered pin with the new hardware into the new boss. Torque the flanged nut to 203 N·m (150 lb ft) NOTE: The pin will keep the tapered bore round during welding and keep weld spatter out of the bore.

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15. Weld the new boss in place. Refer to the weld information in image 21.

RAIL12SSL0492FA

Weld information Weld information (1) = 2x multi-pass weld from (C) to (D). Final total weld is 12 mm (15/32 in) high, extending out 36 mm (1 7/16 in) from the boss. (2) = 34 mm (1 11/32 in) weld (4) = 6 mm (15/64 in) (3) = 12 mm (15/32 in) (5) = 12 mm (15/32 in) 16. After the parts have cooled, prepare and paint as required.

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Arm - Remove WE WE

C227 L221 TIER 4B (FINAL) [NEM479941 - ]

Prior operation: Relieve the pressure in the lift arm cylinder. Please see Lift arm cylinder - Depressurising (35.701) 1. If applicable, disconnect the case drain hose (1) on the loader arm.

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2. Label and disconnect the auxiliary coupler hoses (1), and cap the open ports.

931002065

931002066

931001736

RAPH12SSL0049AA

3. Label and disconnect the bucket cylinder hoses, and the cap open ports.

4. Label and disconnect the quick disconnect hoses (if applicable), and cap the open ports.

5. Unplug the electrical connection (1).

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6. Support the loader arm (1) using an adequate lifting device.

931002023

931001618

931001616

931001625

7. Remove the snap rings (1) for the rod ends.

8. Remove the pins and washers (1) for the rod end. NOTE: Right hand side has the lock out.

9. Lower the cylinders (1) away from the loader arm.

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10. Lower the loader arm.

931002067A

11. Remove the left-hand side and right-hand side retaining bolts (1) for the loader arm.

931001622

931002068

931001624A

12. Remove left-hand side and right-hand side pins (1) for the loader arm.

13. Remove the loader arm.

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Arm - Install WE WE

C227 L221 TIER 4B (FINAL) [NEM479941 - ]

1. Using an adequate lifting device, raise the loader arm (1) into position on the machine.

931002023

931002068

931001622

2. Install the left-hand side and right-hand side pins (1) for the loader arm.

3. Install the left-hand side and right-hand side retaining bolts (1).

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4. Raise the cylinders (1), and position them in the loader arm.

931001625

931001616

931001618

RAPH12SSL0049AA

5. Insert the cylinders into the arm and secure the piston rod -end with the pins and washers (1). NOTE: Right-hand side has the lock out.

6. Install the snap rings (1) for the piston rod end.

7. Connect the electrical connections (1).

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8. Connect the quick coupler hoses (if applicable).

931001736

931002066

9. Connect the bucket cylinder hoses.

10. Connect the auxiliary coupler hoses (1).

931002065

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Front loader and bucket - Arm

Arm - Remove WE WE

C232 L228

NOTE: The following steps show left side, loader arm components. Please repeat all steps to right side, loader arm components. 1. Raise the loader arm, and engage the loader arm lock pins (1). Lower the loader arm down on the pins (1).

RAPH14SSL0351BA

RAPH12SSL0312AA

RAPH12SSL0326AA

2. Remove the body panels (1) around the engine area.

3. Remove the hold-down clamp (1) for the auxiliary hoses, located on the loader arm link.

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4. Remove the hold-down clamp (1) for the bucket cylinder hoses, located on the loader arm link.

RAPH12SSL0325AA

RAPH14SSL0351BA

RAPH12SSL0314AA

5. Raise the loader arm, and release loader arm lock pins. Carefully lower the loader arms.

6. Place a suitable lifting device on the bucket end of the loader arm.

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7. Disconnect, label, and cap the auxiliary hoses (2). 8. Remove the horn (1). 9. Disconnect and cap the hydraulic coupler hoses (3) (if applicable).

RAPH12SSL0323AA

RAPH15SSL0014BA

RAPH12SSL0313AA

10. Pull the hydraulic coupler hoses through the loader arm (if applicable).

11. Disconnect, label, and cap the bucket cylinder hoses (1).

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12. Remove the cylinder hardware (1) for the loader arm, and disconnect the loader arm cylinders from the loader arm.

RAPH12SSL0320AA

RAPH15SSL0018BA

RAPH15SSL0017BA

13. Support the loader arm link with a suitable lifting device.

14. Support the loader arm with a suitable lifting device, and remove the loader arm link hardware (1).

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15. Remove the hardware (1) for the loader arm link.

RAPH12SSL0322AA

RAPH15SSL0015BA

RAPH15SSL0016BA

16. Carefully remove the loader arm link.

17. Support the loader arm with a suitable lifting device.

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18. Remove the loader arm hardware (1), and lower the loader arm links (2).

RAPH12SSL0318AA

RAPH12SSL0317AA

19. Carefully remove the loader arm.

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Front loader and bucket - Arm

Arm - Install WE WE

C232 L228

NOTE: The following steps show left side, loader arm components. Please repeat all steps to right side, loader arm components. 1. Carefully move the loader arm into the installation position.

RAPH12SSL0317AA

RAPH12SSL0318AA

RAPH15SSL0015BA

2. Apply LOCTITE® SILVER GRADE ANTI-SEIZE to the tapered area of the pins and bosses. 3. Carefully place the loader arm link into installation position. 4. Install the loader arm link hardware (1).

5. Carefully place the loader arm link into installation position.

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6. Apply LOCTITE® SILVER GRADE ANTI-SEIZE to the tapered area of the pins and bosses. 7. Install the loader arm hardware (1). Torque the link bolt (1) to 645 - 873 N·m (476 - 644 lb ft).

RAPH15SSL0017BA

RAPH12SSL0322AA

RAPH12SSL0320AA

8. Install the hardware (1) for the loader arm link.

9. Connect the loader arm cylinders to the loader arm. 10. Install the hardware (1) for the loader arm cylinder.

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11. Push the hydraulic coupler hoses through the loader arm (if applicable).

RAPH15SSL0014BA

RAPH12SSL0323AA

RAPH12SSL0313AA

12. Connect the auxiliary hoses (2). 13. Install the horn (1). 14. Connect the hydraulic coupler hoses (3) (if applicable).

15. Connect the bucket cylinder hoses (1).

16. Remove the lifting device.

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17. Raise the loader arm, and engage the loader arm lock pins (1).

RAPH14SSL0351BA

RAPH12SSL0325AA

RAPH12SSL0326AA

18. Install the bucket cylinder hoses hold-down clamp (1) located on the loader arm link.

19. Install the hold-down clamp (1) for the auxiliary hoses, located on the loader arm link.

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20. Install the body panels (1) around the engine area.

RAPH12SSL0312AA

Next operation: Grease all lubrication points on the loader arm. Please see the operator’s manual for locations.

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Index Front loader and bucket - 82 Arm - 100 Arm - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Arm - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Arm - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Arm - Repair (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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Front loader and bucket - 82 Bucket - 300

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Front loader and bucket - 82 Bucket - 300

TECHNICAL DATA Bucket General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Bucket release device Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Bucket Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Bucket release device Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Quick coupler Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

(*) See content for specific models 47683911 27/02/2015

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Front loader and bucket - Bucket

Bucket - General specification WE WE WE WE

C227 C232 L221 L228

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)

3. 6 mm ( 1/4 in) groove 6 mm ( 1/4 in) fillet (weld twice-wrap ends)

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Front loader and bucket - Bucket

Bucket release device - Exploded view WE WE WE WE

C227 C232 L221 L228

BS04E150

Mechanical coupling mounting plate assembly (1) Mounting Plate (2) Left Hand Handle

(7) Latch Pin (8) Plug 47683911 27/02/2015

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(13) Pin (14) Bolt

Front loader and bucket - Bucket

(3) (4) (5) (6)

Dust Cap Grease Zerk Plate Spring Pin

(9) Clip (10) Pin (11) Compression Spring (12) Guide

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(15) Right Hand Handle (16) Pin (17) Bushing

Front loader and bucket - Bucket

Bucket - Replace WE WE WE WE

C227 C232 L221 L228

1. Cut or grind the old cutting edge from the bucket floor and sides. Remove all old weld and foreign material from the welding area.

SH88030

2. Straighten the bucket floor and sides if required. 3. Thoroughly clean the area where the new cutting edge will be welded. 4. Use dry AWS-E7018 low hydrogen electrodes or either of the following equivalent low hydrogen wire feed electrodes: Gas metal arc welding (C0² or argon C0²) AWS-E70S6 or flux cored arc welding AWS-E70T1. 5. Preheat the parts to be welded (both tack and final welds) to a minimum of 204 °C (400 °F). The preheat temperature must be throughout the entire thickness of the parts joined, and at least 51 mm ( 2 in) back from the joint. Maintain preheat throughout the entire welding operation. NOTE: This is a hardened steel edge. If not preheated, the cutting edge may later crack during use. 6. Tack weld the preheated parts starting at the center of the bucket and working toward the outside ends. 7. Finish welding the preheated parts starting at the center of the front edge of the bucket floor and working toward the outside ends. Repeat this operation at the back side of the cutting edge to bucket floor. 8. Do not remove the bucket from the welding environment until the weld and metal temperature drops to the ambient temperature. Do not force the cooling rate of the welds and material. 9. Follow the same welding procedure for welding the side cutting edges and bottom wear plates to the bucket.

Bolt On Cutting Edge Replacement 10. Loosen and remove the bolts from the cutting edge. 11. Remove the cutting edge from the bucket. 12. Install new cutting edge on the bucket. Install new bolts and tighten the bolts.

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Front loader and bucket - Bucket

Dirt Tooth Kit Installation/Bucket Dirt Tooth Kit 13. The dirt tooth kit consists of six teeth that are welded to the bucket cutting edge as indicated in image 4. The teeth are used to break up the material when rough digging conditions are experienced. This will make it easier to fill the bucket. The teeth are intended to be used only on dirt and foundry or low-profile buckets.

SH88032

SH88033

SH88034

Tooth Point Replacement 14. The points of the teeth are a replaceable "pin-on" design and can be obtained from Parts. 15. To replace the "pin-on" points, use a punch that just fits into the pin hole, (1), and drive the old retaining pin from the shank. 16. Place the new point over the shank and insert the retaining pin into the hole, (1). With a punch that contacts both sides of the metal part of the retaining pin, drive the pin until it is centered in the shank. NOTE: If the punch or driver is too small and just contacts the rubber center of the retaining pin, the pin will be damaged and will not retain the point.

Tooth Location and Installation 17. The bucket should be flat on the floor when placing and welding the teeth to maintain good weld points, (1). NOTICE: Remove the bucket from the loader while welding teeth to prevent damage to the loader electrical system. 18. Slide the replaceable points in place but do not attach with the steel/rubber pins as the rubber may be damaged during the welding process.

19. Locate the teeth on the bucket edge as indicated (see image 5). Please see table below for spacing values.

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Front loader and bucket - Bucket

BS04E165

Bucket Tooth Spacing NOTE: Position the teeth at these spacings, then re-center if necessary for equal spacing. Bucket width (1) 152.4 cm (60 in) 167.6 cm (66 in) 182.8 cm (72 in) 198.1 cm (78 in) 213.3 cm (84 in)

From end (2)

2nd tooth (3)

3rd tooth (4)

4th tooth (5)

5th tooth (6)

4.6 cm (1 13/16 in) 4.6 cm (1 13/16 in) 4.6 cm (1 13/16 in) 4.6 cm (1 13/16 in) 4.6 cm (1 13/16 in)

27.7 cm (10 15/16 in) 35.1 cm (13 27/32 in) 33 cm (13 in)

54.1 cm (21 5/16 in) 66.4 cm (25 27/32 in) 66 cm (26 in)

36 cm (14 3/16 in) 39 cm (15 3/8 in)

73.2 cm (28 5/6 in) 78.1 cm (30 3/4 in)

81.3 cm (32 in) 108.2 cm 5/8 in) 98.2 cm (37 127.5 cm 29/32 in) 7/32 in) 98.9 cm (38 131.7 cm 15/16 in) 7/8 in) 107.9 cm (42 143.9 cm 1/2 in) 11/16 in) 117.1 cm (46 156.2 cm 1/8 in) 1/2 in)

(42 (50 (51 (56 (61

6th tooth (7) 135.4 cm (53 5/16 in) 158.1 cm (62 1/4 in) 164.7 cm (64 7/8 in) 180 cm (70 7/8 in) 195.1 cm (76 13/16 in)

20. Welds are high carbon steel (tooth) to high carbon steel (bucket). Use welding rods marked 7018 or some comparable rod. Weld on both sides of the tooth from the back of the tooth towards the replaceable point at (1). Stop welding 13 mm ( 1/2 in) from the cutting edge as noted at (2). Weld along the back of the tooth at (3). A minimum 5 mm ( 3/16 in) fillet weld is required for this application.

SH88036

21. Weld in the direction shown at (1). 47683911 27/02/2015

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Front loader and bucket - Bucket

22. Weld a 5 mm ( 3/16 in) fillet weld along both sides and rear of the tooth at (2), high carbon steel to high carbon steel.

BS04E166

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Front loader and bucket - Bucket

Bucket release device - Remove WE WE WE WE

C227 C232 L221 L228

Before removing the coupler, remove any attachment from the machine. 2. Tilt the coupler forward until the face of the plate is resting on the ground. 3. On the left-hand side of the coupler, remove the hardware (1) securing the pin (2) attached to the tilt cylinder. 4. Remove the pin (2) from the coupler. This will remove the tilt cylinder from the coupler. 5. Repeat steps 3 and 4 on the right-hand side.

931002056

20115831

6. Remove the hardware (1) from the pivot pin (2) securing the coupler to the machine. 7. Repeat step 7 for the left-hand side.

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Front loader and bucket - Bucket

Bucket release device - Disassemble WE WE WE WE

C227 C232 L221 L228

Prior operation: Remove the bucket release device. See Bucket release device - Remove (82.300) NOTE: Remove all attachments from working arm prior to removal of the mechanical coupler 1. Release locking pins by placing coupler handles (1) in up position.

931002056

86092923

931001791

2. Using a hammer and punch remove the spring pin (1), dropping the latch pin out of the bottom of the coupler (2).

3. Remove clip (1) from handle pivot pin.

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Front loader and bucket - Bucket

4. While supporting coupler handle, remove handle pivot pin (1).

931001788

20115824

20115823

5. Remove handle and locking pin assembly from coupler.

6. To disassemble the locking pin assembly carefully unthread pin (1), from bolt (2) and check parts for wear.

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Front loader and bucket - Bucket

Bucket release device - Assemble WE WE WE WE

C227 C232 L221 L228

1. Assemble the handle and locking pin assembly by inserting pin (1) through hole (2) in the handle. Install bolt (3) through pin (2). Install bushing spacer (4), compression spring (5), and thread pin (6) onto bolt (3) holding assembly together.

20115823

20115824

86092923

2. Install the assembled unit (1) through the inside of the coupler (2).

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Front loader and bucket - Bucket

3. While supporting the coupler handle in place, install pivot pin (1).

931001788

931001790

86092922

4. Install clip (1) on backside of pivot pin.

5. Insert the latch pin (1) through the bottom of the coupler, and secure to the locking pin assembly with a spring pin (2).

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Front loader and bucket - Bucket

Bucket release device - Install WE WE WE WE

C227 C232 L221 L228

1. Move the machine into position, and align the holes to insert the pivot pins (2). 2. On the right-hand side of machine, insert the pivot pin and install the hardware (1) to secure the pin in place. Torque the hardware (1) to 181.0 - 245 N·m (134 181 lb ft). 3. Repeat step 2 for the left-hand side of the machine.

931002057

931002056

4. Extend the tilt cylinders (3) until they align with the top holes of the coupler. 5. On the left-hand side of machine, insert the pin (2) into the coupler as shown, through the cylinder-end and out the other side of the coupler. 6. Install the hardware (1) to the pin locking plate, and securing the pin to the coupler. 7. Repeat steps 5 and 6 for the right-hand side of the machine.

8. Start the machine and cycle through the positions of the coupler to bleed the system of air.

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Front loader and bucket - Bucket

Quick coupler - Remove WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Hydraulic fluid is under extreme pressure. Rest the bucket or attachment on the ground. Shut the engine off, turn the key on, and move the hydraulic control lever through all movements several times to relieve residual pressure in the system. Failure to comply could result in death or serious injury. W0161A

WARNING Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0178A

1. Remove the bucket or attachment from the mounting plate.

20092924

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Front loader and bucket - Bucket

2. Set the quick coupler in the unlocked position.

93106838

20111348

20111349

3. Tilt the coupler forward until the face of the plate is resting on the ground. 4. On the right-hand side of the coupler, remove the hardware (1) securing the pin (2) attached to the tilt cylinder. 5. Remove the pin (2) from the couple. This will remove the tilt cylinder from the coupler.

6. Repeat steps 4 and 5 on the left-hand side. 7. Mark the hoses and ports on the valve. This will help when reinstalling the hoses to the proper ports. 8. Remove the two hoses (1) from the hydraulic valve (2). 9. Plug or cap the valve ports and the hose ends. This will keep the hydraulic system from getting contaminated.

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Front loader and bucket - Bucket

NOTE: For units built November 2013 and prior follow steps 10 through 14. 10. Remove the dust cap (1) by prying it from the inner side of the coupler hub. NOTE: Loader arm removed from Figure 5 for clarity.

RAPH16SSL0068BA

RAPH16SSL0069BA

931002057

11. Remove the M16 x 180 mm flange bolt (1).

12. Remove the hardware (1) from the pivot pin (2) securing the coupler to the loader arm. 13. Remove the pivot pin from the machine. 14. Repeat steps 10 through 13 on the left-hand side.

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Front loader and bucket - Bucket

NOTE: For units built November 2013 and later follow steps 15 through 19. 15. Remove the snap ring (1) from the inner side of the coupler hub.

RAPH16SSL0070BA

RAPH16SSL0071BA

16. Remove the o-ring (1), then the cap (2) from the coupler hub.

17. Remove the M16 nut (1).

RAPH16SSL0073BA

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Front loader and bucket - Bucket

18. Remove the M16 x 180 mm flange bolt (1) from the loader arm, the washer (2), the rod wiper (3), and the pivot pin to disconnect from the loader arm.

RAPH16SSL0072BA

19. Repeat steps 15 through 18 on the left-hand side.

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Front loader and bucket - Bucket

Quick coupler - Install WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

NOTE: The images in these instructions may not be the actual model being worked on. All models have the same concept. NOTE: For units built November 2013 and prior, follow steps 1 through 5. 1. Move the machine into position and align the holes to insert the pivot pins (2). NOTE: Apply LOCTITE® ANTI-SEIZE to the tapered ends of the pivot pins (2) prior to the installation. 2. On the right-hand side of machine, insert the pivot pin (2) and place the wiper seal then the washer onto the pin, in between the coupler and the loader arm. 3. Install the M16 x 180 mm bolt (3) from the inside of the coupler frame outwards through the loader arm and secure with the M16 nut (1). Torque the nut (1) to 181 - 215 N·m (134 - 159 lb ft). 931002057

RAPH16SSL0069BA

RAPH16SSL0068BA

4. Install the dust cap (1) onto the inner side of the coupler hub by tapping it into place. 5. Repeat steps 2 through 4 for the left-hand side of the machine.

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Front loader and bucket - Bucket

NOTE: For units built November 2013 and later, follow steps 6 through 11. 6. Move the machine into position and align the holes to insert the pivot pins (1). NOTE: Apply LOCTITE® ANTI-SEIZE to the tapered ends of the pivot pins (1) prior to the installation. 7. Install the rod wiper (2), and the washer (3) onto the pivot pin (1). 8. Insert the M16 x 180 mm bolt (4) through the loader arm and into the pivot pin (1) securing with the M16 nut (5). Torque the nut (5) to 181 - 215 N·m (134 - 159 lb ft).

RAPH16SSL0072BA

RAPH16SSL0073BA

RAPH16SSL0071BA

9. Install the cap (2) and the o-ring (1) over the nut.

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Front loader and bucket - Bucket

10. Secure the cap and the o-ring with the snap ring (1). 11. Repeat steps 6 through 10 for the left-hand side of the machine.

RAPH16SSL0070BA

20111348

20111349

12. Extend the tilt cylinders until they align with the top holes of the coupler. 13. On the right hand side of machine, insert the pin (2) into the coupler as shown, through the cylinder end and out the other side of the coupler. 14. Install the hardware (1) to the pin locking plate, securing the pin to the coupler. 15. Repeat steps five and six for the left hand side of the machine.

16. Remove the caps or plugs from the hydraulic valve (2) and the hoses (1) and install the two hoses into their correct ports. Tighten hoses to standard torque.

17. Start the machine and cycle through the positions of the coupler to bleed the system of air.

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Index Front loader and bucket - 82 Bucket - 300 Bucket - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket release device - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket release device - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket release device - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket release device - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket release device - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quick coupler - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quick coupler - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

47683911 27/02/2015 EN

SERVICE MANUAL Platform, cab, bodywork, and decals C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

47683911 27/02/2015

Contents Platform, cab, bodywork, and decals - 90

[90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.154] Cab doors and hatches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3 [90.124] Pneumatically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4

47683911 27/02/2015

Platform, cab, bodywork, and decals - 90 Cab - 150

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Platform, cab, bodywork, and decals - 90 Cab - 150

SERVICE Cab Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Cab tilting system Tilt (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Lower (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Tilt (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Lower (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

(*) See content for specific models 47683911 27/02/2015

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Platform, cab, bodywork, and decals - Cab

Cab - Remove WE WE WE WE

C227 TIER 4B (FINAL) [NDM471837 - ] C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

The following procedure has been performed on a vertical lift machine with an inclosed, HVAC cab. Removing an opened cab is very similar. Removing the cab on a radial lift machine is very similar. Please use this procedure for all cab removals on all types of machines. Prior operation: If equipped with a cab heater, drain the coolant. Please see Radiator - Drain fluid (10.400) Prior operation: If equipped with a cab air conditioner, discharge the refrigerant. Please see Air conditioning - Discharging (50.200) Prior operation: Tilt the cab. Please see Cab tilting system - Tilt (90.150) 1. Disconnect the A/C lines (1), if applicable. 2. Disconnect the heater hoses (2), if applicable.

931001757

93106923

3. Remove the cup holder (1).

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Platform, cab, bodywork, and decals - Cab

4. Detach the grounds (1) from the body.

RAIL14SSL0464BA

RAPH14SSL0494BA

RAIL14SSL0466BA

WARNING Crushing hazard! Use extreme caution during the following procedure. Perform this procedure exactly as instructed in this manual. Failure to comply could result in death or serious injury. W0368A

Verify that the red lock tube (2) is over the pivot linkage. 6. Disconnect the support strut (1) from the cab. NOTICE: Do not remove the pivot linkage. 7. Remove the support strut mount (3). 8. Remove the red knob from the override valve for the loader arm. 9. Detach the rubber mat from the heel plate.

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Platform, cab, bodywork, and decals - Cab

10. Detach the linkage (1) from the locking device for the loader arm, if applicable.

RAIL14SSL0465BA

23112407

RAPH12UTL0646AA

11. Detach the linkage (1).

12. Unbolt the heel plate (1).

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Platform, cab, bodywork, and decals - Cab

13. Unbolt the heel plate.

RAIL14SSL0471BA

14. Disconnect the harnesses (1).

RAIL14SSL0465BA

RAIL14SSL0468BA

15. Move the heel plate (1) away from the harness. 16. Carefully pull the harness through the access hole.

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Platform, cab, bodywork, and decals - Cab

17.

WARNING Heavy parts! Support designated component(s) with adequate lifting equipment. Failure to comply could result in death or serious injury. W1024A

Using adequate lifting equipment, carefully lower the cab.

RAPH14SSL0351BA

RAIL14SSL0469BA

RAIL14SSL0470BA

18. Remove the bolts on the pivot points.

19. Remove the CAN diagnostic connector (1). 20. Disconnect the pivot linkage (2) from the cab and from the body.

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21. Remove the windows from the cab, if applicable. 22. Using adequate lifting equipment, carefully lift and remove the cab.

RAIL14SSL0473BA

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Platform, cab, bodywork, and decals - Cab

Cab - Install WE WE WE WE

C227 TIER 4B (FINAL) [NDM471837 - ] C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228

The following procedure has been performed on a vertical lift machine with an inclosed, HVAC cab. Installing an opened cab is very similar. Installing a cab on a radial lift machine is very similar. Please use this procedure for all cab installations on all types of machines. Prior operation: If applicable, remove the windows from the cab. 1. Using adequate lifting equipment, carefully lower the cab onto the frame.

RAIL14SSL0473BA

RAIL14SSL0469BA

2. Install the bolts on the pivot mounts. Torque the bolts to 42 N·m (31 lb ft). NOTE: The bolts must have the nuts on the inside of the mounts.

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Platform, cab, bodywork, and decals - Cab

WARNING Heavy parts! Support designated component(s) with adequate lifting equipment. Failure to comply could result in death or serious injury. W1024A

Tilt the cab forward and onto a jack stand. 4. Secure the cab to the jack stand by attaching a strap to the top of the cab and bottom of the chassis, and tighten the strap.

RAIL14SSL0014BA

RAPH14SSL0494BA

RAPH15SSL0076BA

5. Attach the pivot linkage (1) to the cab. 6. Verify that the red lock tube (2) is over the pivot linkage (1). 7. Apply LOCTITE® 567™ PST PIPE SEALANT to the threads of the mounting bolt (3) for the support strut (4). 8. Install the mounting bolt (3) into the body. Torque the mounting bolt (3) to 27 N·m (20 lb ft). 9. Install the support strut (4).

10. Install the CAN diagnostic connector (1).

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Platform, cab, bodywork, and decals - Cab

11. Attach the grounds (1) to the body.

RAIL14SSL0464BA

RAIL14SSL0468BA

23111115

12. Carefully insert the harness through the access hole.

13. Apply a bead of LOCTITE® RTV SILICONE CLEAR (2), from arrow to arrow, between frame and the heel plate (1). NOTE: The cab, axles, motors, and pumps have been removed for picture clarity. You do not need to remove these items to apply silicone to the required areas.

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Platform, cab, bodywork, and decals - Cab

14. Install the heel plate. NOTE: Install the bolts closest to the foot plate first for easier assembly.

RAIL14SSL0471BA

15. Install the heel plate (1). NOTE: Install the bolts closest to the foot plate first for easier assembly.

RAPH12UTL0646AA

RAIL14SSL0465BA

16. Connect the harnesses (1). 17. Attach the linkage (2) to the locking device for the loader arm, if applicable.

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Platform, cab, bodywork, and decals - Cab

18. Attach the linkage (1). 19. Connect the linkage (1) to the hydrostatic drive pumps and main control valve, if applicable.

23112407

RAIL14SSL0466BA

93106923

931001817

20. Install the rubber mat onto the heel plate. 21. Install the red knob onto the override valve for the loader arm. Torque the red knob to 11 - 16 N·m (97 142 lb in).

22. Install the cup holder (1).

23. Connect the A/C lines (1), if applicable. 24. Connect the heater hoses (2), if applicable.

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Platform, cab, bodywork, and decals - Cab

25. Carefully lower the cab. Verify that the cab tilts and lowers without damaging any components.

RAPH14SSL0351BA

Next operation: Remove the lifting equipment from the cab. Next operation: Install the windows, If applicable.

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Platform, cab, bodywork, and decals - Cab

Cab tilting system - Tilt WE WE

C227 L221

DANGER Crushing hazard! The loader arm is unsupported during support strut removal. Do not enter or exit the operator's compartment with an unsupported loader arm. Two persons are required during storage. One person should remove and store the support strut while the operator remains in the operator's compartment. Failure to comply will result in death or serious injury. D0021B

1. Park the machine on a level surface. 2. Remove the bucket or attachment from the mounting plate.

20092924

93106848A

RAIL14SSL0418AA

3. Remove the support strut pin (A) and let the support strut (B) rest on the lift cylinder barrel (C).

4. Raise the loader arm.

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Platform, cab, bodywork, and decals - Cab

5. The support strut (B) will fall onto the cylinder rod (D). 6. Ask an assistant to insert the pin (A) into the support strut (B). 7. Stop the engine. 8. Gently lower the loader arm so the support strut (B) is against the cylinder barrel (C) and in the locked position. NOTE: The loader arm can be lowered by pulling up on the red control knob located on the right-hand side of the operator’s seat. 93106854A

931001633

93107498

9. Remove the two, rear retaining nuts (E).

10. Using the hand holds located at the front of the cab, pull the cab forward.

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Platform, cab, bodywork, and decals - Cab

11. Confirm that the red lock tube (F) has lowered over pivot linkage.

RAPH12SSL0420BA

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Platform, cab, bodywork, and decals - Cab

Cab tilting system - Lower WE WE

C227 L221

1. Raise the red lock tube (F) over the cab pivot linkage. 2. Push the cab down.

RAPH12SSL0420BA

931001633

93106854A

3. Install the retaining nuts (E). Torque the nuts (E) to 170 N·m (125 lb ft).

Placing the support strut in storage requires a second person. The operator must remain in the seat during this procedure. 4. While sitting in the operator's seat with the seat belt fastened and the engine running, engage the hydraulics then raise the loader arm until the support strut (B) is not resting on the end of the cylinder barrel (C).

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Platform, cab, bodywork, and decals - Cab

5. Instruct the second person to remove the support strut pin (A) and place the support strut in the stowed position and reinstall the support strut pin (A). When the second person has cleared the area, the loader arm can be lowered.

93106848A

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Platform, cab, bodywork, and decals - Cab

Cab tilting system - Tilt WE WE

C232 L228

DANGER Crushing hazard! Failure to engage the loader arm support pin(s) could cause the loader arm to fall unexpectedly. Verify that the loader arm support pin(s) are engaged. Failure to comply will result in death or serious injury. D0133B

1. Park the machine on a level surface. 2. Remove the bucket or attachment from the mounting plate.

20092924

RAPH14SSL0351BA

3. Fully raise the loader arm.

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Platform, cab, bodywork, and decals - Cab

4. Rotate the lock lever toward the operator’s seat (clockwise) to engage the lock pin(s). NOTE: The lock lever for the lift arm is located on the lefthand side of the operator’s seat. See the instructional sign located by the lock lever.

93109334

93107457

931001633

5. Stop the engine. 6. Gently lower the loader arm onto the lock pin(s). NOTE: The loader arm can be lowered onto the lock pin(s) by pulling up on the red control knob located near the righthand side of the operator’s seat.

7. Remove the two, rear retaining nuts (E).

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Platform, cab, bodywork, and decals - Cab

8. Using the hand holds located at the front of the cab, pull the cab forward.

RAPH11SSL0016BA

RAPH12SSL0420BA

9. Confirm that the red lock tube (F) has lowered over the pivot linkage.

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Platform, cab, bodywork, and decals - Cab

Cab tilting system - Lower WE WE

C232 L228

1. Raise the red lock tube (F) over the cab pivot linkage. 2. Push the cab down.

RAPH12SSL0420BA

931001633

RAPH14SSL0351BA

3. Install the retaining nuts (E). Torque the nuts (E) to 170 N·m (125 lb ft).

4. Start the engine, and engage the hydraulics. 5. Fully raise the loader arm.

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Platform, cab, bodywork, and decals - Cab

6. Rotate the lock lever away from the seat (counter clockwise) to retract the lock pin(s). 4. Slowly lower the loader arm.

93109334B

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Index Platform, cab, bodywork, and decals - 90 Cab - 150 Cab - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab tilting system - Lower (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab tilting system - Tilt (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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Platform, cab, bodywork, and decals - 90 Cab doors and hatches - 154

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Platform, cab, bodywork, and decals - 90 Cab doors and hatches - 154

FUNCTIONAL DATA Cab doors and hatches Overview - Door switch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Platform, cab, bodywork, and decals - Cab doors and hatches

Cab doors and hatches - Overview - Door switch WE WE WE WE

C227 C232 L221 L228

If a unit has a door, the door switch will prevent the operator from operating the loader arm and bucket while the door is open. This safety switch prevents damage to the machine and to the operator. If the operator opens the door, the joystick control of loader and bucket will be shut off and the port locks will engage. Once the door is closed, the operator will regain control of the attachment. The door switch is a magnetic reed switch. The switch operates on low current, and closes in the presence of metal. The switch mush be adjusted properly to function correctly. The door switch function is active when Ignition is ON. ATTENTION: Usage of the override connector (1) will bypass all safety features associated with the door switch. Use the override connector with extreme caution. Failure to comply will result in serious injury or death. Failure to comply can result in machine damage. The operator can bypass the door switch by using the override connector (1). To use, unplug the washer nozzle tube (2) and remove the override connector (1), disconnect the door switch harness (3), and plug the override connector (1) into the door switch harness (3).

RAPH12SSL0300BA

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Index Platform, cab, bodywork, and decals - 90 Cab doors and hatches - 154 Cab doors and hatches - Overview - Door switch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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Platform, cab, bodywork, and decals - 90 Mechanically-adjusted operator seat - 120

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Platform, cab, bodywork, and decals - 90 Mechanically-adjusted operator seat - 120

SERVICE Operator seat Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat

Operator seat - Remove WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

Prior operations 1. Remove the bucket and/or attachments from the coupler. 2. Raise the loader arms, and tilt the cab forward. See 3. Disconnect the battery from the machine. See Battery - Disconnect (55.302) for the procedure.

Removal 1. Remove the four nuts (1) and the four washers (2) that retain the seat assembly from the underside of the cab. NOTE: The right-hand nuts (1) are shown in Figure 1. The Heating, Ventilation, and Air-Conditioning (HVAC) lines are covering the left-hand nuts.

RAIL15SSL0042BA

RAPH16SSL0198BA

2. Disconnect the connector (1) from the rear of the seat to the cab harness. 3. Lift the seat out of the cab.

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Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat

Operator seat - Install WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

1. Place the seat into the cab, aligning the seat adjustment studs into the cab holes. 2. Connect the connector (1) from the rear of the seat to the cab harness.

RAPH16SSL0198BA

RAIL15SSL0042BA

3. Install the four washers (1) and the four nuts (2) to the protruding seat studs from the underside of the cab. Torque the nuts (2) to 15.0 - 24.0 N·m (11.0 - 18.0 lb ft).

Post operations 1. Connect the battery to the machine. See Battery Connect (55.302) for the procedure. 2. Tilt the cab back and secure to the chassis. Lower the loader arms. See

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Index Platform, cab, bodywork, and decals - 90 Mechanically-adjusted operator seat - 120 Operator seat - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator seat - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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Platform, cab, bodywork, and decals - 90 Pneumatically-adjusted operator seat - 124

C227 TIER 4B (FINAL) [NDM471837 - ] C232 TIER 4B (FINAL) [NFM402195 - ] L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

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Contents Platform, cab, bodywork, and decals - 90 Pneumatically-adjusted operator seat - 124

SERVICE Pneumatically-adjusted operator seat Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

(*) See content for specific models 47683911 27/02/2015

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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat

Pneumatically-adjusted operator seat - Remove WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

RAIL15SSL0042BA

RAPH16SSL0198BA

2. Disconnect the connector (1) from the rear of the seat to the cab harness. 3. Lift the seat out of the cab.

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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat

Pneumatically-adjusted operator seat - Install WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

1. Place the seat into the cab, aligning the seat adjustment studs into the cab holes. 2. Connect the connector (1) from the rear of the seat to the cab harness.

RAPH16SSL0198BA

RAIL15SSL0042BA

3. Install the four washers (1) and the four nuts (2) to the protruding seat studs from the underside of the cab. Torque the nuts (2) to 15.0 - 24.0 N·m (11.0 - 18.0 lb ft).

Post operations 1. Connect the battery to the machine. See Battery Connect (55.302) for the procedure. 2. Tilt the cab back and secure to the chassis. Lower the loader arms. See

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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat

Pneumatically-adjusted operator seat - Assemble WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

NOTICE: Instructions include individual torque values. If an individual torque value is not present, then hand tighten only. 1. Install the electric lift pump (3), the heater switch (4), and the air valve (5) into the frame and the front bracket. NOTE: DO NOT exceed the max torque on the air valve nut which is 21.7 N·m (16.0 lb ft). 2. Install the air bladder (1), and the shock (2) into the frame.

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RAPH16SSL0222BA

RAPH16SSL0221BA

Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat

3. Install the pneumatic lines (2) into the frame and connect them to the components. NOTE: Finger tighten the sleeve nuts on the air fitting bodies, and insert the tubing until it bottoms out in the fitting. Tighten the sleeve nut one full turn ( 360 °) with a wrench to complete the seal. NOTE: The electrical harness is highlighted in RED, the pneumatic hose is highlighted in BLUE. 4. Secure the electrical harness (1) into the base frame and connect it to the components.

RAPH16SSL0220BA

RAPH16SSL0219BA

RAPH16SSL0217BA

5. Install the front bracket (6) to the upper frame structure (1) using the bolts. Install the upper frame structure (1) to the lower frame structure (2), by sliding the weight adjustment bar (4) into the front side cages (5), then installing the pins (3).

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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat

6. Connect the operators presence switch (1) to the electrical harness under the seat cushion and install the seat cushion (2) to the frame. Install the push-in fasteners and the screws to the seat cushion to secure the front bracket in place.

RAPH16SSL0215BA

RAPH16SSL0216BA

RAPH16SSL0218AA

RAPH16SSL0214AA

7. Install the lower boot (1) to the frame assembly with the push-in fasteners (2). 8. Install the seat adjustment slider assemblies (3) by securing with the four bolts to the seat frame. 9. Install the seat belt tether strap (4) by installing the bolt (5) on the right-hand side of the seat. NOTE: Torque the bolt and nut to 58.0 N·m (43.0 lb ft).

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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat

10. Install the upper frame to the seat assembly by installing the one shoulder bolt (1) on the left-hand side, and the two bolts (2)(shoulder bolt on top, hex bolt on the bottom) on the right-hand side of the seat. NOTE: The lower hex bolt on the right-hand side is to be torqued to 6.8 - 13.6 N·m (5.0 - 10.0 lb ft). NOTE: The upper shoulder bolt on the right-hand side and the shoulder bolt on the left-hand side are to be torqued to 13.5 - 20.3 N·m (10.0 - 15.0 lb ft).

RAPH16SSL0213BA

RAPH16SSL0212BA

RAPH16SSL0211BA

11. Install the upper seat cushion by pressing the cushion into the frame and securing the cloth with the six push-in fasteners (1).

12. Install the back seat cover by installing the four screws (1) to the upper frame. NOTE: Torque the screws (1) to 4.1 - 8.1 N·m (3.0 - 6.0 lb ft).

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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat

13. Install the seat literature tray by installing the screw (1) at the top of the seat cover. NOTE: Torque the screw (1) to 4.1 - 8.1 N·m (3.0 - 6.0 lb ft).

RAPH16SSL0210BA

Post operation 1. Install the seat assembly into the cab. See Pneumatically-adjusted operator seat - Install (90.124) for the proper procedure.

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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat

Pneumatically-adjusted operator seat - Disassemble WE WE WE WE

C227 C232 L221 TIER 4B (FINAL) [NEM479941 - ] L228 TIER 4B (FINAL) [NFM401134 - ]

Prior operations 1. Remove the seat assembly from the cab. See Pneumatically-adjusted operator seat - Remove (90.124) for the proper procedure. 2. Relieve the air pressure from the pneumatic bladder by pulling the air valve on the front side of the seat and allowing the pressure to escape.

Disassembly 1. Remove the seat literature tray by removing the screw (1) at the top of the seat cover.

RAPH16SSL0210BA

RAPH16SSL0211BA

2. Remove the back seat cover by removing the four screws (1) securing the cover to the upper frame.

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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat

3. Remove the upper seat cushion by removing the six push-in fasteners (1) securing the cloth to the upper frame.

RAPH16SSL0212BA

RAPH16SSL0213BA

RAPH16SSL0214AA

4. Remove the upper frame from the seat by removing the one bolt (1) on the left-hand side, and the two bolts (2) on the right-hand side of the seat.

5. Remove the seat belt tether strap (1) by removing the bolt (2) on the right-hand side of the seat. 6. Remove the seat adjustment slider assemblies (3) by removing the four bolts securing them to the seat frame.

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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat

7. Remove the lower boot (1) from the seat by removing the push-in fasteners (3) securing it to the frame. 8. Disconnect the operators presence switch (4) from the electrical harness under the seat cushion and remove the seat cushion (2) from the frame. Remove the push-in fasteners and the screws from the seat cushion that are securing the front bracket in place.

RAPH16SSL0218AA

RAPH16SSL0216BA

RAPH16SSL0215BA

RAPH16SSL0217BA

9. Remove the front bracket (6) from the upper frame structure (1) by removing the bolts. Remove the upper frame structure (1) from the lower frame structure (2), by removing the pins (3) and sliding the weight adjustment bar (4) out of the front-side frame cages (5).

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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat

10. Disconnect the electrical harness (1) from the components, and remove the harness from the base frame. NOTE: The electrical harness is highlighted in RED, the pneumatic hose is highlighted in BLUE. 11. Disconnect the pneumatic lines (2) and remove from the frame.

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RAPH16SSL0219BA

RAPH16SSL0220BA

Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat

12. Remove the air bladder (1), and the shock (2) from the frame. 13. Remove the electric lift pump (3), the heater switch (4), and the air valve (5) from the frame and the front bracket.

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RAPH16SSL0221BA

RAPH16SSL0222BA

Index Platform, cab, bodywork, and decals - 90 Pneumatically-adjusted operator seat - 124 Pneumatically-adjusted operator seat - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pneumatically-adjusted operator seat - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pneumatically-adjusted operator seat - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pneumatically-adjusted operator seat - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47683911 27/02/2015

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

47683911 27/02/2015 EN

SPECIAL TOOL INDEX Genuine 380003339 [Small Universal rolling torque tool] 380003339 [Small Universal rolling torque tool] 380500129 [7 Gauge Hydraulic Pressure Test Kit] 380500129 [7 Gauge Hydraulic Pressure Test Kit] 380500129 [7 Gauge Hydraulic Pressure Test Kit] 380500128 [4 Gauge Hydraulic Pressure Test Kit] CAS1871 [Seal Press] CAS1871 [Seal Press] CAS1871 [Seal Press] CAS1871 [Seal Press] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500129 [7 Gauge Hydraulic Pressure Test Kit] 34788 [Refrigerant Recover Station for R134a] 34788 [Refrigerant Recover Station for R134a] 34788 [Refrigerant Recover Station for R134a] 34788 [Refrigerant Recover Station for R134a] 34788 [Refrigerant Recover Station for R134a] 34788 [Refrigerant Recover Station for R134a] 380040185 [Harness Diagnostic /Repair Kit (NEF)]

Reference

PAGE

Axle - Assemble

25.1 / 14

Axle - Assemble

27.1 / 14

Pump Charge pressure relief valve - Pressure test

29.2 / 15

Pump Charge pressure relief valve - Pressure test

29.2 / 15

Pump Pressure limiter valve - Pressure test

29.2 / 17

Pump - Test

29.2 / 21

Hydraulic systems - Cleaning Hydraulic systems - Cleaning Hydraulic systems - Cleaning Oil reservoir - Apply vacuum Fixed displacement pump - Flow test - Auxiliary couplers

35.1 / 45 35.1 / 45 35.1 / 46 35.2 / 4 35.3 / 5

Fixed displacement pump - Flow test - T fitting

35.3 / 8

Fixed displacement pump - Preliminary test

35.3 / 16

Main control valve - Test - Circuit leakage

35.4 / 5

Main relief valve - Pressure test - T fitting

35.4 / 24

Relief valve - Pressure test - Auxiliary couplers

35.4 / 28

Auxiliary hydraulic function control - Test

35.5 / 6

Pilot valve - Pressure test

35.6 / 8

Air conditioning - Discharging

50.2 / 8

Air conditioning - Discharging

50.2 / 8

Air conditioning - Discharging

50.2 / 8

Air conditioning - Charging

50.2 / 10

Air conditioning - Charging

50.2 / 10

Air conditioning - Charging

50.2 / 10

Harnesses and connectors - Overview

55.8 / 12

47683911 27/02/2015

Genuine 380040185 [Harness Diagnostic /Repair Kit (NEF)] 380100288 [Loader Arm Pivot Boss Alignment Tool] 380100288 [Loader Arm Pivot Boss Alignment Tool] 380100288 [Loader Arm Pivot Boss Alignment Tool] 380100288 [Loader Arm Pivot Boss Alignment Tool] 380100288 [Loader Arm Pivot Boss Alignment Tool] 380100288 [Loader Arm Pivot Boss Alignment Tool]

Kit CAS10162A [Portable Filter Caddy] CAS10162A [Portable Filter Caddy] CAS10192 [Vacuum Pump] CAS10508 [Fitting Kit For Unions] CAS10193 [ Kit For Vacuum Pump] 380001737 [Nitrogen Charging Kit With High Pressure Regulator And Hoses Complete]

Reference

PAGE

Harnesses and connectors - Overview

55.8 / 22

Arm - Repair

82.1 / 3

Arm - Repair

82.1 / 4

Arm - Repair

82.1 / 4

Arm - Repair

82.1 / 8

Arm - Repair

82.1 / 8

Arm - Repair

82.1 / 8

Reference

PAGE

Hydrostatic transmission - Decontaminating

29.3 / 4

Hydraulic systems - Cleaning

35.1 / 45

Hydraulic systems - Cleaning Hydraulic systems - Cleaning

35.1 / 45 35.1 / 46

Oil reservoir - Apply vacuum

35.2 / 4

Accumulator - Discharging

35.8 / 39

47683911 27/02/2015

CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

47683911 27/02/2015 EN