New Holland Skid Steer Loader L218, L220 Tier 4B Service Repair Manual (47711684) – PDF Download by www.heydownloads.com

SERVICE MANUAL L218 L220 Tier 4B (final) 200 Series Skid Steer Loader

SERVICE MANUAL L218 L220 Tier 4B (final) 200 Series Skid Steer Loader L218 PIN NEM476231 and above L220 PIN NEM475087 and above

1/2 Part number 47711684

Part number 47711684 1st editon English May 2014

SERVICE MANUAL L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

47711684 06/05/2014 EN

Link Product / Engine Product L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

Market Product Europe Europe

47711684 06/05/2014

Engine N4LDI-TA-45SL N4LDI-TA-50SL

Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

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

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

Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.128] Auxiliary hydraulic function control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.350] Safety and main relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5 [35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6 [35.600] High flow hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7 [35.701] Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8 [35.723] Front loader bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9 [35.724] Front loader hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10 47711684 06/05/2014

[35.734] Tool quick coupler hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.11

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

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 [55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.019] Hydrostatic drive control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.031] Parking brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 [55.036] Hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11 [55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.12 [55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.13 [55.525] Cab engine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.14 [55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.15 [55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.16

Front loader and bucket............................................................... 82 [82.100] Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.1 47711684 06/05/2014

[82.300] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.2

Platform, cab, bodywork, and decals ............................................. 90 [90.154] Cab doors and hatches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1

47711684 06/05/2014

INTRODUCTION

47711684 06/05/2014

Contents INTRODUCTION Foreword - Important notice regarding equipment servicing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety rules (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety rules - Personal safety (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety rules - Ecology and the environment (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Torque - Minimum tightening torques for normal assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Torque - Standard torque data for hydraulics (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Basic instructions - Shop and assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Hydraulic contamination – Contamination (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 General specification - Left-hand instrument cluster (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 General specification - Electronic Instrument Cluster (EIC) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 General specification - Advanced Instrument Cluster (AIC) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 General specification - Biodiesel fuels (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Product identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

(*) See content for specific models 47711684 06/05/2014

INTRODUCTION

Foreword - Important notice regarding equipment servicing L218 L220

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 information in this manual is up-to-date at the date of the publication. It is the policy of the manufacturer for continuous improvement. Some information could not be updated due to modifications of a technical or commercial type, or changes to the laws and regulations of different countries. In case of questions, refer to your NEW HOLLAND CONSTRUCTION Sales and Service Networks.

47711684 06/05/2014

INTRODUCTION

Safety rules L218 L220

WE WE

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 - Personal safety L218 L220

WE WE

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

Safety rules - Ecology and the environment L218 L220

WE WE

Soil, air, and water are vital factors of agriculture and life in general. When legislation does not yet rule the treatment of some of the substances required by advanced technology, sound judgment should govern the use and disposal of products of a chemical and petrochemical nature. NOTE: The following are recommendations that may be of assistance: • Become acquainted with and ensure that you understand the relative legislation applicable to your country. • Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, antifreeze, cleaning agents, etc., with regard to their effect on man and nature and how to safely store, use, and dispose of these substances. • Agricultural consultants will, in many cases, be able to help you as well.

Helpful hints • Avoid filling tanks using cans or inappropriate pressurized fuel delivery systems that may cause considerable spillage. • In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them 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 draining off used engine coolant mixtures, engine, gearbox and hydraulic oils, brake fluids, etc. Do not mix drained brake fluids or fuels with lubricants. Store them safely until they can be disposed of in a proper way to comply with local legislation and available resources. • Modern coolant mixtures, i.e. antifreeze and other additives, should be replaced every two years. They should not be allowed to get into the soil, but should be collected and disposed of properly. • Do not open the air-conditioning system yourself. It contains gases that should not be released into the atmosphere. Your NEW HOLLAND CONSTRUCTION dealer or air conditioning specialist has a special extractor for this purpose and will have to recharge the system properly. • Repair any leaks or defects in the engine cooling or hydraulic system immediately. • Do not increase the pressure in a pressurized circuit as this may lead to a component failure. • Protect hoses during welding as penetrating weld splatter may burn a hole or weaken them, allowing the loss of oils, coolant, etc.

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INTRODUCTION

Torque - Minimum tightening torques for normal assembly L218 L220

WE WE

METRIC NON-FLANGED HARDWARE NOM. SIZE

M4 M5 M6 M8

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

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

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

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

M10

37 N·m (27 lb ft)

M12

64 N·m (47 lb ft)

M16 M20 M24

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

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

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

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

LOCKNUT CL.8 W/CL8.8 BOLT

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

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

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

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INTRODUCTION

METRIC FLANGED HARDWARE NOM. SIZE

CLASS 8.8 BOLT and CLASS 8 NUT PLATED W/ZnCr

UNPLATED M4 M5 M6 M8

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

M10

40 N·m (30 lb ft)

M12

70 N·m (52 lb ft)

M16 M20 M24

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

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

CLASS 10.9 BOLT and CLASS 10 NUT

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

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

Metric Hex head and carriage bolts, classes 5.6 and up

1. Manufacturer's Identification 2. Property Class

Metric Hex nuts and locknuts, classes 05 and up

20083681

47711684 06/05/2014

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

Torque - Standard torque data for hydraulics L218 L220

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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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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 L218 L220

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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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Hydraulic contamination – Contamination L218 L220

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Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination is any foreign material in the hydraulic oil. Contamination can enter the hydraulic system in several ways. 1. When you drain the oil or disconnect any line. 2. When you disassemble a component. 3. From normal wear of the hydraulic components. 4. From damaged or worn seals. 5. From a damaged component in the hydraulic system. All hydraulic systems operate with some contamination. The design of the components in this hydraulic system permits efficient operation with a small amount of contamination. An increase in this amount of contamination can cause problems in the hydraulic system. The following list includes some of these problems. 1. Cylinder rod seals leak. 2. Control valve spools do not return to neutral. 3. Movement of control valve spools is difficult. 4. Hydraulic oil becomes too hot. 5. Pump gears, housing, and other parts wear rapidly. 6. Relief valves or check valves held open by dirt. 7. Quick failure of components that have been repaired. 8. Cycle times are slow; machine does not have enough power. If your machine has any of these problems, check the hydraulic oil for contamination. See types of contamination below. If you find contamination, use the Portable Filter to clean the hydraulic system. NOTE: There are two types of contamination, microscopic and visible. Microscopic contamination occurs when very fine particles of foreign material are in suspension in the hydraulic oil. These particles are too small to see or feel. Microscopic contamination can be found by identification of the following problems or by testing in a laboratory. Examples of the problems: 1. Cylinder rod seal leak. 2. Control valve spools do not return to NEUTRAL. 3. The hydraulic system has a high operating temperature. Visible contamination is foreign material that can be found by sight, touch, or odor. Visible contamination can cause a sudden failure of components. Examples of visible contamination: 1. Particles of metal or dirt in the oil. 2. Air in the oil. 3. The oil is dark and thick. 4. The oil has an odor of burned oil. 5. Water in the oil.

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General specification - Left-hand instrument cluster L218 L220

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(1)

HVAC DIAL Rotate this dial to adjust temperature.

(2)

FAN SWITCH Rotate this dial to activate the fan.

(3)

AIR CONDITIONING SWITCH The lamp will illuminate, to confirm the system is operational, once the fan switch has been activated.

(4)

TURN SIGNAL INDICATOR Indicates directional turn signal operation when flashing.

(5)

HYDRAULIC ATTACHMENT COUPLER SWITCH Push the unlock side of this switch to unlock the coupler from the attachment. This switch must be used in conjunction with hydraulic pressure from the lift arm down, attachment curl in or auxiliary. To Lock: with the coupler properly inserted in the attachment, apply hydraulic pressure from the lift arm down, attachment curl in or auxiliary making sure that the hydraulic system goes over system relief to set lock pins.

(6)

2 SPEED INDICATOR Indicates 2 speed system is in use.

(7)

ROTATING BEACON SWITCH If equipped, push the switch to activate the rotating beacon.

(8)

HAZARD FLASHER SWITCH If equipped, push the switch to activate the 4-way flashers.

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(9)

SELF LEVELING SWITCH If equipped, use this switch to activate the self leveling feature.

(10)

AUXILIARY HYDRAULIC SWITCH Push the switch to the upper (HF) position to engage the high flow auxiliary hydraulic mode that produces 207 bar (3000 psi). Push the switch into the lower (HP) position to engage the enhanced high flow mode to produce 276 bar (4000 psi) if equipped with approved attachment. The lamp will illuminate when activated. Keep the switch in the neutral position to disable high flow.

(11)

AUXILIARY ELECTRIC SWITCH #2 If equipped, this switch is for the front electric connector.

(12)

LOADER LOCKOUT If equipped, push to disable loader control while roading the unit. The bucket and loader arm will be locked in the position they are in when the loader lockout switch is pressed to the ON position. This prevents the operator from inadvertently lowering or raising the loader arm or bucket while driving the machine on roads. NOTE: A mechanical machine with the loader lockout activated will result in DTC 4952 being displayed along with an amber lamp and buzzer. The auxiliary override button (lower left) on the instrument cluster can be pressed to clear the display and silence the buzzer. The amber lamp will remain illuminated.

(13)

WINDSHIELD WIPER SWITCH If equipped, this three position switch turns the wiper ON/OFF and operates the washer fluid spray.

(14)

BLANK This location is left open for any options you may add in the future.

(15)

12 V POWER PORT Supplies 12 V of power for accessories.

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General specification - Electronic Instrument Cluster (EIC) L218 L220

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The EIC is located on the right hand cab post. Once in the seat, the alarm sounds and selected lamps illuminate briefly. Monitor these lamps on a daily basis to confirm that they will function in the event of a system alarm. The fuel gauge and hour meter will remain illuminated for operator monitoring. When started, the machine will be in park with the PARK BRAKE lamp illuminated. The PARK BRAKE lamp is located on the instrument cluster. The PARK BRAKE button switch is located on the right-hand control handle. The operator must be in the seat with the seat belt fastened and the restraint bar lowered. The operator must push the OPERATE button to activate the loader arms and ground drive, after the loader is started. A semi-hidden SETUP menu allows the user to view, select, change and customize a number of machine settings. A security code may be entered into the Instrument Cluster. Once the security code has been entered, each user will have to enter the code before the machine will start. Contact your dealer for detailed information on the SETUP menu and security feature activation. NOTE: Fault code definitions are located in the troubleshooting section. The updated fault code is visible to the operator on the display on the right-hand column. NOTICE: Low hydraulic charge pressure will cause engagement of the park brake. With an Electro Hydraulic (EH) control unit, the PARK BRAKE lamp will flash and an audible alarm will sound, if this condition exists.

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(1)

KEY SWITCH This four position key switch has AUX, OFF, RUN and START operations.

(2)

STOP Severe warning requiring immediate shut down, RED lamp will flash and audible alarm will sound.

(3)

ENGINE MALFUNCTION Yellow lamp will flash when an engine fault is detected. Use the fault code that appeared in text display and reference it in the trouble shooting section of this manual.

(4)

HYDRAULIC SYSTEM MALFUNCTION Yellow Lamp will flash when a hydraulic fault is detected. Use the fault code that appeared in text display and reference it in the trouble shooting section of this manual.

(5)

ELECTRONIC SYSTEM MALFUNCTION This yellow lamp will flash and the alarm will sound. Use the fault code that appeared in text display and reference it in the troubleshooting section of this manual.

(6)

SEAT BELT RED lamp will illuminate when the restraint bar is raised. RED lamp will also illuminate when the operator lifts his body off of the operator’s seat.

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(7)

PARK BRAKE LAMP: This Red lamp illuminates to indicate the park brake is engaged. Under normal conditions the park brake will be set when: • The PARK BRAKE button switch is activated (located on the right-hand control handle) • The OPERATE button is activated • The engine is shut off • The engine is running and the restraint bar is raised • The operator leaves the seat

(8)

ENGINE PREHEATING LAMP: In cold climate starting conditions, after turning the KEY switch to RUN, this yellow engine pre-heating lamp will illuminate, instructing the operator that incoming air is being preconditioned for smoother starting. The operator must wait until the lamp goes out before attempting to start the engine.

(9)

FUNCTION BUTTON Use this, when in the SETUP menu, as the "enter" data key NOTE: This button is used for user code lock and unlock.

(10)

FUNCTION BUTTON Use this when in the SETUP menu, also used to scroll within the setup menu. NOTE: This button is used for user code lock and unlock.

(11)

OPERATE This button activates and deactivates the hydraulic system when engine is running. NOTE: This button is used for user code lock and unlock.

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(12)

AUXILIARY HYDRAULIC INTERLOCK OVERRIDE: When an operator leaves the seat, oil flow to an attachment will normally be halted via direct hydraulic flow cutoff. Depress this button and leave the seat within 30 seconds to defeat this interlock. Small red indicator lamp below the switch illuminates when the interlock is defeated. NOTE: This button is used for user code lock and unlock.

(13)

H / ISO control pattern selector, if equipped` This selects the drive pattern type of hand control operation. Read the proper steps listed in this chapter to activate.

(14)

WORK LIGHTS This knob controls the external working lights and road lights.

(15)

FUEL GAUGE: The fuel gauge consists of a series of bars that indicate the level of fuel in the fuel tank. When all 8 bars are visible the fuel tank is full. Bottom bar flashing indicates approximately 1 gal of fuel remaining.

(16)

ENGINE COOLANT TEMPERATURE BAR GRAPH: This bar graph indicates the relative temperature of the engine coolant from 0 - 110 °C (32 - 230 °F). If the coolant temperature goes above 110 °C (230 °F), all 8 bars will display, the backlighting will flash, and the audible alarm will sound.

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(17)

HYDRAULIC FLUID TEMPERATURE BAR GRAPH: This hydraulic oil temperature bar graph indicates the relative temperature of the hydraulic oil from 0 - 110 °C (32 - 230 °F). If the temperature exceeds 110 °C (230 °F), all 8 graph segments will display, backlighting will flash, and the audible alarm will sound.

(18)

TEXT DISPLAY: This display will show the following during normal operation, as selected by the operator. • Engine hours: Engine hours will always be displayed momentarily when the operator initially sits in the seat. The operator may choose to leave engine hours on display continuously or select one of the following. • Engine RPM • Engine coolant temperature (degrees F or C) • Hydraulic oil temperature (degrees F or C) • Cycle: If this display option is chosen, the display will continuously cycle through all four of the above items The text display will also help the operator or technician with information as the SETUP menu is utilized. NOTE: To change display mode "on the go" hold the AUX OVERRIDE (3) until the current option name is displayed, push the AUX OVERRIDE button repeatedly until desired option name is displayed. This display mode value will continue to be shown until another selection is made.

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General specification - Advanced Instrument Cluster (AIC) L218 L220

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The AIC is located on the right hand cab post. Once in the seat, the alarm sounds and selected lamps illuminate briefly. Monitor these lamps on a daily basis to confirm that they will function in the event of a system alarm. The fuel gauge and hour meter will remain illuminated for operator monitoring. When started, the machine will be in park with the PARK BRAKE lamp illuminated. This lamp and the PARK BRAKE switch will be covered in the following pages. The operator must be in the seat with the seat belt fastened. The operator must push the OPERATE button to activate the loader arms and ground drive, after the loader is started. A semi-hidden SETUP menu allows the user to view, select, change and customize a number of machine settings. A security code may be entered into the Instrument Cluster. Once the security code has been entered, each user will have to enter the code before the machine will start. Contact your dealer for detailed information on the SETUP menu and security feature activation. NOTE: Fault code definitions are located in the troubleshooting Section. The updated fault code is visible to the operator on the display on the right-hand column. NOTICE: Low hydraulic charge pressure will cause engagement of the park brake. With an Electro Hydraulic (EH) control unit, the PARK BRAKE lamp will flash and an audible alarm will sound, if this condition exists.

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(1)

STOP Severe warning requiring immediate shut down, RED lamp will flash and audible alarm will sound.

(2)

ENGINE MALFUNCTION Yellow Lamp will flash when an engine fault is detected. Use the fault code that appeared in text display and reference it in the troubleshooting section of this manual.

(3)

HYDRAULIC SYSTEM MALFUNCTION Yellow Lamp will flash when a Hydraulic fault is detected. Use the fault code that appeared in the text display and reference it in the troubleshooting section of this manual.

(4)

ELECTRONIC SYSTEM MALFUNCTION This yellow lamp will flash and the alarm will sound. Use the fault code that appeared in the text display and reference it in the troubleshooting section of this manual.

(5)

SEAT BELT RED lamp will illuminate when the seat belt is not latched. RED lamp will also illuminate when the operator lifts his body off of the operator’s seat.

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(6)

PARK BRAKE LAMP: This Red lamp illuminates to indicate the park brake is engaged. Under normal conditions the Park Brake will be set when: • The PARK BRAKE switch is activated • The OPERATE button is activated • The engine is shut off • The engine is running and the seat belt is not latched • The operator leaves the seat

(7)

ENGINE PREHEATING LAMP: In cold climate starting conditions, after turning the KEY switch to RUN, this yellow Engine Pre-Heating Lamp will illuminate, instructing the operator that incoming air is being preconditioned for smoother starting. The operator must wait until the lamp goes out before attempting to start the engine.

(8)

SYSTEM POWER: Push for Start-up power and Engine shut down power. Use this, when in the SETUP menu, as the "enter" Data Key. NOTE: This button is used for user code lock and unlock.

(9)

START: Push to actuate the starter motor and start the engine. Use this when in the SETUP menu, Also used to scroll within the setup menu. NOTE: This button is used for user code lock and unlock.

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(10)

OPERATE This button activates and deactivates the hydraulic system when engine is running. NOTE: This button is used for user code lock and unlock.

(11)

(12)

H / ISO Control Pattern Selector, if equipped This selects the drive pattern type of hand control operation. Read the proper steps listed in this chapter to activate.

(13)

PARK BRAKE SWITCH Press the PARK BRAKE switch to activate or deactivate the parking brake. The park symbol on the instrument panel will illuminate red when the parking brake is on. The other hydraulic functions remain active when the parking brake is on.

(14)

WORK LIGHTS This knob controls the external working lights and road lights.

(15)

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(16)

(17)

HYDRAULIC FLUID TEMPERATURE BAR GRAPH: This Hydraulic Oil Temperature Bar Graph indicates the relative temperature of the hydraulic oil from 0 - 110 °C (32 - 230 °F). If the temperature exceeds 110 °C (230 °F), all 8 graph segments will display, backlighting will flash, and the audible alarm will sound.

(18)

TEXT DISPLAY: This display will show the following during normal operation, as selected by the operator. • Engine Hours: Engine hours will always be displayed momentarily when the operator initially sits in the seat. The operator may choose to leave engine hours on display continuously or select one of the following. • Engine RPM • Engine Coolant Temperature (degrees F or C) • Hydraulic Oil Temperature (degrees F or C) • Cycle: If this display option is chosen, the display will continuously cycle through all four of the above items The text display will also help the operator or technician with information as the SETUP menu is utilized. NOTE: To change display mode "on the go" hold the AUX OVERRIDE button (3) until the current option name is displayed, push the AUX OVERRIDE button repeatedly until desired option name is displayed. This display mode value will continue to be shown until another selection is made.

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INTRODUCTION

General specification - Biodiesel fuels L218 L220

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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).

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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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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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Capacities Fuel tank Capacity L213 and L216 L218 and L220 L230 and C238 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 L218, L220, and L216 L230 and C238 Specifications

15.0 l (4.0 US gal) 15.6 l (4.2 US gal) 19 l (5 US gal) 50 % distilled water and 50 % ethylene glycol

Hydraulic system Reservoir capacity System capacity: L213 and L216 L218 and L220 L230 and C238 Specifications

15.0 l (3.96 US gal) 29.2 l (7.7 US gal) 38.1 l (10.0 US gal) 45.4 l (12.0 US gal) NEW HOLLAND AMBRA SUPER GOLD 10W-30

Chain compartments Capacity - each side L213 and L216 L218 and L220 L230 Specifications

6.25 l (6.6 US qt) 7.4 l (7.9 US qt) 22.2 l (23.5 US qt) NEW HOLLAND AMBRA SUPER GOLD 10W-30

Grease fittings As required Molydisulfide grease

Quantity Specifications

Engine crank case oil Capacity - with filter change L213, L216, L218, and L220, L230 and C238 Specifications

7 l (7.5 US qt) 8.5 l (8.9 US qt) NEW HOLLAND AMBRA UNITEK MASTERGOLD SBL CJ-4

Final track drive Capacity - each side Specifications

1.0 l (1.06 US qt) +/- 0.1 l (0.1 US qt) NEW HOLLAND GEAR 135 EP

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INTRODUCTION

Product identification L218 L220

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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 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Engine - 10

[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

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Engine - 10 Engine and crankcase - 001

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Engine - 10 Engine and crankcase - 001

SERVICE Engine Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Engine - Engine and crankcase

Engine - Drain fluid L218 TIER 4 [NEM476231 - ] L220

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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 WARNING Avoid injury! Always do the following before lubricating, maintaining, or servicing the machine. 1. Disengage all drives. 2. Engage parking brake. 3. Lower all attachments to the ground, or raise and engage all safety locks. 4. Shut off engine. 5. Remove key from key switch. 6. Switch off battery key, if installed. 7. Wait for all machine movement to stop. Failure to comply could result in death or serious injury. W0047A

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

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

Prior operation: Tilt the Roll Over Protection Structure (ROPS). Prior operation: Disconnect the battery. See Battery - Disconnect (55.302). Prior operation: Drain the coolant. See Prior operation: Drain the oil. Prior operation: Recover the A/C refrigerant (if applicable). See Air conditioning - Evacuate (50.200) 1. Remove the external, rear trim panels (1).

RAIL13SSL0148AA

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Engine - Engine and crankcase

2. Remove the engine hood strut from the side by gently prying the retaining clip just enough to release the strut. 3. Disconnect the A/C lines (if applicable). 4. Disconnect the lights and disconnect the harness from the hood. 5. Remove the engine hood mounting hardware from lefthand and right-hand side of the engine hood. 6. Remove the engine hood (1).

RAIL13SSL0149AA

RAIL13SSL0128AA

RAIL13SSL0145AA

7. Remove the engine cover (1).

8. Remove the air filter assembly (1) and hoses.

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9. Remove the fuel filter assembly (1) and plug the hoses. 10. Remove the bracket (2) for the air filter assembly. 11. Remove the oil fill tube (3). 12. Disconnect the mount (4) for the oil dip stick from the cooling package bracket. 13. For vertical lift machines, remove the cotter pin on the lock pin link for the left boom. Unbolt the boom lock bellcrank (5) and place it away from the engine area.

RAIL13SSL0144AA

RAIL13SSL0143AA

RAIL13SSL0142AA

14. Remove the bracket (1) for the coolant overflow bottle.

15. Remove the air cooler (1).

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16. Remove the coolant overflow bottle.

RAIL13SSL0141AA

RAIL13SSL0140AA

17. Remove the radiator (1).

18. Loosen the alternator mounting bolt (3) and the mounting bolt (2) for the adjustment bolt (1). 19. Remove the tension from the belt by turning the adjustment screw (1) on the alternator.

RAIL13SSL0139AA

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Engine - Engine and crankcase

20. Remove the engine fan assembly.

RAIL13SSL0138AA

RAIL13SSL0604AA

RAIL13SSL0130AA

21. Remove the cooling package bracket assembly (1).

22. Disconnect the positive battery cable (1) on the alternator. 23. Disconnect the electrical connector (2) on the alternator. 24. Disconnect the starter ignition wire (3). 25. Disconnect the positive battery cable (4) on the starter.

26. If applicable, disconnect the supply and return hoses for the heater core. NOTE: The supply hose is located on the left-hand side of the engine and the return hose is located on the right-hand side of the engine.

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Engine - Engine and crankcase

27. Disconnect and cap the lines (1) for the remote, oil filter housing.

RAIL13SSL0129AA

RAIL13SSL0132AA

RAPH12SSL0233AA

28. Disconnect and cap the fuel feed line (1) and the fuel return line (2).

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

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Engine - Engine and crankcase

30. Disconnect the remote drain line (1) from the engine oil pan.

RAIL13SSL0147AA

RAIL13SSL0137AA

RAIL13SSL0136AA

31. Disconnect the following sensors: • pressure sensor (1) • pre-oxidation temperature sensor (2) • post-oxidation temperature sensor (3)

32. Unbolt the pressure sensor from the cross member.

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33. Disconnect both exhaust pipes (2). 34. Remove the mounting bolts (1), and carefully remove the filter/muffler assembly.

RAIL13SSL0146AA

RAIL13SSL0126AA

RAIL13SSL0131AA

35. Disconnect the joystick linkage (1) from the hydrostatic pump assembly.

36. Support the hydrostatic pump assembly with a suitable lifting device.

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Engine - Engine and crankcase

37. Disconnect the ground wire (1). 38. Unplug the engine harness (2). 39. Unbolt the engine harness (3) from the bell housing. 40. Carefully remove the return spring assembly (4).

RAIL13SSL0135AA

RAIL13SSL0134AA

931001933

41. Remove the rear engine mount bolts (1).

42. Remove the front engine mount bolts (1).

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43. Unbolt the hydrostatic pump assembly (1), and disengage the pump assembly (1) from the bell housing.

RAIL13SSL0133AA

RAIL13SSL0127AA

44. Apply suitable lifting equipment to the engine, and carefully lift the engine out the machine.

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Engine - Engine and crankcase

Engine - Install 1. Carefully lower the engine into the machine.

RAIL13SSL0127AA

RAIL13SSL0133AA

931001933

2. Engage the pump assembly into the bell housing. Apply LOCTITE® 243 to the bolts (1). Torque the bolts (1) to 87 - 117 N·m (64 - 86 lb ft).

3. Install the front engine mount bolts (1). Apply LOCTITE® 243 to the bolts (1). Torque the bolts (1) to 163 176 N·m (120 - 130 lb ft).

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Engine - Engine and crankcase

4. Install the rear engine mount bolts (1). Apply LOCTITE® 243 to the bolts (1). Torque the bolts (1) to 163 176 N·m (120 - 130 lb ft).

RAIL13SSL0134AA

RAIL13SSL0135AA

RAIL13SSL0131AA

5. Carefully install the return spring assembly (4). 6. Connect the ground wire (1). 7. Bolt the engine harness (3) to the bell housing. 8. Connect the engine harness (2).

9. Remove the lifting device (1) from the hydrostatic pump assembly.

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10. Connect the joystick linkage (1) to the hydrostatic pump assembly.

RAIL13SSL0126AA

RAIL13SSL0146AA

RAIL13SSL0136AA

11. Carefully install the filter/muffler assembly. Torque the bolts (1) to 27 - 37 N·m (20 - 27 lb ft). 12. Connect both exhaust pipes (2). Torque the bolts to 27 - 37 N·m (20 - 27 lb ft).

13. Attach the pressure sensor to the cross member.

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Engine - Engine and crankcase

14. Connect the following sensors: • pressure sensor (1) • pre-oxidation temperature sensor (2) • post-oxidation temperature sensor (3)

RAIL13SSL0137AA

RAIL13SSL0147AA

RAPH12SSL0233AA

15. Connect the remote drain line (1) to the engine oil pan.

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

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Engine - Engine and crankcase

17. Connect the fuel feed line (1) and the fuel return line (2).

RAIL13SSL0132AA

RAIL13SSL0129AA

RAIL13SSL0130AA

18. Connect the lines (1) for the remote, oil filter housing.

19. Connect the positive battery cable (1) to the alternator. Torque the nut to 4 N·m (35 lb in). 20. Connect the electrical connector (2) to the alternator. 21. Connect the starter ignition wire (3). 22. Connect the positive battery cable (4) to the starter.

23. If applicable, connect the supply and return hoses for the heater core. NOTE: The supply hose is located on the left-hand side of the engine and the return hose is located on the right-hand side of the engine.

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Engine - Engine and crankcase

24. Install the cooling package bracket assembly (1).

RAIL13SSL0604AA

RAIL13SSL0138AA

RAPH12SSL0407BA

25. Install the engine fan assembly.

26. Install the belt. 27. Turn the adjuster bolt (3) clockwise to tighten. The belt is tightened properly when a force of 5 kg (11 lb) is applied perpendicular to the belt at the center of the span with a 5 mm (13/64 in) deflection. 28. Tighten locking bolt (2) and pivot bolt (1).

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

RAIL13SSL0140AA

RAIL13SSL0141AA

RAIL13SSL0142AA

30. Install the coolant overflow bottle.

31. Install the air cooler (1). Torque the bolts to 27 37 N·m (20 - 27 lb ft). Torque the hose clamps to 3 - 4 N·m (27 - 35 lb in).

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Engine - Engine and crankcase

32. Install the bracket (1) for the coolant overflow bottle. Torque the bolts to 27 - 37 N·m (20 - 27 lb ft).

RAIL13SSL0143AA

RAIL13SSL0144AA

RAIL13SSL0145AA

33. Install the fuel filter assembly (1). 34. Install the bracket (2) for the air filter assembly. 35. Install the oil fill tube (3). 36. Connect the mount (4) for the oil dip stick to the cooling package bracket. 37. For vertical lift machines, install the boom lock bellcrank (5). Install the cotter pin on the lock pin link for the left, boom lock pin.

38. Install the air filter assembly (1) and hoses. Torque the bolts to 27 - 37 N·m (20 - 27 lb ft). Torque the hose clamps to 3 - 4 N·m (27 - 35 lb in)

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Engine - Engine and crankcase

39. Install the engine cover (1). Torque the bolts to 2 3 N·m (20 - 25 lb in)

RAIL13SSL0128AA

RAIL13SSL0149AA

RAIL13SSL0148AA

40. Carefully install the engine hood (1). Torque the nuts (2) to 4.5 - 6 N·m (40 - 57 lb in). 41. Install the engine hood strut. 42. Connect the A/C lines (if applicable). 43. Connect all the lights and reattach the harness to the hood.

44. Install the external, rear trim panels (1). Apply LOCTITE® 243 to the bolts (2). Torque the bolts (2) to 1 - 1 N·m (10 - 12 lb in) .

Next operation: Charge the A/C system (if applicable). See Air conditioning - Charging (50.200) Next operation: Fill the engine oil pan with oil. Next operation: Fill the radiator with coolant. Next operation: Connect the battery. See Battery - Connect (55.302)

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Index Engine - 10 Engine and crankcase - 001 Engine - Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - 10 Fan and drive - 414

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Engine - 10 Fan and drive - 414

SERVICE Belt Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - Fan and drive

Belt - Adjust NOTE: An eight rib alternator pulley is used with a six rib belt. When installing a belt, install the belt on the six ribs furthest from the engine. The two ribs closest to the engine will not be used. 1. Loosen the pivot bolt (1) and locking bolt (2).

RAPH12SSL0407BA

2. Turn the bolt (3) clockwise to tighten. The belt is tightened when the center of the span of the belt (4) has 5.0 mm (3/16 in) deflection. 3. Tighten the locking bolt (2) and pivot bolt (1).

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Index Engine - 10 Fan and drive - 414 Belt - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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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.

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SERVICE MANUAL Front axle system L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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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

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Front axle system - 25 Chain drive system - 450

SERVICE Axle Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Chain drive Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Measure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Front axle system - Chain drive system

Axle - Remove L218 L220

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 L218 L220

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 L218 L220

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

NOTE: Properly grease all bearings before beginning this procedure. 1. Heat the outer bearing to 60 °C (140 °F).

RAIL13SSL0396BA

RAIL13SSL0394BA

RAIL13SSL0395BA

2. Carefully place the outer bearing in the bearing race.

3. Install the seal.

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Front axle system - Chain drive system

4. 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).

RAIL13SSL0397BA

RAIL13SSL0385BA

RAIL13SSL0386BA

5. Install the inner bearing.

6. Install the spacer.

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Front axle system - Chain drive system

7. Install the shim.

RAIL13SSL0387BA

RAIL13SSL0388BA

8. Install the snap ring.

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Front axle system - Chain drive system

Axle - Install L218 L220

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. Install the chain tank cover (1).

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Front axle system - Chain drive system

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

RAIL13SSL0562BA

RAIL13SSL0383BA

RAIL13SSL0560AA

8. 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).

9. Fill the chain tank by remove the fill plug (1). 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 L218 L220

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 L218 L220

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 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Axle - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Axle - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Axle - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Chain drive - Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Chain drive - Measure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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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 Rear axle system L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Rear axle system - 27

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

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Rear axle system - 27 Chain drive system - 650

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Rear axle system - 27 Chain drive system - 650

SERVICE Axle Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Rear axle system - Chain drive system

Axle - Remove L218 L220

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 - Install L218 L220

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. Install the chain tank cover (1).

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Rear axle system - Chain drive system

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

RAIL13SSL0562BA

RAIL13SSL0383BA

RAIL13SSL0560AA

8. 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).

9. Fill the chain tank by remove the fill plug (1). 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

Axle - Disassemble L218 L220

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 L218 L220

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

NOTE: Properly grease all bearings before beginning this procedure. 1. Heat the outer bearing to 60 °C (140 °F).

RAIL13SSL0396BA

RAIL13SSL0394BA

RAIL13SSL0395BA

2. Carefully place the outer bearing in the bearing race.

3. Install the seal.

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Rear axle system - Chain drive system

4. 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).

RAIL13SSL0397BA

RAIL13SSL0385BA

RAIL13SSL0386BA

5. Install the inner bearing.

6. Install the spacer.

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Rear axle system - Chain drive system

7. Install the shim.

RAIL13SSL0387BA

RAIL13SSL0388BA

8. Install the snap ring.

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Rear axle system - Chain drive system

Chain drive - Check L218 L220

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 L218 L220

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 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Axle - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Axle - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Axle - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Chain drive - Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Chain drive - Measure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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

47711684 06/05/2014 EN

SERVICE MANUAL Hydrostatic drive L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Hydrostatic drive - 29

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

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Hydrostatic drive - 29 Hydrostatic transmission - 202

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Hydrostatic drive - 29 Hydrostatic transmission - 202

FUNCTIONAL DATA Hydrostatic transmission Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Hydrostatic drive - Hydrostatic transmission

Hydrostatic transmission - Dynamic description L218 L220

WE WE

In a closed loop, hydrostatic transmission, the engine provides power to a tandem, hydrostatic pump assembly 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) Main relief 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 fresh, charge pump 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 main relief valve (4) is installed on each side of the closed loop to limit the maximum pressure. These main relief valves (4) are nonadjustable and operate in only one direction.

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Index Hydrostatic drive - 29 Hydrostatic transmission - 202 Hydrostatic transmission - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(*) See content for specific models 47711684 06/05/2014

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Hydrostatic drive - 29 Two-speed assembly - 134

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Hydrostatic drive - 29 Two-speed assembly - 134

TECHNICAL DATA Control valve General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Control valve Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

(*) See content for specific models 47711684 06/05/2014

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Hydrostatic drive - Two-speed assembly

Control valve - General specification L218 L220

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 L218 L220

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

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Hydrostatic drive - Two-speed assembly

Control valve - Component localisation L218 L220

WE WE

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) Loader arm lockout valve

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(7) Self level valve

Index Hydrostatic drive - 29 Two-speed assembly - 134 Control valve - Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Control valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Control valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(*) See content for specific models 47711684 06/05/2014

29.2 [29.134] / 6

Hydrostatic drive - 29 Mechanical control - 200

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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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 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

(*) See content for specific models 47711684 06/05/2014

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Hydrostatic drive - Mechanical control

Mechanical control - Adjust - Machines with only hand controls L218 L220

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

Neutral adjustment for hydrostatic pumps with mechanical hand 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. Raise the machine off of the ground, and support the machine with a suitable lifting device.

Before adjustment 2. Check the spring caps (1) to make sure that they are pushing against the centering plate and that there is no gap (2) between the jam nuts (3) and the spring caps (1). Replace the spring if necessary.

23112911

23112912

Adjustment 3. Loosen the jam nut (1). 4. Start the machine and set to high idle. 5. With the levers in neutral, turn the rod/spring assembly (2) until the wheels begin to turn in a forward direction. 6. With the levers in neutral, turn the rod/spring assembly (2) in the opposite direction until the wheels begin rotate in the reverse direction. NOTE: Record the number of rod turns. You will need this number in the following step. 7. Turn the rod back ½ the number of turns recorded in step 6. 8. Tighten the jam nut (1). 9. Move the handle in the forward direction and reverse direction to confirm that neutral is set. Adjust if needed.

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Hydrostatic drive - Mechanical control

10. Repeat steps 3 - 8 for the other pump. Please note the differences between the right side and left side, as shown in images 2 and 3. Reference these images when repeating steps 3 - 8.

23112912

23112914

23112913

11. The factory setting for the handles is 75 °, which is represented by (X). Please see step 12 to adjust the handles to the factory setting.

12. Loosen the jam nut (2) on the left hand side and the jam nut (3) right hand side. Rotate the rods (1) until the handles are in the correct position, and tighten the jam nuts (2), (3).

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.

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Hydrostatic drive - Mechanical control

13. Turn the stop bolt (1) out several turns. 14. 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. 15. Repeat steps 13 and 14 for the other side

16. Lower the machine by remove the lifting equipment from the machine. Lower the Roller Over Protection Structure (ROPS). 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. 17. To make the machine travel in a straight line at full lever travel, adjust the stop bolts. NOTE: The stop bolt should touch the casting when the pump is at full stroke.

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23112915

23112916

Hydrostatic drive - Mechanical control

Mechanical control - Adjust - Machines with foot controls L218 L220

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

Neutral adjustment for hydrostatic pumps with mechanical foot 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. Raise the machine off of the ground, and support the machine with a suitable lifting device. 2. Loosen the clamp bolts (1), but do not remove. 3. Start the machine and set to high idle. 4. Move wear plate until pump is centered. 5. Tighten the clamp bolts (1) and move handle in the forward direction and backward direction to confirm that neutral is set. Adjust if needed. 6. Repeat for other pump.

23112917

23112918

23112922

7. Loosen the jam nuts (2), (3). Rotate the control rod (4) until handle is in the correct position of 75 ° (see image 3). Tighten both jam nuts (2), (3).

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.

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8. Turn the stop bolt (1) out several turns. 9. 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. 10. Repeat steps 8 and 9 for the other side

11. Lower the machine by remove the lifting equipment from the machine. Lower the Roller Over Protection Structure (ROPS). 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. 12. To make the machine travel in a straight line at full lever travel, adjust the stop bolts. NOTE: The stop bolt should touch the casting when the pump is at full stroke.

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23112915

23112916

Index Hydrostatic drive - 29 Mechanical control - 200 Mechanical control - Adjust - Machines with foot controls (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Mechanical control - Adjust - Machines with only hand controls (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(*) See content for specific models 47711684 06/05/2014

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Hydrostatic drive - 29 Pump and motor components - 218

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Hydrostatic drive - 29 Pump and motor components - 218

TECHNICAL DATA Pump General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Motor General specification – Single speed motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 General specification – Two-speed motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUNCTIONAL DATA Pump Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Motor Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SERVICE Pump and motor components Pressure test – Charge pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Pressure test – Main relief valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Remove – Charge pressure relief valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install – Charge pressure relief valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Remove – Main relief valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Install – Main relief valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Remove – Drive shaft seal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Install – Drive shaft seal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Remove – Charge pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Install – Charge pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Pump Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Visual inspection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Measure – Piston travel (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 (*) See content for specific models 47711684 06/05/2014

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Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Servo control Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Motor Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Disassemble – Single speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Assemble – Single speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Disassemble – Two speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Assemble – Two speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

DIAGNOSTIC Pump Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

(*) See content for specific models 47711684 06/05/2014

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Hydrostatic drive - Pump and motor components

Pump - General specification L218 L220

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

RAPH12SSL0357HA

Hydrostatic pump Manufacturer Type Pump displacement Charge pump displacement Charge pressure relief (3) Main relief (1), (2) NOTE: (2) not shown Charge pump flow at 1800 RPM Port identification

Sauer-Danfoss Axial piston/swash plate 35 cm³ (2.1 in³) 19.7 cm³ (1.2 in³) 24 - 26 bar (350 - 370 psi) 345 - 362 bar (5000 - 5250 psi) 27 l (7 US gal) minimum M3 - System pressure for E - Charge pressure M1 - System pressure for M4 - System pressure for L2 - Case outlet L1 - Case outlet M2 - System pressure for

Pump - General specification L218 L220

WE Electro hydraulic controls WE Electro hydraulic controls

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port C port A port D

port B

Hydrostatic drive - Pump and motor components

RAPH13SSL0964FA

Hydrostatic pump Manufacturer Pump displacement Charge pump displacement Charge pressure relief (1) Main relief (2) Charge pump flow Port identification

Bosch Rexroth 35 cm³ (2.1 in³) 14.9 cm³ (0.9 in³) 24 - 26 bar (347 - 377 psi) 350 - 370 bar (5075 - 5365 psi) 40 l (10.5 US gal) A - Service line B - Service line T - Case drain port X1 - Control Pressure, before the orifice X2 - Control Pressure, before the orifice R - Air bleed Ma - Pressure gauge operating pressure A Mb - Pressure gauge operating pressure B G - Pressure for auxiliary circuit G2 - Pressure for auxiliary circuit S - Boost suction Mg - Pressure gauge operating pressure G Yst - Control pressure gauge

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Motor - General specification – Single speed motor L218 L220

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 L218 L220

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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Port identification

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

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Hydrostatic drive - Pump and motor components

Pump - Dynamic description L218 L220

WE WE

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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Hydrostatic drive - Pump and motor components

Motor - Dynamic description L218 L220

WE WE

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

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Hydrostatic drive - Pump and motor components

Pump and motor components - Pressure test – Charge pump L218 L220

WE WE

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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Hydrostatic drive - Pump and motor components

3. Connect a 41 bar (600 psi) pressure gauge to the test port for charge pressure, or connect a T-fitting (1) to an outlet hose of the charge pump and attach a 41 bar (600 psi) pressure gauge 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, L221

RAPH12SSL0420AA

RAPH12SSL0421AA

RAPH12SSL0424AA

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

Models (electrohydraulically controlled): L213, L215, L216, L218, L220, L221, L223, L225, L230, C227, C232, C238

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Hydrostatic drive - Pump and motor components

4. Start the machine and run at high idle. Read the pressure gauge and record the charge pressure reading. Stop the engine. NOTE: Image 5 is an example of a pressure reading. Image 5 may not match your reading. 5. The pressure reading must be a minimum of 24 bar (350 psi). If the pressure reading does not meet the specifications, repair/replace the relief valve for the charge pressure. Please see Pump - General specification (29.218) for general specifications about the hydrostatic pumps.

RAPH12SSL0422AA

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Hydrostatic drive - Pump and motor components

Pump and motor components - Pressure test – Main relief valve L218 L220

WE WE

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

Prior operation: See Hydraulic systems - Depressurising (35.000) to depressurize the hydraulic system. NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: You will need two people to perform this test. NOTE: An error code may appear on the instrument cluster during this test. When the unit is shut down and all connections are returned to normal, the fault code will be stored as inactive. This fault can be cleared using the Electronic Service Tool (EST). 1. Raise the machine off of the floor until the tires/tracks are not touching. Support the machine with proper lifting equipment. NOTICE: This is a safety precaution if the parking brakes fail to hold. 2. Connect a 690 bar (10000 psi) pressure gauge 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 pump assembly are easily accessible. Remember, you can test all four main relief valves by plugging a pressure gauge into the most available main relief, pressure test port and exchanging main relief valves. Test port identification for the main relief valves Mechanical controls Models: L213, L215, L216, L218, L220, L221 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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Hydrostatic drive - Pump and motor components

Mechanical controls Models: L223, L225, 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

RAPH12SSL0358GA

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 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 - General specification (33.110) for specifications on the parking brake control valve.

RAPH12SSL0392AA

4. Start the machine and adjust the throttle to high idle. NOTE: If equipped with two speed drive motors, press and hold the two speed button. 5. Slowly move the correct control lever for the corresponding hydrostatic pump in the correct position.

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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.

RAPH12SSL0407AA

7. Refer to Pump - General specification (29.218) for specifications on the hydrostatic pumps. If the pressure is not correct, repair or replace the main relief valve. 8. Retest the circuit after repair.

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Hydrostatic drive - Pump and motor components

Pump and motor components - Remove – Charge pressure relief valve L218 L220

WE Electro hydraulic controls WE Electro hydraulic 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

Prior operation: To depressurize the system, refer to Hydraulic systems - Depressurising (35.000). NOTICE: The pictures below may vary from the pump you are working on. The removal procedure is the same. 1. Locate the low pressure relief valve (1).

20115485

20115786

2. Remove the low pressure relief valve (1).

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Hydrostatic drive - Pump and motor components

3. Remove the spring collar (1).

83115530

83115531

4. Remove the pressure spring (1).

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Hydrostatic drive - Pump and motor components

Pump and motor components - Install – Charge pressure relief valve L218 L220

WE Electro hydraulic controls WE Electro hydraulic controls

NOTICE: The pictures below may vary from the pump you are working on. The install procedure is the same. 1. Place the collar (1) and pressure spring (2) onto the low pressure relief valve.

20115786

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Hydrostatic drive - Pump and motor components

Pump and motor components - Remove – Main relief valve L218 L220

WE Electro hydraulic controls WE Electro hydraulic 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

20115485

20115785

2. Remove the high pressure relief valve(s) (1).

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Hydrostatic drive - Pump and motor components

Pump and motor components - Install – Main relief valve L218 L220

WE Electro hydraulic controls WE Electro hydraulic controls

NOTICE: The pictures below may vary from the pump you are working on. The install procedure is the same. 1. Lubricate the threads (1) and support surface (2).

20115785

20115485

2. Thread the high pressure relief valve(s) (1) into the pump housing. Torque to 250 N·m (184.4 lb ft).

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Hydrostatic drive - Pump and motor components

Pump and motor components - Remove – Drive shaft seal L218 L220

WE Electro hydraulic controls WE Electro hydraulic controls

NOTE: Currently the Bosch Rexroth electro-hydraulic pump is limited to certain serviceable parts. NOTICE: The pictures below may vary from the pump you are working on. The removal procedure is the same. 1. Locate the drive shaft seal (1).

20115485

20115783

20115784

2. Remove snap ring (1).

3. Screw in self tapping screw(s) (1) into the holes (2) fitted with rubber. Pull out shaft seal with pliers.

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Hydrostatic drive - Pump and motor components

Pump and motor components - Install – Drive shaft seal L218 L220

WE Electro hydraulic controls WE Electro hydraulic controls

NOTE: Currently the Bosch Rexroth electro-hydraulic pump is limited to certain serviceable parts. NOTICE: The pictures below may vary from the pump you are working on. The install procedure is the same. 1. Lubricate the lip of the seal (1) with clean oil.

20115827

83115476

20115783

2. Carefully press the new seal, with the lip down, into the cover. NOTE: Be careful not to press the seal too far.

3. Insert the snap ring (1).

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Hydrostatic drive - Pump and motor components

Pump and motor components - Remove – Charge pump L218 L220

WE Electro hydraulic controls WE Electro hydraulic controls

Prior operation: To remove the hydrostatic pump, refer to Pump - Remove (29.218). NOTE: Some of the pictures in the following procedure may vary from the pump you are repairing. The procedure is the same. 1. Remove the mounting flange bolts (1).

83115502

83115503

83115510

2. Remove the flange (1).

3. Apply reference mark (1) on pump housing and charge pump housing.

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4. Remove the charge pump housing (1).

83115511

83115512

83115513

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5. Remove o-ring (1) from charge pump housing.

6. Remove the outer gear (1).

7. Remove the inner gear (1).

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8. Remove the coupler (1).

83115515

83115516

9. Apply reference mark (1) on wear plate.

10. Remove the wear plate (1).

83115517

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Pump and motor components - Install – Charge pump L218 L220

WE Electro hydraulic controls WE Electro hydraulic controls

NOTE: Some of the pictures in the following procedure may vary from the pump you are repairing. The procedure is the same. 1. Install the wear plate (1).

83115517

20115828

83115515

2. Check that the locating pin (1) and channels (2) are correct (direction of rotation Clockwise looking on the drive shaft).

3. Install the coupler (1).

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4. Install the inner gear (1) with the chamfered side of the gear facing the outside (facing away from the wear plate). Align the shaft key on the coupling (2) with the notch (3) on the inner gear.

83115514

83115513

83115512

83115510

5. Install the outer gear (1) with chamfered side facing outward.

6. Replace the o-ring (1) on charge pump housing.

7. Install charge pump housing (1) using reference mark from removal procedure.

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8. Install the flange (1).

83115503

83115502

9. Install and tighten the mounting flange bolts (1).

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Pump - Test L218 L220

WE Mechanical hydraulic controls WE Mechanical hydraulic 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

Prior operation: See Hydraulic systems - Depressurising (35.000) to depressurize the hydraulic system.

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 - General specification (33.110) for specifications on the parking brake control valve.

RAPH12SSL0392AA

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3. Install a T-fitting (2) at the charge pump outlet. NOTE: Image 2 is an example of a pressure reading. Image 2 may not match your reading. 4. Connect a hose with a 41 bar (600 psi) pressure gauge (1) to the T-fitting outlet (2).

RAPH12SSL0420AA

RAPH12SSL0422AA

5. Start the machine and run at high idle. NOTE: If equipped with two-speed drive motors, press and hold the two-speed button. 6. 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. 7. 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. 8. 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. 9. Repeat steps 7 and 8 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 - Cleaning L218 L220

WE WE

The hydrostatic system is a closed loop made up of the charging pump, piston pump, drive motors and the hoses between these components. The hydraulic cooler and reservoir are also part of the closed loop system. Any contamination in the hydrostatic system will stay in the closed loop, and probably cause damage. If the piston pump or a motor in the hydrostatic system is removed for repair or replacement, you must clean the hydrostatic system. If any contamination is left in the closed loop, the contamination will damage the remaining components of the hydrostatic system. 1. Remove the piston pumps and at least the motor in the circuit that failed. If there is a quantity of contamination present, removal of the opposite pump and motor is also required. 2. Disassemble, clean, and inspect the piston pumps and motor(s). 3. Clean all hoses and tubes in the hydrostatic system. Remove each hose and tube from the machine. Flush and clean the hoses and tubes with hot soapy water. Hang and allow them to air dry. Hoses and tubes must be dry before installing. 4. Install, inspected and repaired, or new piston pumps and motors. 5. Change the hydraulic filter. 6. Make sure that the hydraulic system is clean so that the charge pump will not cause new contamination in the closed loop. Remember that the oil cooler may have internal passages that can trap and hold contamination that can be dislodged later and cause a repeat failure. NOTE: THE FOLLOWING PROCEDURE SHOULD BE USED FOR CLEANING HOSES, TUBES, AND FITTINGS. It is recommended that hoses, tubes and fittings be cleaned with a steam cleaner and dried with compressed air. 7. Fasten the parts to a rack in a position as near to vertical as possible. This will allow water to drain as you flush parts. 8. Clean the exterior surfaces of the parts thoroughly. 9. Clean the interior surfaces of the parts. Use hot water and soap first. Then use clean hot water to rinse. NOTE: If the steam cleaner does not have a soap injection system, spray an oil solvent into the parts. This will dissolve the oil film that holds contaminants inside the parts. Then use clean hot water to rinse. 10. Fasten the parts in the rack so that the parts can be flushed from opposite ends. Repeat steps 8 an 9. 11. Use compressed air to dry the inside of each part. Dry the parts from both ends to make sure all of the water is removed. 12. Install caps or plugs in the ends of each hose, tube or fitting as soon as the parts are dry. This will prevent entry of contaminants. Remove the caps or plugs from the part only when the part is in position in the machine and you are ready to make the connection.

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Pump - Visual inspection L218 L220

WE WE

1. Inspect the face of the cylinder block for wear, scoring, and other damage. Use a new cylinder assembly as necessary. 2. Inspect the cylinder bores for wear, scoring, and other damage. Use new cylinder assembly as necessary. 3. Inspect the bronze surface of the wear plate. Use a new wear plate as necessary. 4. Inspect the parts of the charging pump for wear and damage. Use a new pump as necessary. 5. Inspect the pistons for wear and damage, use new parts as necessary. 6. Inspect the shaft for damage to the splines and wear at the seal surfaces. 7. Inspect the bearings. Replace any damaged bearings. 8. Inspect the circular relief valve seats in the housings.

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Pump - Measure – Piston travel L218 L220

WE WE

NOTE: This procedure is for all M46 Sauer Danfoss hydrostatic pumps. 1. Measure the free travel between the shoes and the pistons. If all the measurements are not equal to within 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 within 0.02 mm ( 0.0001 in), use a new cylinder assembly.

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

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Pump - Remove L218 L220

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

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

Prior operation: Tilt the ROPS NOTE: See Hydraulic systems - Depressurising (35.000) to depressurize the hydraulic system. 1. Label and disconnect the four left hand side hydraulic hoses (1) and cap open ports

931002072

931002073

931002074

2. Label and disconnect the gear pump hydraulic tube (1) and supply hose (2) and cap open ports.

3. Label and disconnect right hand side hydraulic hoses (1) and cap open ports

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4. Disconnect control linkage hardware (1). NOTE: Image 4 is an example of mechanical linkage. Your machine may not have this style of linkage.

931002075

931002076

931002077

931002078

5. Disconnect electrical connection (1).

6. Using a metal rod as a brace across the pump attach lifting straps and hoist to support pump, as shown.

7. Remove the four pump mounting bolts (1) and (2).

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Using the hoist carefully remove pumps. 931002079

Next operation: Pump - Install (29.218)

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Pump - Disassemble L218 L220

WE Mechanical hydraulic controls WE Mechanical hydraulic 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. Separate the pumps by removing the left and right side pump mounting bolts (1).

20115788A

20105293N

2. Remove the coupling (1) and gerotor (2) assembly from the gerotor cover.

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3. Note the orientation of the gerotor assembly (1) and pins (2) for reassembly into housing (3).

20115791

20115790

20115820

4. Remove pin (1) from the coupler. For inspection of the charge pump, refer to Pump - Visual inspection (29.218).

5. Remove the end cap mounting bolts (1) from the pump housing (2). Discard the gasket.

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6. Remove the valve plate.

83115796

20115795

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7. Remove circuit relief valve (1) from both sides of end cap.

8. Remove charge relief plug (1).

9. Remove the needle bearing.

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10. Remove cylinder and piston assembly.

83115797

20115826

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83115801

11. Remove the thrust plate.

12. Remove pistons and guide.

13. Remove the retainer guide, washer, pins and pin retainer.

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14. Install a bolt with two washers to compress the spring.

83115798

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20115787

15. Remove retaining ring. Release the spring. Remove the spring seats and spring

16. Remove the snap ring (1).

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17. Remove seal and retainer.

83115802

83115804

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18. Discard o-ring and seal.

19. Remove drive shaft and bearing.

20. Remove snap ring and bearing from drive shaft.

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21. Remove trunnion cover (1).

20105288N

20115822

83115809

22. Remove top trunnion cover bolts (1) and cover.

23. Remove swashplate and bearing.

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Pump - Assemble L218 L220

WE Mechanical hydraulic controls WE Mechanical hydraulic 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 a new seal in trunnion cap. Seal lip goes to inside.

83115810

83115811

83115812

2. Install bearing cone on the swash plate.

3. Install swash plate. Shaft comes out the side of housing nearest the serial number plate.

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4. Install the bearing, original shims, spacers, a new quad ring and blank trunnion cover.

83115805

83115807

20115822

20115829

5. Install the bearing cup, original shims, spacer, and new quad ring.

6. Install the trunnion cover. Tighten the bolts to a torque of 24.4 - 32.5 N·m (18 - 24 lb ft)

7. Remove approximately 0.1 mm (0.005 in) of shims from each of the trunnion shim packs. Assemble the trunnion assemblies with the reduced shim packs. Tighten the bolts to a torque of 24.4 - 32.5 N·m (18 - 24 lb ft). Move the control arm up and down while measuring the end play with a dial indicator. Add shims to provide a 0.1 - 0.1 mm (0.002 - 0.004 in) preload on the swash plate bearings. Add shims equally on each side of pump housing. The swash plate should move freely with a torque of 0.6 - 1.7 N·m (5 - 15 lb in) applied to the control arm.

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8. Install the bearing and snap ring on the drive shaft. Install the drive shaft and bearing into the housing.

83115806

83115804

9. Install a new seal and o-ring in the seal retainer. Install the seal retainer and snap ring.

10. Install the thrust plate.

20115826

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11. Install the inner spring seat, spring and outer spring seat into the cylinder. Compress the spring with the bolt and washers and install the retaining ring.

83115800

83115798

83115801

83115799

12. Install the pin retainer flush with top of cylinder. Install the pins in the recesses of the splines. Install the washer then retainer guided on top of the pins.

13. Install the pistons in the slipper guide. Lubricate the pistons and cylinder block bores. Install the pistons into the cylinder block.

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14. Install the cylinder assembly into the housing. Turn the shaft to help align the splines. The cylinder must go into the housing until the slippers contact he thrust plate.

83115797

20115794

20115795

20115825

15. Install the needle bearing so 2.0 - 2.5 mm (0.08 0.1 in) protrudes above the end cap surface. Printed end of bearing cage must face up.

16. Install the two circuit relief valves, springs and plugs with new o-rings. Both relief valves are the same. Tighten to a torque of 40.7 - 67.8 N·m (30 - 50 lb ft).

17. Install the charge relief valve, shims, spring and poppet into the housing with a new o-ring. Tighten to a torque of 54.2 - 135.6 N·m (40 - 100 lb ft).

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18. Install the valve plate on the end cap with the brass side toward the pump cylinder. The cut out notch on OD locates on the roll pin in the end cap. Do not interchange valve plates. RH Drive Pump valve plate (1), LH Drive Pump valve plate (2)

83115796

20115821

83115813

20105293N

19. Install the end cap with a new gasket. Tighten the socket head screws to a torque of 47.5 - 61.0 N·m (35 - 45 lb ft). Rotate the shaft to assure correct assembly. When properly assembled, a torque of 2.3 5.7 N·m (1.7 - 4.2 lb ft) should be required to turn the shaft.

20. Install the coupling on the shaft. Assemble the two piston pumps using new o-rings.

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21. Tighten the socket head screws (1) to a torque of 47.5 - 61.0 N·m (35 - 45 lb ft). Check for proper internal assembly by slowly rotating the pump shaft while tightening these screws.

20115788A

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Pump - Install L218 L220

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

Prior operation: Pump - Remove (29.218) 1. Before pump installation, apply MOLYKOTE ® G-N METAL ASSEMBLY PASTE or NEW HOLLAND AMBRA GR 75 MD to the pump and the coupling splines. Pre-fill the pump with clean hydraulic oil. Inspect O-ring on the pump pilot and replace if necessary. Lubricate the O-ring with clean hydraulic oil. 2. Position the pump in the mounting location. Rotate the gear pump shaft until it aligns with the coupling splines at the rear of the hydrostatic pump. After the splines are aligned, move the pump inward until the mounting flange is flush with the mounting surface of the hydrostatic pump.

931002077

931002078

3. Apply LOCTITE® 243 to the pump mounting bolts (1). Install washers on the bolts and install the bolts (1) into the pump mounting flange. Tighten the mounting bolts to 86 - 117 N·m (63.4 - 86.3 lb ft). Apply LOCTITE® 243 to pump support bracket bolts (2). Install washer on bolts and install bolts. Tighten the pump support bracket bolts 55 - 60 N·m (40.6 - 44.3 lb ft).

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4. Connect electrical connection (1).

931002076

931002075

931002074

931002073

5. Connect control linkage (1). NOTE: Image 4 is an example of mechanical linkage. Your machine may not have this style of linkage.

6. Connect the right hand side hydraulic hoses (1).

7. Connect the rear hydraulic tube (1) and supply hose (2).

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8. Connect the four left hand side hydraulic hoses (1) to the correct ports.

931002072

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Pump - Remove L218 L220

WE Electro hydraulic controls WE Electro hydraulic 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

NOTE: See Hydraulic systems - Depressurising (35.000) to depressurize the hydraulic system. 2. Label and disconnect the two front (1) and two rear (2) pump control connections.

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

931001963

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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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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15. Using the hoist, carefully remove pumps.

931001976

Next operation: Pump - Install (29.218)

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Pump - Install L218 L220

WE Electro hydraulic controls WE Electro hydraulic 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

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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

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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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Servo control - Adjust L218 L220

WE Electro hydraulic controls WE Electro hydraulic controls

Travel adjustments for the Electro-Hydraulic (EH) pumps are less involved because the EH pumps do not have mechanical control linkage. Before attempting to adjust the pumps, verify that the problem is not with a drive motor. Also, test the charge pressure and main relief pressure before proceeding. Please see Pump and motor components Pressure test (29.218) for test details. Please see Pump - General specification (29.218) and Motor - General specification (29.218) for specifications about the hydrostatic pumps and drive motors. If there are no problems with the drive motors and the charge pressure and main relief pressure are within specifications, please use the Electronic Service Tool (EST) to calibrate the joysticks and the ground drive. If the machine continues to travel inappropriately 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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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.

RAPH12SSL0443AA

RAPH12SSL0450AA

10. Repeat steps 8 and 9 to verify your records. 11. Center the adjustment screw based on your records. 12. Tighten the jam nut. 13. Connect the inlet line. 14. Calibrate the joysticks and ground drive, using the EST. 15. Test drive the machine. If the machine steers in either direction more than 1.8 m (6 ft) from the centerline after traveling 30.5 m (100 ft) forward or 15.2 m (50 ft) backward, please see the steps in the “Adjust the piston stops” section of this document.

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

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

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

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RAPH12SSL0443AA

Hydrostatic drive - Pump and motor components

Motor - Remove L218 L220

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

931002070

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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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6. Remove front and rear axle housings

931002083B

931002084

931002085B

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

NOTE: See Hydraulic systems - Depressurising (35.000) to depressurize the hydraulic system. 47711684 06/05/2014

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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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Motor - Disassemble – Single speed drive motor L218 L220

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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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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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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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 L218 L220

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 L218 L220

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 L218 L220

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. 47711684 06/05/2014

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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 L218 L220

WE WE

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

931001687A

931002004

2. Apply a 3 mm (0.1 in) bead of LOCTITE® 598 ULTRA 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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Pump - Troubleshooting L218 L220

WE WE

Problem Possible Cause One Transmission (Right 1.If you have a EH unit perform EH pump or Left) Works Correctly electrical check and verify that unit has been properly calibrated. and the Other Does Not Check the interlock valve power/function. 2. Check the brake valve power/function. Make sure park brakes are released. 3. Check the pressure setting of the circuit relief valve for the transmission with the problem.

Machine does not have enough power

Correction A. Is there still a problem? No: Troubleshooting complete. Yes: Go to Step 2. Is there still a problem? No: Troubleshooting complete. Yes: Go to Step 3. Do - Check the Circuit Relief Valve Pressure. Is there still a problem? No: Troubleshooting complete. Yes: Go to Step 4. Do - Check the Charge Pressure/Flow. Is there still a problem? No: Troubleshooting complete. Yes: Go to Step 2.

4. Check the charge pressure. 1. If you have a EH unit perform EH pump electrical check and verify that unit has been properly calibrated. Check the interlock valve power/function. 2. Full throttle engine speed is OK, rated A. Problem in engine or fuel system. Repair engine speed is low. as required. B. Is there still a problem? No: Troubleshooting complete. Yes: Go to Step 3. 3. Check charge pressure. Refer to Pump and motor components Pressure test (29.218) to determine if the pump or drive motor(s) have failed.

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Index Hydrostatic drive - 29 Pump and motor components - 218 Motor - Assemble – Single speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Motor - Assemble – Two speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Motor - Disassemble – Single speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Motor - Disassemble – Two speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Motor - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Motor - General specification – Single speed motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Motor - General specification – Two-speed motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Motor - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Motor - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Pump - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Pump - Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Pump - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Pump - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Pump - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Pump - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Pump - Measure – Piston travel (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Pump - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Pump - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Pump - Visual inspection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Pump and motor components - Install – Charge pressure relief valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Pump and motor components - Install – Charge pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Pump and motor components - Install – Drive shaft seal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Pump and motor components - Install – Main relief valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Pump and motor components - Pressure test – Charge pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Pump and motor components - Pressure test – Main relief valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Pump and motor components - Remove – Charge pressure relief valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Pump and motor components - Remove – Charge pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Pump and motor components - Remove – Drive shaft seal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

(*) See content for specific models 47711684 06/05/2014

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Pump and motor components - Remove – Main relief valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Servo control - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

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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 Brakes and controls L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Brakes and controls - 33

[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1

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Contents Brakes and controls - 33 Parking brake or parking lock - 110

TECHNICAL DATA Parking brake control valve General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Parking brake control valve Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Brakes and controls - Parking brake or parking lock

Parking brake control valve - General specification L218 L220

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 - General specification L218 L220

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 - General specification L218 L220

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 - General specification L218 L220

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

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Brakes and controls - Parking brake or parking lock

Parking brake control valve - Component localisation L218 L220

WE WE

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) Loader arm lockout valve

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(7) Self level valve

Index Brakes and controls - 33 Parking brake or parking lock - 110 Parking brake control valve - Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Parking brake control valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Parking brake control valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Parking brake control valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Parking brake control valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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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 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Hydraulic systems - 35

[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.128] Auxiliary hydraulic function control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.350] Safety and main relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5 [35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6 [35.600] High flow hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7 [35.701] Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8 [35.723] Front loader bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9 [35.724] Front loader hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10 [35.734] Tool quick coupler hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.11

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Contents Hydraulic systems - 35 Hydraulic systems - 000

FUNCTIONAL DATA Hydraulic systems Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic schematic frame 01 - Valves (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic schematic frame 02 - Pump and motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Hydraulic schematic frame 01 - Valves (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Hydraulic schematic frame 02 - Pump and motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SERVICE Hydraulic systems Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Decontaminating (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Depressurising (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Component localisation L218 L220

WE WE

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) Loader arm lockout valve

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(7) Self level valve

Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic schematic frame 01 - Valves L218 L220

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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RAIL14SSL0257JA

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Hydraulic systems - Hydraulic schematic frame 02 - Pump and motor L218 L220

WE Mechanical hydraulic controls WE Mechanical 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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RAIL14SSL0258JA

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Hydraulic systems - Hydraulic schematic frame 01 - Valves L218 L220

WE Electro hydraulic controls WE Electro 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 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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RAIL14SSL0261JA

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Hydraulic systems - Hydraulic schematic frame 02 - Pump and motor L218 L220

WE Electro hydraulic controls WE Electro 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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RAIL14SSL0262JA

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Cleaning L218 L220

WE WE

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. To clean the lines refer to the following procedure: Pump - Cleaning (29.218) 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. 47711684 06/05/2014

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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 - Decontaminating L218 L220

WE WE

WARNING Crushing hazard! If you service the machine with the loader lift arms raised, always use the support strut. Remove the retaining pin and place the support strut onto the cylinder rod. Install the retaining pin into the support strut. Lower the lift arms onto the support strut. Failure to comply could result in death or serious injury. W0230A

1. Start and run the engine at 1500 rpm (r/min). 2. Completely retract all attachment cylinders on the machine. Stop the engine. 3. Depress the auxiliary hydraulic interlock override button, and leave the seat within 30 s. Move each control lever in both directions to release pressure in the hydraulic circuits. 4. Loosen and remove the filler cap from the reservoir. 5. Drain the hydraulic oil from the reservoir. (A) Have available acceptable equipment to drain the hydraulic oil. (B) Remove the drain plug from the bottom of the reservoir. 6. Remove the hydraulic filter element from the machine. 7. Install new hydraulic filter element on the machine. 8. Install the drain plug in the bottom of the reservoir. 9. Fill the hydraulic reservoir. (35.300)

Oil reservoir - Filling

10. Disconnect the line from the ROD end and BARREL end of each cylinder. 11. Be sure all control levers are in the NEUTRAL position. 12. Start and run the engine at low idle. NOTICE: Check the oil level in the hydraulic reservoir frequently while doing step 13. Have another person hold a container under the hydraulic lines while you do step 13. 13. Slowly move the control lever for each bucket and lift cylinders in both directions until oil begins to flow from the open line. Hold the control lever in place until clean oil flows from the open line. 14. Stop the engine. 15. Connect the system line to the BARREL end of each cylinder. 16. Connect a suitable drain line to the ROD end of each cylinder and place the other end in an acceptable container for contaminated oil. 17. Start the engine and run the engine at low idle.

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Hydraulic systems - Hydraulic systems

18. Slowly and completely extend all cylinders. As the piston rod comes in/out of the cylinder, oil will be pushed out of the ROD end of the cylinders. NOTICE: Any attachment or part of an attachment that is raised must be supported with acceptable equipment to prevent the attachment from falling. 19. Support any attachments that will be in the RAISED position. 20. Stop the engine. 21. Disconnect the drain lines and connect the system lines to the cylinders. 22. Check the oil level in the hydraulic reservoir. Add oil as required. 23. Install the filler cap on the reservoir. 24. Remove the hydraulic filter element from the machine. 25. Install a new hydraulic filter element on the machine. 26. Start and run the engine at 1500 RPM, operate each hydraulic circuit to completely extend and retract the cylinders. 27. Stop the engine and check for leaks. Check the oil level in the hydraulic reservoir. Add oil as required. Oil reservoir - Filling (35.300)

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Hydraulic systems - Depressurising L218 L220

WE WE

1. Before removing components from the hydraulic system, depressurize the circuit you are working on. 2. For hydraulic cylinders: • Loader — support loader frame, shut off engine, use manual boom lower valve to relieve pressure in base end. • Bucket – remove bucket from unit. Move coupler off of stops at either end, shut off engine. • Hydraulic Coupler – move coupler to unlocked position, shut off engine. 3. For hydraulic pumps or motors: • Shut off engine. 4. For Ride Control or Glide-Ride accumulator: • Raise boom and support loader frame, shut off engine, turn ignition “ON” (do not start), turn Ride Control/Glide-Ride switch on, use manual boom lower valve to relieve pressure in base end of cylinder/accumulator. 5. For attachments connected to standard aux or standard high flow: • All units are equipped with “connect under pressure” manifold that bleeds pressure from circuit during connect or disconnect. 6. 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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Index Hydraulic systems - 35 Hydraulic systems - 000 Hydraulic systems - Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Hydraulic systems - Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic systems - Decontaminating (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Hydraulic systems - Depressurising (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Hydraulic systems - Hydraulic schematic frame 01 - Valves (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic systems - Hydraulic schematic frame 01 - Valves (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Hydraulic systems - Hydraulic schematic frame 02 - Pump and motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Hydraulic systems - Hydraulic schematic frame 02 - Pump and motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Hydraulic systems - 35 Fixed displacement pump - 104

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Contents Hydraulic systems - 35 Fixed displacement pump - 104

TECHNICAL DATA Fixed displacement pump General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Fixed displacement pump Flow test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Flow test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Hydraulic systems - Fixed displacement pump

Fixed displacement pump - General specification

RAPH14SSL0002GA

Fixed displacement pump Type

Gear pump

Pump displacement

27.9 cm³ (1.7 in³)

Engine RPM

2860 RPM

Pump flow at RPM

73.1 L/min (19.3 US gpm)

High flow pump displacement (if applicable) 13.7 cm³ (0.8 in³) Combined pump flow at RPM (if applicable) 109.8 L/min (29.0 US gpm)

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Fixed displacement pump - Flow test L218 L220

WE WE

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 to the auxiliary couplers on the loader arm. NOTE: Verify that the flow inlet and outlet direction is correct on the flow meter.

RAPH12SSL0241AA

2. Start the machine and run at full throttle. Adjust the machine’s RPM to 200 RPM less than the full throttle RPM. Record the set RPM on the data collection sheet located on the following page.

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Hydraulic systems - Fixed displacement pump

Pump flow with no restriction 3. 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 2 is an example of a flow reading. Image 2 may not match your reading.

RAPH12SSL0242AA

RAPH12SSL0243AA

Pump flow with restriction 4. Adjust the flow meter pressure until 152 bar (2200 psi) is achieved. Verify that the machine is running at the set RPM recorded on the data collection sheet located on the following page. Adjust RPM if necessary. Record the pump flow on the data collection sheet located on the following page. Please see Fixed displacement pump - General specification (35.104) for specification about the gear pumps. NOTE: Image 3 is an example of a flow reading. Image 3 may not match your reading.

Pump efficiency 5. Pump efficiency is determined by dividing the pump flow with restriction value by the pump flow without restriction value, then multiplying that new value by 100. Record the pump efficiency on the data collection sheet located on the following page. NOTE: Pump efficiency should be no less than 70 %.

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Hydraulic systems - Fixed displacement pump

Engine RPM - Set RPM

__________RPM

Notes: Test 1: Pump flow - Pump flow at without restriction

__________l/min __________gpm

Notes: Test 2: Pump flow with restriction - Pump flow with 152 bar (2200 psi) restriction

__________l/min __________gpm

Notes: Test 3: Pump efficiency - Calculated pump efficiency __________% NOTE: Calculated pump efficiency is determined by dividing Test 2’s value by Test 1’s value, then multiplying that new value by 100. Notes:

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Hydraulic systems - Fixed displacement pump

Fixed displacement pump - Flow test L218 L220

WE WE

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: 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 (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.

4. Start the machine and run at full throttle. Adjust the machine’s RPM to 200 RPM less than the full throttle RPM. Record the set RPM on the data collection sheet located on the following page.

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Hydraulic systems - Fixed displacement pump

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 4 is an example of a flow reading. Image 4 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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Hydraulic systems - Fixed displacement pump

Engine RPM - Set RPM

__________RPM

Notes: Test 1: Pump flow - Pump flow without restriction

__________l/min __________gpm

Notes: Test 2: Pump flow with restriction - Pump flow with 152 bar (2200 psi) restriction

__________l/min __________gpm

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Hydraulic systems - Fixed displacement pump

Fixed displacement pump - Remove L218 L220

WE WE

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

Prior operation: For depressurizing the hydraulics, refer to Hydraulic systems - Depressurising (35.000). 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. Label and disconnect gear pump supply hose (1). Cap open ports.

931001955

931002073

2. Label and disconnect gear pump hydraulic tube (1). Cap open ports. NOTE: Picture shown is of a single gear pump. If the pump you are working on is a double gear pump, label and remove second hydraulic tube. Cap open ports.

3. Remove the gear pump retaining bolts (1). Remove gear pump.

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Hydraulic systems - Fixed displacement pump

Fixed displacement pump - Install L218 L220

WE WE

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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Index Hydraulic systems - 35 Fixed displacement pump - 104 Fixed displacement pump - Flow test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fixed displacement pump - Flow test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Fixed displacement pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fixed displacement pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Fixed displacement pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Hydraulic systems - 35 Auxiliary hydraulic function control - 128

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Contents Hydraulic systems - 35 Auxiliary hydraulic function control - 128

TECHNICAL DATA Control valve General specification – Secondary auxiliary valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Control valve Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Auxiliary hydraulic function control Pressure test – Circuit relief valve. (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Test – Circuit leakage (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Hydraulic systems - Auxiliary hydraulic function control

Control valve - General specification – Secondary auxiliary valve L218 L220

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 function control

Control valve - Component localisation L218 L220

WE WE

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) Loader arm lockout valve

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(7) Self level valve

Hydraulic systems - Auxiliary hydraulic function control

Auxiliary hydraulic function control - Pressure test – Circuit relief valve. L218 L220

WE WE

1. Park the machine on a level surface. 2. Lower all attachments to the floor. 3. Stop the engine. 4. Move the control levers in all directions to release any circuit pressure. 5. The best way to connect the hand pump is directly to the control valve. Disconnect the tube from the port of the control valve and connect the hand pump to the port. Please see Main control valve - General specification (35.359) for specifications on ports. 6. Remove all dirt and grease from the connecting point. 7. Connect the hose of the hand pump to the connecting point, but do not tighten the connection. 8. Make sure that the hand pump is filled with oil. The temperature of the oil must be at least 21°C (70°F). 9. Operate the hand pump to fill the hose of the hand pump with oil. Then tighten the connections. 10. Operate the hand pump and read the pressure gauge. Record the highest indication. Check the pressure several times to make sure that the indications are correct. 11. Compare the indication with the specification on Main control valve - General specification (35.359) the indication is not correct, replace the circuit relief valve. NOTE: The circuit relief valves for the loader circuit are not adjustable and must be replaced if they do not meet the specification. 12. Repeat this test after installing a new circuit relief valve.

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Hydraulic systems - Auxiliary hydraulic function control

Auxiliary hydraulic function control - Test – Circuit leakage L218 L220

WE WE

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 hydraulic gear pump(s). Install the “T” fitting into the hydraulic gear pump outlet (1), and attach the flow meter hose to the “T” fitting. NOTE: Verify that the flow inlet direction is correct on the flow meter.

931001956

RAPH12SSL0247AA

2. 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.

3. Start the machine and run at full throttle.

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Hydraulic systems - Auxiliary hydraulic function control

4. 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 gear pumps. NOTE: Image 3 is an example of a flow reading. Image 3 may not match your reading.

RAPH12SSL0329AA

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Hydraulic systems - Auxiliary hydraulic function control

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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Index Hydraulic systems - 35 Auxiliary hydraulic function control - 128 Auxiliary hydraulic function control - Pressure test – Circuit relief valve. (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Auxiliary hydraulic function control - Test – Circuit leakage (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Control valve - Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Control valve - General specification – Secondary auxiliary valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Hydraulic systems - 35 Reservoir, cooler, and filters - 300

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Contents Hydraulic systems - 35 Reservoir, cooler, and filters - 300

SERVICE Oil reservoir Apply vacuum (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Filling (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Visual inspection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Oil filters Remove – Filter housing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install – Filter housing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Hydraulic systems - Reservoir, cooler, and filters

Oil reservoir - Apply vacuum L218 L220

WE WE

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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Hydraulic systems - Reservoir, cooler, and filters

Oil reservoir - Drain fluid L218 L220

WE WE

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.

931001657

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Hydraulic systems - Reservoir, cooler, and filters

Oil reservoir - Filling L218 L220

WE WE

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. 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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93107491

Hydraulic systems - Reservoir, cooler, and filters

Oil reservoir - Visual inspection L218 L220

WE WE

1. Check the reservoir for wear, cracks, and leaks. Repair as required. NOTICE: Do not modify the strainer, as any material that gets past the strainer can go directly to the gear pump, control valve, cylinders, and auxiliary hydraulic attachment and cause major damage to these components. 2. Inspect the strainer. Remove and replace if the strainer is dirty or clogged. 3. Inspect the return line port, and suction line port, for cracks and debris buildup. Repair as required.

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Hydraulic systems - Reservoir, cooler, and filters

Oil filters - Remove – Filter housing L218 L220

WE WE

Prior operation: Oil reservoir - Apply vacuum (35.300). 1. The filter base can be removed by opening the rear door and lifting the rear engine hood. Loosen and remove the filter element (1) from the filter base. 2. Remove the ground wire (2).

93107491

93106865

3. Remove the inlet, (3), and outlet, (4), oil lines and cap to prevent loss of oil. 4. Stop vacuum pump. 5. Loosen and remove the filter base mounting bolts (5).

6. Remove the filter base assembly from the unit.

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Hydraulic systems - Reservoir, cooler, and filters

Oil filters - Install – Filter housing L218 L220

WE WE

Prior operation: Oil reservoir - Apply vacuum (35.300). 1. Reinstall the filter base with the hardware previously removed (1). Torque the mounting hardware to 20 Nm ( 15 lb ft).

93106865

93107491

93106865

2. Reinstall the hydraulic lines (2) and (3) and tighten the lines to seat line on fittings; loosen and re-torque.

3. Stop vacuum pump. 4. Connect the ground wire (4) to the filter sensor.

5. Coat the seal ring on a new filter element with clean 10W-30 oil, and tighten the new filter element hand tight 23.0 - 17.6 N·m (17 - 13 lb ft) .

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Index Hydraulic systems - 35 Reservoir, cooler, and filters - 300 Oil filters - Install – Filter housing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Oil filters - Remove – Filter housing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Oil reservoir - Apply vacuum (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Oil reservoir - Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Oil reservoir - Filling (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Oil reservoir - Visual inspection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Hydraulic systems - 35 Safety and main relief valves - 350

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Hydraulic systems - 35 Safety and main relief valves - 350

TECHNICAL DATA Main relief valve General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Main relief valve Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Hydraulic systems - Safety and main relief valves

Main relief valve - General specification L218 L220

WE WE

RAIL12SSL0332GA

Main control valve Main relief setting Circuit relief setting

Valve identification

Port identification

Solenoid 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) A1, pressure relief (3) A2, pressure relief (4) Load check (5) B1, hydraulic, anti-cavitation (6) B2, pressure relief 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 (7) Port lock

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Hydraulic systems - Safety and main relief valves

Main relief valve - Pressure test L218 L220

WE WE

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 to the auxiliary couplers on the loader arm. NOTE: Verify that the flow inlet and outlet direction is correct on the flow meter.

RAPH12SSL0241AA

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Hydraulic systems - Safety and main relief valves

Main relief pressure 1. Activate the auxiliary function in one direction on the machine, and hold the auxiliary switch in that position. 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 2 is an example of a flow reading. Image 2 may not match your reading.

RAPH12SSL0244AA

2. Release the auxiliary switch. Reset the flow meter.

Cracking pressure 3. Activate the auxiliary function in one direction on the machine, and hold the auxiliary switch in that position. 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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Hydraulic systems - Safety and main relief valves

Main relief valve - Pressure test L218 L220

WE WE

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 (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.

4. Start the machine and run at full throttle.

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Hydraulic systems - Safety and main relief valves

Main relief pressure 1. 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. 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

2. Release the stroked bucket function. Reset the flow meter.

Cracking pressure 3. 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. 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 stroked bucket function. Reset the flow meter.

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Index Hydraulic systems - 35 Safety and main relief valves - 350 Main relief valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Main relief valve - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Main relief valve - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Hydraulic systems - 35 Main control valve - 359

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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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 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remove – Proportional auxiliary valve retract solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install – Proportional auxiliary valve retract solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Remove – Proportional auxiliary valve extend solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install – Proportional auxiliary valve extend solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Remove – Spool solenoids (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install – Spool solenoids (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Remove – Spool position sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install – Spool position sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Remove – Loader port lock solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Install – Loader port lock solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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Hydraulic systems - Main control valve

Main control valve - General specification L218 L220

WE WE

RAIL12SSL0332GA

Main control valve Main relief setting Circuit relief setting

Valve identification

Port identification

Solenoid identification

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Hydraulic systems - Main control valve

Main control valve - Test – Circuit leakage L218 L220

WE WE

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 (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.

4. Start the machine and run at full throttle.

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5. Adjust the flow meter pressure until 124 bar (1800 psi) is achieved. While watching the flow meter liter per minute (l/min) gauge or gallon per minute (gpm) gauge, stroke each loader arm and bucket function to the end of cylinder travel on the machine, and activate the primary auxiliary couplers in both directions. Record the pump flow on the data collection sheet 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 3 is an example of a flow reading. Image 3 may not match your reading.

RAPH12SSL0329AA

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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 L218 L220

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

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 L218 L220

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

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 L218 L220

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

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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Main control valve - Install – Proportional auxiliary valve extend solenoid L218 L220

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

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 L218 L220

WE Electro hydraulic controls WE Electro hydraulic 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 L218 L220

WE Electro hydraulic controls WE Electro hydraulic 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 L218 L220

WE Electro hydraulic controls WE Electro hydraulic 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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Main control valve - Install – Spool position sensors L218 L220

WE Electro hydraulic controls WE Electro hydraulic 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 L218 L220

WE Electro hydraulic controls WE Electro hydraulic controls

1. Locate the loader control valve (1) on the right hand side of the machine. NOTE: Image 1 is an example of the main control valve for Electro-Hydraulic (EH) controlled machines. The loader control valve on mechanically controlled machines is in the same location.

RAPH12SSL0446AA

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 L218 L220

WE Electro hydraulic controls WE Electro hydraulic controls

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 L218 L220

WE Electro hydraulic controls WE Electro hydraulic 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

NOTICE: Before removing components from the hydraulic system, depressurize the system you are working on. See reference Hydraulic systems - Depressurising (35.000) Prior operation: Tilt the ROPS. 1. Apply vacuum to 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 six hydraulic tubes (1) from control valve and cap open ports.

5. Label and disconnect drain hoses (1) from control valve.

6. Label and disconnect two hoses (1) and one tube (2) from top of control valve.

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Hydraulic systems - Main control valve

7. Disconnect hydraulic tubes (1) located at bottom of valve block.

931001714

931001711

931001718

931001719

8. Disconnect hydraulic hoses (1) from solenoid block.

9. Remove the three valve mounting bolts (1) (one shown).

10. Remove loader valve.

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Hydraulic systems - Main control valve

Main control valve - Install L218 L220

WE Electro hydraulic controls WE Electro hydraulic controls

1. Position the control valve into the machine mounting location.

931001719

931001718

931001711

931001714

2. Install the three valve mounting bolts (1) (one shown).

3. Connect hydraulic hoses (1) to solenoid block.

4. Connect hydraulic tubes (1) located at the bottom of valve block.

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5. Connect two hoses (1) and one tube (2) to the top of control valve.

931001710

931001715

931001713

931001709

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.

8. Connect the six front solenoid connections (1).

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Hydraulic systems - Main control valve

9. Connect rear solenoid connections (1).

931001708

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Index Hydraulic systems - 35 Main control valve - 359 Main control valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Main control valve - Install – Loader port lock solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Main control valve - Install – Proportional auxiliary valve extend solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Main control valve - Install – Proportional auxiliary valve retract solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Main control valve - Install – Spool position sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Main control valve - Install – Spool solenoids (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Main control valve - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Main control valve - Remove – Loader port lock solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Main control valve - Remove – Proportional auxiliary valve extend solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Main control valve - Remove – Proportional auxiliary valve retract solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Main control valve - Remove – Spool position sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Main control valve - Remove – Spool solenoids (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Main control valve - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Main control valve - Test – Circuit leakage (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Hydraulic systems - 35 High flow hydraulics - 600

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Hydraulic systems - 35 High flow hydraulics - 600

TECHNICAL DATA Pilot valve General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

High flow hydraulic pump General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA High flow hydraulics Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Pilot valve Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

High flow hydraulic pump Flow test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Flow test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Hydraulic systems - High flow hydraulics

Pilot valve - General specification L218 L220

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 hydraulic pump - General specification

RAPH14SSL0003GA

High flow pump Type

Gear pump

Pump displacement

13.7 cm³ (0.84 in³)

Engine RPM

1800 RPM

Pump flow

23 l/min (6.1 US gpm)

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Hydraulic systems - High flow hydraulics

High flow hydraulics - Overview L218 L220

WE WE

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 - Pressure test L218 L220

WE WE

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 to the high flow, outlet auxiliary coupler. NOTE: Verify flow direction for accurate reading and machine safety.

93106839B

RCPH11SSL003AAD

931001689

2. Start the machine, and raise the engine speed to full throttle. 3. Engage the auxiliary hydraulics and 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. 4. Select High Flow (HF) on the rocker switch (1).

5. Record the pressure on the pressure gauge. Please see Pilot valve - General specification (35.600) for specifications on the high flow pilot valve. 6. Release the stroked bucket function and disengage the auxiliary hydraulics. 7. If the recorded pressure is not within specification, remove the cap (1) on the relief valve and adjust.

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8. Repeat steps 2 through 7 until the relief valve is within specification.

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Pilot valve - Remove L218 L220

WE WE

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.

4. Disconnect the valves electrical connection (5).

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5. Remove the two mounting bolts (2).

931001689

931001690

6. Remove valve.

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Pilot valve - Install L218 L220

WE WE

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.

4. Connect the top hydraulic tube (4). NOTE: Arrow indicates forward direction.

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Hydraulic systems - High flow hydraulics

5. Connect electrical connection (5). NOTE: Arrow indicates forward direction.

931001689

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High flow hydraulic pump - Flow test L218 L220

WE WE

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 to the auxiliary couplers on the loader arm. NOTE: Verify that the flow inlet and outlet direction is correct on the flow meter.

RAPH12SSL0241AA

RCPH11SSL003AAD

2. Start the machine and run at full throttle. Adjust the machine’s RPM to 200 RPM less than the full throttle RPM. Record the set RPM on the data collection sheet located on the following page. 3. Select HF on the rocker switch (1) and activate the auxiliary couplers.

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Hydraulic systems - High flow hydraulics

Pump flow with no restriction 4. 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 5. 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 4 is an example of a flow reading. Image 4 may not match your reading.

Pump efficiency 6. Pump efficiency is determined by dividing the pump flow with restriction value by the pump flow without restriction value, then multiplying that new value by 100. Record the pump efficiency on the data collection sheet located on the following page. NOTE: Pump efficiency should be no less than 70 %.

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Hydraulic systems - High flow hydraulics

Engine RPM __________RPM

- Set RPM Notes: Test 1: Pump flow - Pump flow at full throttle without restriction

__________l/min __________gpm

Notes: Test 2: Pump flow with restriction - Pump flow at full throttle with 152 bar (2200 psi) restriction

__________l/min __________gpm

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Hydraulic systems - High flow hydraulics

High flow hydraulic pump - Flow test L218 L220

WE WE

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: 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 (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.

4. Start the machine and run at full throttle. Adjust the machine’s RPM to 200 RPM less than the full throttle RPM. Record the set RPM on the data collection sheet located on the following page.

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Hydraulic systems - High flow hydraulics

5. Select High Flow (HF) on the rocker switch (1) and activate the auxiliary couplers.

RCPH11SSL003AAD

RAPH12SSL0242AA

RAPH12SSL0243AA

Pump flow with no restriction 6. Verify that the flow meter has no restriction on the hydraulic pump. Record the pump flow on the data collection sheet located on the following page. Please see Fixed displacement pump - General specification (35.104) for specification about the gear pumps. NOTE: Image 4 is an example of a flow reading. Image 4 may not match your reading.

Pump flow with restriction 7. Adjust the flow meter pressure until 152 bar (2200 psi) is achieved. Verify that the machine is running at the set RPM recorded on the data collection sheet located on the following page. Adjust RPM if necessary. Record the pump flow on the data collection sheet located on the following page. Please see Fixed displacement pump - General specification (35.104) for specification about the gear pumps. NOTE: Image 5 is an example of a flow reading. Image 5 may not match your reading.

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Pump efficiency 8. Pump efficiency is determined by dividing the pump flow with restriction value by the pump flow without restriction value, then multiplying that new value by 100. Record the pump efficiency on the data collection sheet located on the following page. NOTE: Pump efficiency should be no less than 70 %.

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Hydraulic systems - High flow hydraulics

Engine RPM __________RPM

- Set RPM Notes: Test 1: Pump flow - Pump flow at full throttle without restriction

__________l/min __________gpm

Notes: Test 2: Pump flow with restriction - Pump flow at full throttle with 152 bar (2200 psi) restriction

__________l/min __________gpm

Notes: Test 3: Pump efficiency - Calculated pump efficiency NOTE: Pump efficiency should be no less than 70 %

__________%

Notes:

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Index Hydraulic systems - 35 High flow hydraulics - 600 High flow hydraulic pump - Flow test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 High flow hydraulic pump - Flow test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 High flow hydraulic pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 High flow hydraulics - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pilot valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pilot valve - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Pilot valve - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Pilot valve - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Hydraulic systems - 35 Front loader arm hydraulic system - 701

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Hydraulic systems - 35 Front loader arm hydraulic system - 701

TECHNICAL DATA Front loader arm hydraulic system General specification - Lockout valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Ride control solenoid valve block General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Accumulator General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

FUNCTIONAL DATA Front loader arm hydraulic system Overview – Loader lock control valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SERVICE Front loader arm hydraulic system Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Lift arm cylinder Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Ride control solenoid valve block Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Relief valve Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Accumulator Visual inspection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Discharging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Charging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

DIAGNOSTIC Front loader arm hydraulic system Testing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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Hydraulic systems - Front loader arm hydraulic system

Front loader arm hydraulic system - General specification - Lockout valve L218 L220

WE WE

RAPH12SSL0340GA

Loader arm lockout valve 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 L218 L220

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

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Ride control solenoid valve block - General specification L218 L220

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 L218 L220

WE WE

Manufacturer

Parker

Fluid Capacity

750 ml (25.4 US fl oz)

Charge with dry nitrogen

21 bar (300 psi)

Port

Internal straight thread 3/4-16 UNF - 2B

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Front loader arm hydraulic system - Overview – Loader lock control valve L218 L220

WE WE

On-Road regulations require the loader arm and bucket to be locked in a ‘traveling’ position. To prevent the operator from inadvertently lowering or raising the loader or bucket causing damage to roadway, vehicles or machine. The operator places the bucket and loader in the appropriate position. Then the operator then switches the loader lock to the on position, locking the bucket and loader in the set position. The operator will not be able to move the bucket and loader until the loader lock switch has been turned off. The switch will illuminate when Loader Lock is on. The function is always active when hydraulics are enabled. A Mechanical Machine with Loader Lock on will trigger trouble code 4952. This is expected.

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Front loader arm hydraulic system - Component localisation L218 L220

WE WE

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) Loader arm lockout valve

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(7) Self level valve

Hydraulic systems - Front loader arm hydraulic system

Front loader arm hydraulic system - Pressure test L218 L220

WE WE

1. If the hydraulic oil is not at operating temperature run the engine at full throttle and hold the bucket control lever in the ROLLBACK position for 30 seconds. Then return the bucket control lever to NEUTRAL for 15 seconds. Repeat this cycle until the temperature of the oil is at least 52°C (125°F). 2. Disconnect the hydraulic lines from the implement controller where they connect to the main control valve. 3. Connect a 41 bar (600 psi) pressure gauges to pilot line at spool ends. 4. Start the engine and run at high idle. Read the pressure gauge and record the pressure reading at high idle. Pressure should be 0 bar (0.0 psi) with lever in neutral. 5. Move the implement controller lever to raise the loader control arms. Read the pressure gauge and record the pressure reading. 6. Move the implement controller lever to lower the loader control arms. Read the pressure gauge and record the pressure reading. 7. The pressure readings should vary from 0 bar (0.0 psi) to 25 bar (360 psi) at high idle for a given angle on the implement control handle. 8. If the pressure readings are correct, the test is complete. If the pressure readings are not correct, repair or replace the charge/hydrostatic pump assembly or the main control valve.

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Lift arm cylinder - Remove L218 L220

WE WE

NOTICE: Before removing components from the hydraulic system, depressurize the system you are working on. See reference Hydraulic systems - Depressurising (35.000)

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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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Lift arm cylinder - Install L218 L220

WE WE

Prior operation: Lift arm cylinder - Remove (35.701) 1. Lubricate the rod end pins, (1), with LOCTITE® SILVER GRADE ANTI-SEIZE 767 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 - Disassemble L218 L220

WE WE

Prior operation: Lift arm cylinder - Remove (35.701) 1. Clean the outside of the cylinder. If the hoses were removed from the cylinder, remove the hoses. 2. Fasten the tube (1) in a vise, or other holding equipment can be used. Be careful not to damage the tube. 3. Loosen the gland (5) in the tube with a gland wrench. 4. To prevent damage to the tube, pull the piston rod (3) straight out of the tube. 5. Fasten the piston rod end in a vise. To prevent damage to the piston rod, place a padded support below the piston rod near the piston. 6. Loosen and remove the nut that connects the piston on the piston rod. 7. Remove the piston (6) from the piston rod. 8. Remove and discard the seal (11), wear ring (13) and backup ring (12) from the piston. 9. Remove and discard the O-ring (9), backup ring (10), seals (8), and wiper (7) from the gland (5).

20111254

(1) Tube (2) Bushing (3) Piston Rod

(4) Bushing (5) Packing gland (6) Piston

(7) Wiper (8) Seal (kit) (9) O-ring 47711684 06/05/2014

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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 L218 L220

WE WE

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.

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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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Ride control solenoid valve block - Remove L218 L220

WE WE

NOTICE: Before removing components from the hydraulic system, depressurize the system you are working on. See reference Hydraulic systems - Depressurising (35.000) 1. Locate 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 L218 L220

WE WE

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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Relief valve - Pressure test L218 L220

WE WE

1. Park the machine on a level surface. 2. Lower all attachments to the floor. 3. Stop the engine. 4. Move the control levers in all directions to release any circuit pressure. 5. The best way to connect the hand pump is directly to the control valve. Disconnect the tube from the port of the control valve and connect the hand pump to the port. Please see Main control valve - General specification (35.359) for specifications on ports. By connecting directly to the control valve, you avoid the possibility of a bad reading because of cylinder movement. 6. Remove all dirt and grease from the connecting point. 7. Connect the hose of the hand pump to the connecting point, but do not tighten the connection. 8. Make sure that the hand pump is filled with oil. The temperature of the oil must be at least 21°C (70°F). 9. Operate the hand pump to fill the hose of the hand pump with oil. Then tighten the connections. 10. Operate the hand pump and read the pressure gauge. Record the highest indication. Check the pressure several times to make sure that the indications are correct. 11. Compare the indication with the specification on Main control valve - General specification (35.359) the indication is not correct, replace the circuit relief valve. NOTE: The circuit relief valves for the loader circuit are not adjustable and must be replaced if they do not meet the specification. 12. Repeat this test after installing a new circuit relief valve.

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Hydraulic systems - Front loader arm hydraulic system

Accumulator - Visual inspection L218 L220

WE WE

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. 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. 47711684 06/05/2014

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13. Body 14. Gland without gas valve

Hydraulic systems - Front loader arm hydraulic system

3. In a rotary motion, use an emery cloth with medium grit to remove small scratches on the piston (3), glands (2) and (14), and tube (1). 4. Inspect the glands (2) and (14), for rust or corrosion. Clean and remove the rust or corrosion from the gland. 5. Inspect the piston (3). Check to see if it is worn or damaged. If the piston is worn or damaged, replace with a new accumulator. 6. Inspect the gland ends of the tube (1) for sharp edges. Remove the sharp edges. Sharp edges can damage the seals (4), quad ring (5), and O-rings (6). Next operation: Accumulator - Assemble (35.701)

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Accumulator - Pressure test L218 L220

WE WE

BS04D004

1. Ensure that the oil side of the accumulator is completely discharged. 2. Put the ride control switch in the "On" position. 3. Lower the loader to the floor. Put the loader control lever in the "Float" position. 4. Stop the engine. Put the key in the "On" position. 5. Move the loader control lever in all directions to release any pressure in the hydraulic circuits. Put the loader control lever in the "Float" position. 6. Find the right and left solenoid valves for the ride control system. Find the pin in the coil end of the solenoid. Depress the pin in the solenoid valves with a soft pin (such as a welding rod) to release any pressure in the loader lift circuit. 7. Leave the ride control switch and key switch in the "On" postion. 8. Leave the loader control lever in the "Float" position. 9. Close the valves (B) and (C) on the nitrogen charging kit. 10. Turn the stem out of valve (F) until the stem stops. 11. Remove the cap screws and guard from the accumulator. 12. Remove the cap from the valve stem on the accumulator. 47711684 06/05/2014

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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 - Discharging L218 L220

WE WE

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 CAS10899 to discharge the accumulator. The tool must be disconnected from the nitrogen tank. 2. Close valves (B), (C) and (D). 3. Adjust the regulator (A) to the minimum pressure setting by turning the knob counterclockwise. 4. Turn the T-handle on valve (F) fully out. 5. Remove the guard and cap from the accumulator charging stem. 6. Connect valve (F) to the stem on the accumulator. 7. Turn the T-handle inward on valve (F) to engage the pin in the valve stem. 8. Open valve (D). Check the charge pressure on gauge (E). 9. Partially open valve (B) to discharge the accumulator. The accumulator charge will bleed down through the regulator. 47711684 06/05/2014

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(G) - To nitrogen tank (H) - To accumulator

Hydraulic systems - Front loader arm hydraulic system

10. Once the accumulator is fully discharged, disconnect valve (F) from the accumulator stem.

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Hydraulic systems - Front loader arm hydraulic system

Accumulator - Charging L218 L220

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

Accumulator - Disassemble L218 L220

WE WE

Prior operation: Accumulator - Remove (35.701) 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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Accumulator - Assemble L218 L220

WE WE

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). Next operation: Accumulator - Install (35.701)

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Front loader arm hydraulic system - Testing L218 L220

WE WE

Test Point Expected Result N° Result 1 Check Check to ensure the cab door is fully Door is closed. Action closed (If equipped with cab door). Go to test 2 Result 2 Check Check the cab door switch (If equipped Switch is okay. Action with cab door). Go to test 3 Result 3 Check Check the Implement Controller interlock Valve functioning as designed. Action valve power/function. Go to test 4 Result Charge pressure okay. Action Go to test 5 5 Check Result Check the pilot pressure from the Im- Pilot pressure is okay. plement Controller to the Loader Control Action Go to test 6 Valve. 4 Check Check the charge pressure.

6 Check Check the main control valve function.

Result Main control valve is okay.

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Other Result (Possible Cause) Result Door is opened. Action Close door. Result No power or ground. Door switch is misaligned. Action Repair. Result No power or ground. Valve doesn’t function. Action Repair or replace. Result Low charge pressure. Action Check the charge pressure.. Result Low pilot pressure. Action Please see Front loader arm hydraulic system - Pressure test (35.701) Result Main control valve not functioning as designed. Action Repair or replace the main control valve.

Index Hydraulic systems - 35 Front loader arm hydraulic system - 701 Accumulator - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Accumulator - Charging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Accumulator - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Accumulator - Discharging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Accumulator - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Accumulator - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Accumulator - Visual inspection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Front loader arm hydraulic system - Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Front loader arm hydraulic system - General specification - Lockout valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Front loader arm hydraulic system - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Front loader arm hydraulic system - Overview – Loader lock control valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Front loader arm hydraulic system - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Front loader arm hydraulic system - Testing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Lift arm cylinder - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Lift arm cylinder - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Lift arm cylinder - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Lift arm cylinder - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Relief valve - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Ride control solenoid valve block - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Ride control solenoid valve block - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Ride control solenoid valve block - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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Hydraulic systems - 35 Front loader bucket hydraulic system - 723

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Hydraulic systems - 35 Front loader bucket hydraulic system - 723

SERVICE Front loader bucket hydraulic system Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

DIAGNOSTIC Front loader bucket hydraulic system Testing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Hydraulic systems - Front loader bucket hydraulic system

Front loader bucket hydraulic system - Pressure test L218 L220

WE WE

1. If the hydraulic oil is not at operating temperature run the engine at full throttle and hold the bucket control lever in the ROLLBACK position for 30 seconds. Then return the bucket control lever to NEUTRAL for 15 seconds. Repeat this cycle until the temperature of the oil is at least 52°C (125°F). 2. Disconnect the hydraulic lines from the implement controller where they connect to the main control valve. 3. Connect a 41 bar (600 psi) pressure gauges to pilot line at spool ends. 4. Start the engine and run at high idle. Read the pressure gauge and record the pressure reading at high idle. Pressure should be 0 bar (0.0 psi) with lever in neutral. 5. Move the implement controller lever to tilt the loader bucket. Read the pressure gauge and record the pressure reading. 6. Move the implement controller lever to dump the loader bucket. Read the pressure gauge and record the pressure reading. 7. The pressure readings should vary from 0 bar (0.0 psi) to 25 bar (360 psi) at high idle for a given angle on the implement control handle. 8. If the pressure readings are correct, the test is complete. If the pressure readings are not correct, repair or replace the charge/hydrostatic pump assembly or the main control valve.

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Hydraulic systems - Front loader bucket hydraulic system

Front loader bucket hydraulic system - Testing L218 L220

WE WE

6 Check Check the main control valve function.

Result Main control valve is okay.

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Index Hydraulic systems - 35 Front loader bucket hydraulic system - 723 Front loader bucket hydraulic system - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Front loader bucket hydraulic system - Testing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Hydraulic systems - 35 Front loader hydraulic system control - 724

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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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 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Loader bucket self-leveling controls Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Remove – Solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install – Solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

DIAGNOSTIC Loader bucket self-leveling controls Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Hydraulic systems - Front loader hydraulic system control

Loader bucket self-leveling controls - Overview L218 L220

WE WE

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

Models: L213, L215, L216 Flow split proportion

Port D = 48 % Port B = 52 %

Models: L218, C238 Flow split proportion

Port D = 60 % Port B = 40 %

Models: L220, L221 Flow split proportion

Port D = 40 % Port B = 60 %

Models: L223, C227 Flow split proportion

Port D = 50 % Port B = 50 %

Models: L225, L230, C232 Flow split proportion

Port D = 72 % Port B = 28 %

Port identification chart Self leveling valve port ID

A B C D

= = = =

Lift cylinder rod end CV work port B1 Tilt cylinder rod end Tilt cylinder base end

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Hydraulic systems - Front loader hydraulic system control

Loader bucket self-leveling controls - Exploded view L218 L220

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 L218 L220

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

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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 localisation L218 L220

WE WE

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) Loader arm lockout valve

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(7) Self level valve

Hydraulic systems - Front loader hydraulic system control

Loader bucket self-leveling controls - Adjust L218 L220

WE WE

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 – Solenoid L218 L220

WE WE

Prior operation: Tilt the ROPS. 1. Locate self level valve solenoid Y-318 (1) on the right side, middle of the machine.

931001804

931001701

931001702

2. Disconnect connector X-318 (1) from the self level valve solenoid Y-318 (2).

3. Loosen and remove nut (1). Remove the self level valve solenoid Y-318 (2).

Next operation: Loader bucket self-leveling controls - Install – Solenoid (35.724)

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Hydraulic systems - Front loader hydraulic system control

Loader bucket self-leveling controls - Install – Solenoid L218 L220

WE WE

Prior operation: Tilt the ROPS. 1. Insert the self level valve solenoid Y-318 (1) into the valve block (2).

931001702

931001701

2. Thread nut (1) on stud and tighten to standard torque.

3. Reconnect connector X-318 (1) to the self level valve solenoid Y-318 (2).

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Hydraulic systems - Front loader hydraulic system control

Loader bucket self-leveling controls - Remove L218 L220

WE WE

Prior operation: Tilt the ROPS. NOTE: Never loosen any hydraulic lines without first relieving all pressure in the system. Refer to Hydraulic systems - Depressurising (35.000) 1. Locate control valve (1).

931001804

931001701

931001702

2. Disconnect electrical connection (1).

3. Disconnect hydraulic tube (1) and cap open ports.

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Hydraulic systems - Front loader hydraulic system control

4. Disconnect lower tubes (1) and cap ports.

931001981

931001707

5. Disconnect front tube (1) and cap port.

6. Remove mounting hardware (1).

7. Remove control valve.

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Hydraulic systems - Front loader hydraulic system control

Loader bucket self-leveling controls - Install L218 L220

WE WE

1. Install control valve (1) onto body in correct location.

931001804

931001981

2. Install mounting hardware (1).

3. Connect front tube (1).

4. Connect lower tubes (1).

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Hydraulic systems - Front loader hydraulic system control

5. Connect hydraulic tube (1).

931001702

931001701

6. Connect electrical connection (1).

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Hydraulic systems - Front loader hydraulic system control

Loader bucket self-leveling controls - Troubleshooting L218 L220

Problem Boom delay at start of self level or unstable self-level.

WE WE

Possible Cause Correction Bucket self-leveling is designed to work at Run engine at high idle. high idle. Air in system.

Loaded bucket dumps or uncurls when control valve is in neutral. Insufficient self-level.

Unloading spool is leaking.

Cycle boom and bucket slowly to rid system of air. Remove and inspect unloading spool for damage.

Adjustable orifice is out of adjustment. Broken unloading spool spring.

Replace the self-leveling valve. Replace unloading spool Replace unloading spool Flow divider spool stuck towards adjust- Remove flow divider spool and check for ment pin side. damage. Dampening orifice in the unloading spool is Remove unloading spool and clean dampening orifice. plugged.

With bucket dumped, boom is slow in starting to raise. Bucket does not move in Bucket self-leveling is designed to work at self-level. high idle. Adjustable orifice is screwed in all the way. Dampening orifice in the unloading spool is plugged. Bucket does not maintain Flow divider spool is stuck. level while raising at high idle. Bad bucket cylinder packing Excessive bucket drift towards the dump direction. Excessive loader control valve port leakage. Unloading spool in the leveling valve stuck. Bad bucket cylinder packing. Excessive bucket drift towards the roll back direction. Excessive loader control valve leakage. Defective lift check in the leveling valve External leakage. Damaged o-ring.

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Run engine at high idle. Replace the self-leveling valve. Remove unloading spool and clean dampening orifice. Check flow divider spool for free operation. Repack cylinder. Replace loader valve. Check unloading spool for free operation. Repack cylinder. Replace loader valve. Check lift check for leakage. Replace o-ring.

Index Hydraulic systems - 35 Front loader hydraulic system control - 724 Loader bucket self-leveling controls - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Loader bucket self-leveling controls - Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Loader bucket self-leveling controls - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Loader bucket self-leveling controls - Install – Solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Loader bucket self-leveling controls - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Loader bucket self-leveling controls - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Loader bucket self-leveling controls - Remove – Solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Loader bucket self-leveling controls - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Loader bucket self-leveling controls - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Loader bucket self-leveling controls - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Hydraulic systems - 35 Tool quick coupler hydraulic system - 734

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Hydraulic systems - 35 Tool quick coupler hydraulic system - 734

TECHNICAL DATA Tool quick coupler hydraulic system General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Tool quick coupler hydraulic system Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Tool quick coupler hydraulic system Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Quick coupler cylinder Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Hydraulic systems - Tool quick coupler hydraulic system

Tool quick coupler hydraulic system - General specification L218 L220

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 localisation L218 L220

WE WE

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) Loader arm lockout valve

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(7) Self level valve

Hydraulic systems - Tool quick coupler hydraulic system

Tool quick coupler hydraulic system - Pressure test L218 L220

WE WE

1. Park the machine on a level surface. 2. Lower all attachments to the floor. 3. Stop the engine. 4. Move the control levers in all directions to release any circuit pressure. 5. Connect the hand pump is directly to the control valve. Disconnect the tube from the port of the control valve and connect the hand pump to the port. 6. Remove all dirt and grease from the connecting point. 7. Connect the hose of the hand pump to the connecting point. Do not tighten the connection. 8. Verify that the hand pump is filled with oil. The temperature of the oil must be at least 21°C (70°F). 9. Operate the hand pump to fill the hose of the hand pump with oil. Tighten the connections. 10. Operate the hand pump and read the pressure gauge. Record the highest indication. Check the pressure several times to verify that the indications are correct. 11. Compare the indication with the specification of the hydraulic coupler valve. If the indication is not correct, repair or replace the circuit relief valve. 12. Repeat this test after installing a new circuit relief valve.

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Hydraulic systems - Tool quick coupler hydraulic system

Tool quick coupler hydraulic system - Remove L218 L220

WE WE

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

NOTE: Never loosen any hydraulic lines without first relieving all pressure in the system. Refer to Hydraulic systems - Depressurising (35.000) 1. Label and disconnect electrical connection (1).

931001722

931001720

2. Label and disconnect the bucket hydraulic tubes (1) and cap the open ports.

3. Label and disconnect the supply tube (1) and cap the open ports.

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Hydraulic systems - Tool quick coupler hydraulic system

4. Label and disconnect the drain hose (1).

931001720

931001721

5. Remove the mounting hardware (2).

6. Remove the command valve.

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Hydraulic systems - Tool quick coupler hydraulic system

Tool quick coupler hydraulic system - Install L218 L220

WE WE

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).

4. Connect the valve supply tube (1).

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Hydraulic systems - Tool quick coupler hydraulic system

5. Connect the bucket hydraulic tubes (2).

931001720

931001722

6. Connect the electrical connection (1).

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Hydraulic systems - Tool quick coupler hydraulic system

Quick coupler cylinder - Remove L218 L220

WE WE

NOTE: Never loosen any hydraulic lines without first relieving all pressure in the system. Refer to Hydraulic systems - Depressurising (35.000) 1. Remove snap ring (1).

931001791

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Hydraulic systems - Tool quick coupler hydraulic system

2. Remove retaining pin (1).

931001788

931001786

931001789

931001783

3. Disconnect hydraulic hoses (1) and (2), from manifold.

4. Remove rod end hydraulic hose (1).

5. Disengage the roll pin and bucket locking pin (1).

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Hydraulic systems - Tool quick coupler hydraulic system

6. Remove cylinder.

931001784

Next operation: Quick coupler cylinder - Install (35.734)

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Hydraulic systems - Tool quick coupler hydraulic system

Quick coupler cylinder - Install L218 L220

WE WE

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 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Quick coupler cylinder - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Tool quick coupler hydraulic system - Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Tool quick coupler hydraulic system - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tool quick coupler hydraulic system - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Tool quick coupler hydraulic system - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Tool quick coupler hydraulic system - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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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 Frames and ballasting L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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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

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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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 L218 L220

WE WE

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 L218 L220

WE WE

1. Place rear center bumper (1) in position.

931001656

RAPH12SSL0040AA

931001655

2. Install center bumper mounting hardware (2).

3. Install left hand side counterweight and secure in place with mounting hardware (3).

NOTE: Perform the same operation on right hand side. Next operation: Battery - Install (55.302). 47711684 06/05/2014

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Index Frames and ballasting - 39 Ballasts and supports - 140 Counterweight - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Counterweight - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

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SERVICE MANUAL Wheels L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Wheels - 44

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

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Wheels - 44 Front wheels - 511

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Wheels - 44 Front wheels - 511

TECHNICAL DATA Front wheels General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Wheels - Front wheels

Front wheels - General specification L218 L220

WE WE

WARNING Explosion hazard! Always maintain correct tire pressure as indicated in this manual. DO NOT inflate tires above the recommended pressure. Excessive pressure could result in tire failure. Failure to comply could result in death or serious injury. W0109A

WARNING Explosion hazard! Tires must be replaced by skilled personnel with the proper tools and technical knowledge. Unskilled personnel replacing wheels or tires could result in serious physical injuries, tire damage, and/or wheel distortion. Always have a qualified tire mechanic service wheels and tires. Failure to comply could result in death or serious injury. W0171A

NOTE: The following also applies to rear wheels. The skid steer will be hard to turn and the tires will wear faster if the correct pressure is not maintained. When a worn or damaged tire is replaced, the replacement must be the same size and tread design as the other tires on the machine. Two different sized tires on one side of the machine will cause accelerated tire wear, loss of power, and excessive strain on the drivetrain. Replace worn tires in pairs with the two new tires used on the same side of the loader. If this tilts the loader too much, replace all four tires.

Adding air to the tires Tire pressure gauges should be checked at regular intervals for calibration and accuracy. TIRE XD2002 XD2002 Beefy Baby II Beefy Baby II Hulk Hulk Bulky Hulk King Kong King Kong Hippo Hippo

SIZE 10x16.5 12x16.5 10x16.5 12x16.5 10x16.5 12x16.5 33/15.5x16.5 10x16.5 12x16.5 31/15.5x16.5 33/15.5x16.5

PRESSURE 40 - 60 psi 40 - 60 psi 40 - 60 psi 40 - 60 psi 40 - 60 psi 40 - 60 psi 40 - 60 psi 40 - 60 psi 40 - 60 psi 40 - 60 psi 40 - 60 psi

Wheel torque Taper nut Flange nut

169.5 N·m (125 lb ft) 203.5 N·m (150 lb ft)

This procedure is only for adding air to the tire. If the tire has lost most or all of the air, do the following: 1. Before you add air, have the wheel correctly installed on the machine or put the wheel in a restraining device (tire inflation cage). 2. Use an air hose with a remote shutoff valve, self-locking air chuck and wear eye protection. 3. Stand behind the tread of the tire and make sure all persons are away from the side of the tire before you start to add air. 4. Inflate the tire to the recommended air pressure. Do not inflate the tire more than the recommended maximum pressure given on the tire.

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Index Wheels - 44 Front wheels - 511 Front wheels - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Wheels - 44 Rear wheels - 520

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Wheels - 44 Rear wheels - 520

TECHNICAL DATA Rear wheels General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Wheels - Rear wheels

Rear wheels - General specification L218 L220

WE WE

The skid steer will be hard to turn and the tires will wear faster if the correct pressure is not maintained. When a worn or damaged tire is replaced, the replacement must be the same size and tread design as the other tires on the machine. Two different sized tires on one side of the machine will cause accelerated tire wear, loss of power, and excessive strain on the drivetrain. Replace worn tires in pairs with the two new tires used on the same side of the loader. If this tilts the loader too much, replace all four tires.

SIZE 10x16.5 12x16.5 10x16.5 12x16.5 10x16.5 12x16.5 33/15.5x16.5 10x16.5 12x16.5 31/15.5x16.5 33/15.5x16.5

PRESSURE 40 - 60 psi 40 - 60 psi 40 - 60 psi 40 - 60 psi 40 - 60 psi 40 - 60 psi 40 - 60 psi 40 - 60 psi 40 - 60 psi 40 - 60 psi 40 - 60 psi

Wheel torque Taper nut Flange nut

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 - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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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 Cab climate control L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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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

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Cab climate control - 50 Heating - 100

SERVICE Cab heater Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Cab climate control - Heating

Cab heater - Remove L218 L220

WE WE

1. Remove the operators seat. If unit is equipped with EH controls remove the control towers.

93104685

93104642

93112374

2. At the front of the chassis, remove the cleanout hole blockoff plate (1), by removing the four hardware bolts (2).

3. Remove the cab lift strut and floor pan. Do not remove the cab tip safety lock! 4. Drain the existing coolant from the engine and radiator. Save for reuse. 5. Remove heater hoses (1), from the back exterior of the cab and the front corners of the upper chassis. Silicone open ports.

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Cab climate control - Heating

6. Disconnect the cab supply hose (1), and cab return hose (2) from the heater box (3).

23112382

23112385

7. Disconnect the heater supply hose (1), from the thermostat housing and install plug fitting.

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Cab climate control - Heating

8. Disconnect the heater return hose (2), from water pump housing.

23112382

23112387D

93104640

9. Remove the heater hoses (1), and all heater hose hardware from the machine. The hoses are mounted under the engine, between the flywheel side engine mounts. 10. Disconnect the chassis harness electrical connector from the water valve.

11. Remove the headliner and left hand and right hand consoles. 12. Remove three fir tree fasteners, to remove the rear trim panel (1), over the heater box and washer bottle. NOTE: Washer bottle cap (2), must be removed first.

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Cab climate control - Heating

13. Remove the six directional louvers (1), in the ducts (2).

93104640

14. Remove the fir tree fasteners (1), from cab side, and bolts (2) from the heater box. Remove ducts (3), and (4), from the heater box.

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15. Disconnect heater box electrical connector from the cab harness. 16. Remove the heater box (1), from the firewall.

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17. Remove air intake duct (1), from firewall.

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Cab heater - Install L218 L220

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1. Tip cab and remove seat; remove the cover plate from behind the seat, if equipped. If unit has EH controls remove the control towers. 2. Remove HVAC switch blanking decal from left hand console.

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3. Take left hand console loose from the a-post. Add heater control decal (1), fan switch (2), and temperature control potentiometer (3) and knob (4). 4. The right hand console and headliner must be removed in order to install the deluxe cab harness and roof foam for added sound reduction. If neither are needed the right hand console and headliner may be left in place. 5. If converting from an open cab without radio, remove and replace the cab harness. Not included in kit. Purchase separately.

6. [Optional] Clean and degrease underside of roof panel and install roof foam (1) using firm even pressure. 7. Remove the blocking plates that cover the fresh air intake hole and plumbing holes in the firewall and cab floor.

8. Install the heater box sealing foam (1) at the back of the cab floor.

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9. Using two of each, bolts (1), nuts (2), and washers (3) install the air intake duct (4) to the firewall.

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10. Using four of each, screws (1) and washers (2) install the heater box (3) to the firewall. Be careful to ensure that the plumbing ports are inserted properly through the hole in the cab floor. 11. Connect heater box electrical connector to the cab harness.

12. Install the left hand and right hand ducts (1) and (2) to heater box using four bolts (3) and anchor to side of cab using eight fir tree fasteners (4). Ensure that wiring harness is not pinched between the ducts and the cab side. Then install six directional louvers (5) in the ducts. 13. Reinstall headliner and consoles.

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14. Remove silicone from bottom of J tubes (A) inside the rear of the cab.

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15. Install the rear trim panel (1) over the heater box and washer bottle. Cap must be removed from washer bottle to install, then replaced once the panel is secure. Seat belt is routed through the slot in the panel and the upper lip of the panel is under the air filter access cover. Secure the panel with fir tree fasteners. 16. Apply silicone to bottom of J tubes at back exterior of cab and in the front corners of the upper chassis (see figure 9).

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17. Clean and degrease front surface of the chassis crossmember behind the cab. Apply crossmember foam (1) with firm even pressure. 18. Remove floorplate. Cab lift struts have to be removed in order to remove floorplate. Do not remove the cab tip safety lock!

19. Install the water valve (1) to the water valve bracket (2) with bolts (3) and nuts (4) and bolt the bracket under the floorboard using bolts (5) and nuts (6). Ensure that the water valve is facing with the outlet rearward. 20. Connect the chassis harness electrical connector to the water valve. 21. Drain the existing coolant from the engine and radiator. Save for reuse.

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22. Remove the plug from the thermostat housing on the right side of the engine and install the 90 ° hose nipple adapter (1). Use pipe thread compound on the threads.

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23. Cut the existing coolant return hose (1) under the injector lines and route the two halves over top of the injector lines.

24. Using ctb clamps (1), install the “Y” fitting (2) between the two halves of return hose (3).

25. Route the heater supply (1) and new return hoses (2) from the engine to the front of the machine. Both hoses route under the engine between the flywheel side engine mounts. The cab side end of the return hose has plastic spiral hose guard installed. The hose guard (3) must be installed over both hoses where they pass under the engine and tandem pump. 26. Using two ctb clamps (4), connect the supply hose (1) to the hose nipple (5) on the thermostat housing and to the inlet of the water valve (6).

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27. Using a ctb clamp (1), connect the new return hose (2) to the “Y” fitting (3).

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28. Using a ctb clamp (1), connect the other end of the return hose (2) to the right hand hose stub (outlet hose) on the heater box using a nylon hose elbow (3). 29. Using ctb clamps (1), connect the cab supply hose (2) to the water valve (5) outlet and to the heater box inlet using a nylon hose elbow (3).

30. Install the carriage bolt (1) to the square hole in the seat pan and hold in place with a flange nut (2). 31. Place a p-clamp (3) over both hoses and attach to the carriage bolt (1) on the seat pan. Order of installation is washer (4), then p-clamp, then flange nut (2).

32. Install the small spring mount bracket (1) to the top front mounting bolt on the right drive motor. Use a thin nut (2) to secure in place. 33. Install the large spring mount bracket (3) between the brake control valve and the chassis nut cages that the valve mounts to.

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34. Slide one eyelet of the spring (2) on the straight section of the other p-clamp (4), and install the p-clamp over both hoses. There should be 350 mm (14 in) between p-clamps. 35. Connect each end of spring to the spring mounting brackets (1) and (3) on the right side motor and the brake valve. On mechanical units route the springs under the tandem pump control rods so that the springs fall down away from the control rods when the cab is lowered. 36. [OPTIONAL] Install the seat pan mat. 37. Reinstall the seat.

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38. Refill the cooling system and run the engine to check for leaks. 39. Reinstall the floor plate and lift struts. 40. [OPTIONAL] Install the heelplate mat followed by the floormat. a. Place 2 rows of seal strip (1) around the outside edge of plate (2).

41. Install the front cleanout hole blockoff plate (2) using 4 bolts (3).

42. Set the cab down and tip it up again to ensure that the hoses are dropping into the chassis correctly without kinking.

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Index Cab climate control - 50 Heating - 100 Cab heater - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Cab heater - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Cab climate control - 50 Air conditioning - 200

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Cab climate control - 50 Air conditioning - 200

TECHNICAL DATA Air conditioning General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Air conditioning Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Overview – Mechanical system (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Overview – Electrical system (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Air conditioning Leakage test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Discharging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Evacuate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Charging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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Air conditioning - General specification L218 L220

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A/C system capacities • 1.5 kg (3.3 lb) of R134A refrigerant. • 197 ml (6.67 US fl oz) of PAG SP20

Air Temperature (F) Entering A/C Unit (Fresh or Recirculated) 50 60 70 80 90 100 110

Inlet - Outlet Temperature Differential (Low Humidity) 10 15 20 25 30 30 35

Inlet - Outlet Temperature Differential (High Humidity) 10 10 15 20 25 25 30

Ambient Air Temperature (F) Entering Condenser 50 60 70 80 90 100 110

Suction Pressure (PSIG) at Evaporator Outlet 5-15 5-15 10-20 10-20 15-25 15-25 15-30

Discharge Pressure (PSIG) at Compressor Outlet 75-125 100-150 125-175 150-225 175-250 200-275 225-352

NOTE: The pressure temperature chart is based on the following conditions: (1) Engine operating at 1500 rpm. No engine load. (2) Fan speed control in maximum position (full clockwise) and all louvers open. (3) Cab temperature control set to maximum cooling (full counterclockwise). (4) A/C switch ON. Cab door open. (5) All panels and access doors installed and closed. (6) Cab filter clean and installed. Heater valve closed. (7) Measurements taken 15 minutes after start-up. (8) The warmest inlet air temperature (Fresh or Recirculated) should be used for the differential equations.

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Air conditioning - Overview L218 L220

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The function of the HVAC system is to improve the operator's comfort by conditioning the air inside the cab. In AC mode, temperature control is achieved by absorbing the heat within the cab into a refrigerant and then allowing the heat absorbed by the refrigerant to be transferred to the outside air. In heat mode, temperature control is achieved by air absorbing heat from a heat exchanger (heater core). The blower switch can provide 4 speed levels (off, low, medium, high) to the electric fan motor (2) (internal to HVAC Box). Low and medium speeds are provided through a resistor (internal to HVAC Box). The fan blows a mix of outside and cab air (1) across an evaporator (3) and across the heater core (4), providing conditioned air entering the cab through vents (5), and is energized anytime the ignition is on.

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HVAC air flow path In AC mode, with the A/C switch on and an electric fan speed selected, the condenser fan and the A/C compressor are energized, starting the refrigeration cycle and providing cool air to the cab. In heat mode, with AC Switch off and the temperature control potentiometer set to “hot”, the potentiometer provides a control signal to the water valve which directs hot engine coolant to flow to the heater core. The electric fan motor (internal to HVAC Box) blows air across the evaporator (not in use) and hot heater core, providing hot air to cab. If both AC switch is on and temperature control potentiometer is turned to "hot", both the Water Valve and AC components are energized, and the air will cool across the evaporator, then heat across the heater core, then enter the cab. The blower switch, AC switch, and temperature control potentiometer are all located on the Left Console. There are three safety switches in the system that protect the compressor. The single-level pressure switch (internal to HVAC Box) protects from a liquid lock condition in the refrigeration cycle. The high pressure switch protects against an overpressure condition caused by a system blockage or compressor failure. The thermostat (internal to HVAC Box) is a freeze sensor, located on the condenser, that cycles the A/C compressor off preventing an ice over condition, which would prevent heat transfer.

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Air conditioning - Overview – Mechanical system L218 L220

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The principal components of an air conditioning system are • Refrigerant • Evaporator • Compressor • Condenser • Expansion Valve To achieve the absorption and the release of heat, which is, in essence, the function of an air conditioning system, requires the use of a suitable refrigerant, a liquid that has a relatively low temperature boiling point, plus certain desirable safety and stability features. The refrigerant used in the air conditioning system is R-134a. The refrigerant starts as a low temperature, low pressure liquid and enters the evaporator. The evaporator (1) consists of a number of turns of continuous coils mounted in a series of thin cooling fins to provide a maximum heat transfer area in a minimum amount of space. Low temperature refrigerant in the evaporator absorbs heat from the hotter air in the cab, cooling the air. The Electric Fan Motor (internal to HVAC Box) blows a mix of outside air and recirculated cab air across the evaporator and blows this cool air into the cab. The refrigerant now changes to a high temperature, low pressure vapor and leaves the evaporator, moving to the suction (low pressure) side of the compressor.

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Refrigeration Cycle The compressor (2) acts as a pump which raises the refrigerant temperature and pressure by compression to a higher degree of temperature than the ambient (outside air) temperature and provides the driving force required to circulate the volume of refrigerant through the system. Refrigerant is drawn into the compressor as a high temperature, low pressure vapor which is compressed and then pumped out as a high temperature, high pressure vapor to the condenser. The thermostat (internal to HVAC Box) cycles power to the A/C compressor via removing power to compressor relay control. The condenser (3) consists of a number of turns of continuous coil mounted in a series of thin cooling fins to provide a maximum of heat transfer in a minimum area of space. The condenser receives the high temperature, high pressure refrigerant vapor from the compressor. The hot vapor passes through the condenser coils and outside air is pushed across the condenser by the condenser fan. Heat moves from the hot refrigerant vapor into the cooler outside air flowing across the condenser coils and fins. When the refrigerant vapor reaches the pressure and temperature that will induce a change of state to a liquid, a large quantity of heat is transferred to the outside air and the refrigerant changes to a low temperature, high pressure liquid. The refrigerant from the condenser enters the expansion valve (4) as a low temperature, high pressure liquid. The expansion valve allows the refrigerant to expand rapidly, which causes the pressure and temperature of the refrigerant to be reduced and the refrigerant leaves the expansion valve as a low temperature, low pressure liquid.

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Air conditioning - Overview – Electrical system L218 L220

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The HVAC system has several power inputs. One line of source power comes from the accessory relay to the HVAC box. This energizes the auxiliary relay for the electric fan coil (internal to HVAC Box). The accessory relay is powered from the instrument cluster when the ignition is on, which shuts the auxiliary relay for electric fan. NOTE: See HVAC Box overview for more information Heating, Ventilation, and Air-Conditioning (HVAC) control system - Overview (55.050) The auxiliary relay for electric fan main power comes directly from the battery via the HVAC fuse. The auxiliary relay for electric fan is shut anytime the ignition is on, allowing power to the water valve and the temperature control potentiometer, also allowing power to the blower switch. Power is provided to the A/C switch from the blower switch, anytime a fan speed is selected. The blower switch, AC switch, and temperature control potentiometer are all located on the left console. Since the water valve and temperature control potentiometer are energized, cab heat is available anytime the ignition is on. When the AC switch is turned “on” and an electric fan speed is selected, power is provided to HVAC, through the single-level pressure switch (internal to HVAC box), through thermostat (internal to HVAC box), out the HVAC box to the HVAC high pressure switch and back into HVAC Box to the compressor relay coil (internal to HVAC box), shutting the compressor relay (internal to HVAC box). When the compressor relay is shut, this allows battery power the compressor fuse through the HVAC box to the compressor relay, and out of the HVAC box to the A/C compressor. When the A/C switch is turned “on” and an electric fan speed is selected, power is also applied to the condenser relay coil, shutting the condenser relay, providing battery power via a fuse to the condenser fan. The blower switch, since energized, can provide four speed levels (off, low, medium, high) to the electric fan motor (internal to HVAC box). This is done through a resistor (internal to HVAC box).

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Air conditioning - Leakage test L218 L220

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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. Make sure the charging station manifold gauge valves are in the closed position. Connect the hose from the low pressure gauge to the port on the suction hose. Connect the hose from the high pressure gauge to the port on the discharge hose . Turn in both thumbscrews to depress the service valves. 3. Open the high and low valves. 4. Make certain the refrigerant tank gas and liquid valves are open. 5. Move the main power switch to the ON position and depress the vacuum start switch. Run a vacuum on the A/C system for fifteen minutes. Watch the high and low pressure gauges. If the machine does not hold a vacuum, inspect all connections and components for damage. 6. Repair all leaks and recharge the system.

Electronic leak detection test 7. Verify the appropriate amount of refrigerant in the machine. 8. Start the engine and run the A/C system for approximately ten minutes. 9. Use the electronic leak detector to inspect all connections. Use instructions from manufacturer of the leak finding tool. ATTENTION: Engine is running. Be aware of moving components. Failure to comply could result in death or serious injury. 10. Shut off the engine. 11. Use the electronic leak detector to inspect all connections. Use instructions from manufacturer of leak finding tool. NOTE: When checking compressor seal for a leak, remove the dust cover and rotate the clutch shaft clockwise. NOTE: To properly check the expansion valve for leaks, remove the insulation tape. 12. Repair all leaks and recharge the system. 47711684 06/05/2014

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UV leak detection test 13. Please see the instructions from the manufacturer of the UV leak detection tool for proper use. 14. Repair all leaks and recharge the system.

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Air conditioning - Discharging L218 L220

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NOTICE: A/C systems are to be maintained by a certified professional. Do not attempt the following without A/C certification. 1. 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. 2. If possible, run the air conditioning system for ten minutes before starting the recovery process. Turn the system off before proceeding. 3. Clean the external surfaces of the compressor and hoses. Remove the caps from the service ports on the suction hose and pressure hose. 4. Make sure the charging station manifold gauge valves are in the closed position. Connect the hose from the low pressure gauge to the port on the suction hose. Connect the hose from the high pressure gauge to the port on the discharge hose . Turn in both thumbscrews to depress the service valves. 5. Open the high and low valves. 6. Make certain the refrigerant tank gas and liquid valves are open. 7. Connect the main power plug to a 115 volt AC outlet. Move the main power switch to the ON position and depress the recovery start switch. The compressor will shut OFF automatically when recovery is complete. Wait for five minutes and observe the manifold pressure gauges for a pressure rise. If pressure rises above zero PSI, depress the hold/cont switch. Then wait for the compressor to automatically shut OFF. 8. Drain the oil separator of the A/C system oil. Open the air purge valve long enough to let some of the compressor discharge pressure back into the separator. 9. Slowly open the oil drain valve and drain the oil into the reservoir. When the oil stops draining, close the oil drain valve completely. 10. Fill the A/C compressor with fresh PAG oil equal to the amount in the reservoir. 11. Disconnect the hoses from the service ports and install the caps.

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Air conditioning - Evacuate L218 L220

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NOTICE: A/C systems are to be maintained by a certified professional. Do not attempt the following without A/C certification. 1. 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. 2. If possible, run the air conditioning system for ten minutes before starting the recovery process. Turn the system off before proceeding. 3. Clean the external surfaces of the compressor and hoses. Remove the caps from the service port on the suction and from the service port pressure hoses. 4. Make sure the charging station manifold gauge valves are in the closed position. Connect the hose from the low pressure gauge to the port on the suction hose . Connect the hose from the high pressure gauge to the port on the discharge hose . Turn in both thumbscrews to depress the service valves. 5. Open the high and low valves. 6. Make certain the refrigerant tank gas and liquid valves are open. 7. Connect the main power plug to a 115 volt AC outlet. Move the main power switch to the ON position and depress the recovery start switch. The compressor will shut OFF automatically when recovery is complete. Wait for five minutes and observe the manifold pressure gauges for a pressure rise. If pressure rises above zero PSI, depress the hold/cont switch. Then wait for the compressor to automatically shut OFF. 8. Drain the oil separator of the A/C system oil. Open the air purge valve long enough to let some of the compressor discharge pressure back into the separator. 9. Slowly open the oil drain valve and drain the oil into the reservoir. When the oil stops draining, close the oil drain valve completely. 10. Fill the A/C compressor with fresh PAG oil equal to the amount in the reservoir. 11. Disconnect the hoses from the service ports and install the caps. 12. Replace the receiver-drier if one or more of the following conditions occurs before you remove the air and moisture from the system. (A.) The system has been opened for service before. (B.) Receiver-drier has operated two or more years. (C.) Disassembly of compressor shows small particles of moisture removing material (gold or brown particles). (D.) Large system leak (broken hose, break in line). (E.)Too much air or moisture in system. (F.) Removal of compressor caused the system to be open (uncapped) longer than 5 minutes. 47711684 06/05/2014

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13. Make sure the charging station manifold gauge valves are in the closed position. Connect the hose from the low pressure gauge to the port on the suction hose. Connect the hose from the high pressure gauge to the port on the discharge hose. Turn in both thumbscrews to depress the service valves. 14. Removal of air and moisture from the system is necessary after the refrigerant has been removed from the system after the system has been opened for maintenance. Air enters the system when the system is opened. Air has moisture that must be removed to prevent damage to the system components. 15. Air and moisture are removed from the system by a vacuum pump. A vacuum pump is on the only equipment made that will lower the pressure in a system enough to change the moisture to a vapor so that the moisture can be removed. NOTE: Refer to the vacuum pump manufacturer's user manual for additional information. 16. Connect the main power plug to a 115 volt AC outlet. Move the main power switch to the ON position. If program and vacuum do not appear at the top of the display press the vacuum key. Program a minimum of 45 minutes and press the Enter key. The display will flash once indicating the programmed data has been accepted. 17. Press the Charge Key. Program and Charge will appear on the display. 18. Program 1.5 kg (3.3 lb) of R134A refrigerant. and press the enter key. The display will flash once indicating the programmed data has been accepted. 19. Full open the low and high pressure valves. 20. Open the red (vapor) and blue (liquid) valves on the tank. 21. Press the Vacuum key. Automatic will show on the display and after a slight delay, the vacuum pump will start. The display will show the amount of time programmed and begin a countdown to zero. 22. When the programmed time has elapsed, an automatic hold occurs. Check the low pressure gauge to see that the A/C system maintains a 28 - 29 1/2 inof mercury (Hg). The low pressure gauge must not increase faster than one inch of mercury (Hg) in 15 minutes. If the system will not hold vacuum, a leak exists that must be corrected before recharging can begin. See Air conditioning - Leakage test (50.200) for a leak test.

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Air conditioning - Remove L218 L220

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Prior operation: Evacuate the A/C system. See Air conditioning - Evacuate (50.200) NOTICE: A/C systems are to be maintained by a certified professional. Do not attempt the following without A/C certification. 1. Raise cab to disconnect air conditioning system hoses (1) and cap open ports. NOTE: If R134A is still in system, it should be drained and captured prior to disconnecting hoses.

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2. Label and disconnect heater hoses (2) and cap open ports. NOTE: Drain coolant into a suitable container prior to disconnecting heater hoses.

3. Remove seat hardware (3).

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4. Disconnect seat safety switch electrical connection (4).

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5. Remove operators seat.

6. Remove mounting screws (5) and remove cover (6).

7. Remove rear panel hardware (7).

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8. Remove window wash bottle lid (8).

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9. Remove rear panel exposing air conditioning unit.

10. Remove left hand side and right hand side duct work hardware (9).

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11. Remove air condition unit mounting hardware (10).

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12. Disconnect air condition electrical connector (11).

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13. Remove air condition unit.

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Air conditioning - Install L218 L220

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NOTICE: A/C systems are to be maintained by a certified professional. Do not attempt the following without A/C certification. 1. Position the air condition (A/C) unit in the cab.

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2. Connect A/C electrical connection (1).

3. Install left and right hand side A/C mounting hardware (2).

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4. Install left hand side and right hand side duct work and secure with hardware (3).

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5. Install the rear panel (4).

6. Install rear panel hardware (5).

7. Install window washer bottle lid (6).

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8. Install cover and mounting screws (7).

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9. Position operators seat in the cab.

10. Connect seat safety switch electrical connection (A).

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11. Install operators seat hardware (2).

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12. Connect heater hoses (3).

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13. Connect air condition hoses (4).

14. After the heater/air conditioning assembly has been installed refer to Radiator - Filling (10.400) and refill the cooling system. 15. Refer to Air conditioning - Evacuate (50.200). Connect the Refrigerant Recovery, Recycling and Charging Station to the high and low charge ports in the hose fitting on the compressor. Evacuate the system to remove all moisture from the system. 16. Refer to Air conditioning - Charging (50.200) and charge the system with reclaimed or new refrigerant. Start the engine and test the air conditioning system for proper operation.

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Cab climate control - Air conditioning

Air conditioning - Charging L218 L220

WE WE

NOTICE: A/C systems are to be maintained by a certified professional. Do not attempt the following without A/C certification. 1. The system charge capacity is 1.5 kg (3.3 lb) of R134A refrigerant. Press the charge key to begin refrigerant charging. Automatic and Charge will appear on the display. The display shows the programmed amount and counts down to zero as charging proceeds. When charging is completed, the display shows CPL. 2. Completely close the high and low pressure manifold valves. 3. 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. 4. Observe the pressure gauge readings to determine that the correct amount of refrigerant has entered the system. NOTICE: Check the OEM equipment manual before performing this step to avoid damaging recovery unit. Pressure reading should be obtainable with valves closed. Damage may occur if the machine is started with the valves accidently open or if either or both valves are opened while the A/C system operating. 5. Stop the engine, close any open valves and carefully remove the manifold gauge hoses. 6. Install the caps on the service ports on the suction hose, and discharge hose.

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Index Cab climate control - 50 Air conditioning - 200 Air conditioning - Charging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Air conditioning - Discharging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Air conditioning - Evacuate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Air conditioning - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Air conditioning - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Air conditioning - Leakage test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Air conditioning - Overview – Electrical system (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Air conditioning - Overview – Mechanical system (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Air conditioning - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Air conditioning - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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

47711684 06/05/2014 EN

SERVICE MANUAL Electrical systems L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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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 [55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.019] Hydrostatic drive control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.031] Parking brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 [55.036] Hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11 [55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.12 [55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.13 [55.525] Cab engine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.14 [55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.15 [55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.16

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Electrical systems - 55 Electrical system - 000

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Electrical systems - 55 Electrical system - 000

FUNCTIONAL DATA Electrical system Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Requirements (*) . . . . . . . . . . . . . . . . . . . . 4 Electronic Service Tool (EST) - H1 - Calibration procedures – Troubleshooting (*) . . . . . . . . . . . . . . . . . . . 5 Electronic Service Tool (EST) - H1 - Calibration procedures – Joystick (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Electronic Service Tool (EST) - H1 - Calibration procedures – Ground Drive (*) . . . . . . . . . . . . . . . . . . . . . 7 Electronic Service Tool (EST) - H1 - Calibration procedures – Throttle (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Electronic Service Tool (EST) - H1 - Calibration procedures – Loader valve (*) . . . . . . . . . . . . . . . . . . . . 11 Electronic Service Tool (EST) - H1 - Calibration procedures – Loader start pressure (*) . . . . . . . . . . . . . 13

DIAGNOSTIC Electrical system Testing - Diode (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Testing - Wires (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Electrical systems - Electrical system

Electrical system - Overview L218 L220

WE WE

An electrical circuit is comprised of three basic elements; a source of electrical energy which provides the current used by the electrical circuit, a load which converts the electrical current into a work form such as heat or light or an electromagnetic energy field and conductors which are used to route the electrical current from the source to the load and back to the source. The device used to provide the electrical current in a direct current (DC) circuit is typically a battery. The battery uses a chemical action to create and store the needed electrical energy. An alternator which converts mechanical energy into electrical energy and is driven by an engine is used to recharge the battery. Load devices are designed to utilize the two natural products created when electrical current flows through a conductive material, that being heat and a magnetic field. Lamps heat alloyed conductive materials to a temperature that produces visible light where as heater elements use an alloyed material to produce heat. Solenoids and motors use the magnetic field produced by the current flow to attract or repel ferrous material and produce linear or rotary motion. Stranded or solid copper or copper clad wire is used to conduct the electrical current between the source and the loads. The return path to the source from the loads in battery sourced systems is often the metallic materials that are the components of the machine or what is referred to as frame or chassis ground. The negative terminal on the battery is then connected to the frame or chassis, thus completing the electrical circuit. In addition to the basic elements required in a electrical circuit, most also contain protective devices, fuses or circuit breakers, that are designed to interrupt the current flow should it exceed the amount the conductors or loads in the circuit are capable of handling without damage. An electrical control scheme is comprised of three categories of devices; input devices like switches, potentiometers and sensors, control or logic devices like relays and programmed or programmable electronic modules and output devices like lights, motors and solenoids. Input devices provide information in the way of an electrical signal to the logic devices. The signal provided may be a digital signal; on or off, high or low, a transition from one predefined level to another either higher or lower which is referred to as leading or trailing edge or an analog signal which is variable measurable levels. Logic or control devices use the signals provided by the input devices to determine how the output devices should be controlled, energized or de-energized and to what level and polarity. Programmed and programmable logic devices often use the system source voltage, battery voltage, to create other voltages which are referred to as reference voltages. The reference voltage or reference source as well as a reference ground or control module ground is provided by the logic or control device to inputs and outputs. This means the control or logic device is capable of switching, sensing or varying different signal levels and types. Configuring the electrical control scheme is done in a variety of ways. The input devices may use: • system source, which is the battery, or • system ground, which is the frame or chassis, or • a reference voltage, which is created by the control module, or • a reference ground, which is provided by the control module, to provide a digital or analog signal to the control or logic device.

• A single input device may provide a signal directly or • two or more input devices sharing the same signal wire, in parallel, may provide the signal or • two or more input devices may provide the signal through one another, in series, to the control or logic device.

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Electrical systems - Electrical system

Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Requirements L218 L220

WE WE

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 Electronic Service Tool (EST) - H1 - Calibration procedures – Troubleshooting (55.000) for troubleshooting steps. 1. The following software will be required • CNH Electronic Service Tool (EST), version 6.3.0.0 or later. • If downloading new application software SL57 UCM Application Software (SSL_SL57_x-x-xx.hx1), and SL57 Instrument Cluster software (SSLCluster_Vx_x_x_x.hx1) 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 SL57 Application Software onto the machine controller (UCM) with the Electronic Service Tool (EST) programming menu. • Flash the new instrument cluster (IC) software to the IC with the EST configuration menu. • Set the machine configurations (serial number, model, door, etc.) in the EST configuration menu. 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 Electronic Service Tool (EST) - H1 - Calibration procedures – Troubleshooting L218 L220

WE WE

These are the codes that may be encountered during calibration. If seen, check condition description and compare to calibration procedure prerequisite conditions. Display Text CD01

Condition Name Calibration Enable Fail

CD02

Calibration Sustain Fail

CD03

Device Fault

CD04

Calibration Timeout

CD05

Operator Interrupt

CD06

Calibration Value High

CD07

Calibration Value Low

CD08

Signal Unstable

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 Electronic Service Tool (EST) - H1 - Calibration procedures – Joystick L218 L220

WE Electro hydraulic controls WE Electro hydraulic controls

The purpose of the Joystick Calibration is to calibrate the main axis of the left and right joystick and the proportional thumbwheel. 1. Ensure the prerequisite requirements are complete per 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 OFF • Operator Present • No Joystick Related Fault Codes 3. In the EST configuration menu, open the 'Calibration Joystick' item. 4. Press the 'SET UP CONTROLLER FOR CALIBRATION' button. • Ensure 'START CALIBRATION' is now active. 5. Press the 'START CALIBRATION' button. • Ensure that the text "C-J1" is displayed on the cluster screen. 6. 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. 7. Move the proportional auxiliary roller switch to the upper or left detent (toward the smaller icon). Move both joysticks to the front right corner. Press and release the loader float button to start capturing step 2 values. • Verify that an audible beep is heard from the instrument cluster and the text "C-J3" is displayed on the cluster screen upon completion of step 2. 8. Move the proportional auxiliary roller switch to the lower or right detent (towards the larger icon). Move and hold both joysticks to the back left corner. Press and release the loader float button to start capturing step 3 values. • Verify that an audible beep is heard from the instrument cluster upon completion of step 3. • Verify that the instrument cluster screen returns to normal message display.

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Electrical systems - Electrical system

Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Ground Drive L218 L220

WE Electro hydraulic controls WE Electro hydraulic controls

The purpose of the Ground Drive Calibration is to calibrate the command current to a nominal pressure and calibrate the neutral position of the ground drive swashplate angles. This is a semi-automatic procedure, therefore most of the operator interaction is via the cluster display screen only. NOTE: It is not unusual to see a small amount of machine movement during calibrations the UCM finds the command current that brings the pump on stroke. Significant machine movement during calibration (more than 1 foot) is not expected and is a symptom of a problem in the system. 1. Ensure the prerequisite requirements are complete per Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Requirements (55.000). 2. Ensure the following conditions are met • No Joystick Related Fault Codes • No Ground Drive Related Fault Codes • Joysticks in Neutral • Proportional Auxiliary Roller Switch in Neutral • Key ON • Engine ON • Hydraulics ON • Hydraulic Oil Temperature between 15 °C (59.0 °F) and 80 °C (176.0 °F) • Operator Present • Engine RPM less than 1200 RPM 3. In the EST configuration menu, open the 'Calibration Ground Drive' item. 4. Press the 'SET UP CONTROLLER FOR CALIBRATION' button. • Ensure 'START CALIBRATION' is now active. 5. Press the 'START CALIBRATION' button. • Ensure that the text "C-G1" is displayed on the cluster screen. 6. Move the right joystick to the front right corner (away from the operator) and press and release the loader float button. Keep the right joystick in the top right corner for the entirety of the ground drive calibration. • Verify that an audible beep is heard from the instrument cluster and the text "C-G2" is displayed on the cluster screen upon completion of step 1. 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-G3" is displayed on the cluster screen upon completion of step 2.

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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-G4" is displayed on the cluster screen upon completion of step 3. 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-G5" is displayed on the cluster screen upon completion of step 4. 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 upon completion of step 5. 11. 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. 12. Exit out of the Calibration - Ground Drive screen

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Electrical systems - Electrical system

Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Throttle L218 L220

WE Electro hydraulic controls WE Electro hydraulic controls

The purpose of the Throttle Calibration is to calibrate the six key throttle position points to improve robustness of the load control algorithm. 1. Ensure the prerequisite requirements are complete per Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Requirements (55.000). 2. Ensure the following conditions are met • Joysticks in Neutral • Key ON • Engine ON • Hydraulics OFF • Operator Present • No Throttle Related Fault Codes 3. In the EST configuration menu, open the 'Calibration Hand Throttle' item. 4. Press the 'SET UP CONTROLLER FOR CALIBRATION' button. • Ensure 'START CALIBRATION' is now active. 5. Press the 'START CALIBRATION' button. • Ensure that the text "C-T1" is displayed on the cluster screen. 6. Move the hand throttle lever to the maximum throttle end-stop position. Step on the foot throttle until it is fully depressed. Press and release the loader float button. • Verify that an audible beep is heard from the instrument cluster and the text "C-T2" is displayed on the cluster screen upon completion of step 1. 7. Very slowly reduce the throttle to approximately 150 RPM below maximum engine RPM until audible alarm sounds and display changes to "C-T3". • Verify that an audible beep is heard from the instrument cluster and the text "C-T3" is displayed on the cluster screen upon completion of step 2. 8. Pull the hand throttle lever to the minimum end-stop position. Ensure that the foot throttle is not depressed. Press and release the loader float button. • Verify that an audible beep is heard from the instrument cluster and the text "C-T4" is displayed on the cluster screen upon completion of step 3. 9. Very slowly increase the throttle to approximately 150 RPM above low idle until audible alarm sounds and display changes to "C-T5". • Verify that an audible beep is heard from the instrument cluster and the text "C-T5" is displayed on the cluster screen upon completion of step 4.

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Electrical systems - Electrical system

10. Adjust the hand throttle lever position such that the engine RPM display flashing on the instrument cluster screen is at 1750 +/- 150 RPM for ISM, 1600 +/150 RPM for F5C. Press and release the loader float button. • Verify that an audible beep is heard from the instrument cluster and the text "C-T6" is displayed on the cluster screen upon completion of step 5. 11. Adjust the hand throttle lever position such that the engine rpm display flashing on the instrument cluster screen is at 2400 +/- 150 RPM for ISM, 2100 +/150 RPM for F5C. Press and release the loader float button. • Verify that an audible beep is heard from the instrument cluster upon completion of step 6. Verify that the EST Calibration Operation Status window says "Calibration Completed Successfully." Verify that the instrument cluster screen returns to normal message display.

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Electrical systems - Electrical system

Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Loader valve L218 L220

WE Electro hydraulic controls WE Electro hydraulic controls

The purpose of the Loader Calibration Procedure is to calibrate the command current to a nominal pressure for each spool and calibrate the neutral position of the loader attachment spool sensors. This is a semi-automatic procedure, therefore most of the operator interaction is via the cluster display screen only. NOTE: It is not unusual to see a small amount of loader or bucket movement during calibration as the UCM finds the command current that shifts the valve spools. Significant implement movement during calibration (more than 1 foot) should not be expected and is a symptom of a problem in the system. 1. Ensure the prerequisite requirements are complete per 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 Electronic Service Tool (EST) - H1 - Calibration procedures – Loader start pressure L218 L220

WE Electro hydraulic controls WE Electro hydraulic controls

The purpose of the Loader Calibration Procedure is to calibrate the command current to a nominal pressure for each spool and calibrate the neutral position of the loader attachment spool sensors. This is a semi-automatic procedure, therefore most of the operator interaction is via the cluster display screen only. 1. Ensure the prerequisite requirements are complete per 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 • Hydraulic Oil Temperature between 15 - 80 °C (59.0 - 176.0 °F) • Operator Present • Engine RPM less than xxxx RPM • Loader Calibration Complete Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Loader valve (55.000) • No Joystick Related Fault Codes • No Loader Related Fault Codes 3. In the EST configuration menu, open the 'Calibration Loader Start Pressures' item. 4. Press the 'SET UP CONTROLLER FOR CALIBRATION' button. • Ensure 'START CALIBRATION' is now active. 5. Press the 'START CALIBRATION' button. • Ensure that the text "C-S1" is displayed on the cluster screen. 6. Move the right joystick to the top right corner (away from the operator) and press the loader float button. Keep the right joystick in the top right corner for the entirety of the loader start pressure calibration. • Verify that an audible beep is heard from the instrument cluster and the text "C-S2" is displayed on the cluster screen upon completion of the previous step. 7. Watch for loader raise motion. When detected, immediately toggle that float button. This process is to be repeated tree times for the calibration step. • Verify that an audible beep is heard from the instrument cluster and the text "C-S3" is displayed on the cluster screen upon completion of the previous step.

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Electrical systems - Electrical system

8. Watch for loader lower motion. When detected, immediately toggle that float button. This process is to be repeated tree times for the calibration step. • Verify that an audible beep is heard from the instrument cluster and the text "C-S4" is displayed on the cluster screen upon completion of the previous step. 9. Watch for bucket dump motion. When detected, immediately toggle that float button. This process is to be repeated tree times for the calibration step. • Verify that an audible beep is heard from the instrument cluster and the text "C-S5" is displayed on the cluster screen upon completion of the previous step. 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-S6" is displayed on the cluster screen upon completion of the previous step. 11. Watch for bucket curl motion. When detected, immediately toggle that float button. This process is to be repeated tree times for the calibration step. • Verify that an audible beep is heard from the instrument cluster upon completion of the previous step. 12. 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. 13. Exit out of the Calibration - Loader Start Pressures screen.

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Electrical systems - Electrical system

Electrical system - Testing - Diode L218 L220

Test Point N° 1 Condition Disconnect the connector from the diode. Using a multi-meter on the diode setting, measure the diode from pin to pin in both directions.

WE WE

Expected Result Result The reading should be near the range of 0.3 V to 0.7 V one way, and infinite the other.

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Other Result (Possible Cause) Result If the reading is the same in both directions, the diode is shorted. If reading is near 3 V or infinite in both directions, the diode is open. Action Replace diode.

Electrical systems - Electrical system

Electrical system - Testing - Wires L218 L220

WE WE

Test Point N° 1 Condition Circuit not functioning. Check Check the wire for an open circuit.

Expected Result Result Wire not broken. Action Go to test 2

2 Condition Circuit not functioning. Check Check wire run for a short circuit to ground by following Electrical system - Electrical test Short to Ground (55.000). 3 Condition Circuit not functioning. Check Check wire run for a short circuit to voltage by following Electrical system - Electrical test Short to Voltage (55.000).

Result Wire not shorted. Action Go to test 3

Result Wire not shorted. Action The fault may be intermittent. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. If no damage is found, continue operation.

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Other Result (Possible Cause) Result Wire is broken. Action Follow Wire harnesses - Repair (55.100) Result Wire is shorted. Action Follow Wire harnesses - Repair (55.100)

Result Wire is shorted. Action Follow Wire harnesses - Repair (55.100)

Index Electrical systems - 55 Electrical system - 000 Electrical system - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Electrical system - Testing - Diode (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Electrical system - Testing - Wires (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Ground Drive (*) . . . . . . . . . . . . . 7 Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Joystick (*) . . . . . . . . . . . . . . . . . . 6 Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Loader start pressure (*) . . . . . 13 Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Loader valve (*) . . . . . . . . . . . . . 11 Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Requirements (*) . . . . . . . . . . . . . 4 Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Throttle (*) . . . . . . . . . . . . . . . . . . 9 Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Troubleshooting (*) . . . . . . . . . . . 5

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Electrical systems - 55 Fuel injection system - 010

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FUNCTIONAL DATA Fuel shutoff solenoid Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Fuel injection system

Fuel shutoff solenoid - Overview L218 L220

WE WE

1Z0O2004112133

Solenoids work in much the same way as relays, except that the iron core is not fixed in place. As a result, the windings in the control circuit cause the iron core to move. In the starting system, for example, the movement of this core is used to send large amounts of current to the starter motor. A solenoid is basically a winding around an iron core. In the centre of the core there is a plunger which is free to move through the core. When an electrical current passes through the winding an electro-magnetic force is produced which causes the plunger to move through the core. If the current is switched off, the magnetic force is stopped and the plunger is returned by a spring. The solenoid plunger may have different uses: the most common are moving a hydraulic spool or a mechanical lever. The MOST COMMON FAULTS that can occur are: • Short circuit winding: if a section of the winding allows the current to pass directly from positive (+) to negative (-) terminals without passing through the winding, this will cause the relevant circuit fuse to blow. • Broken winding: causing an open circuit, it will not allow the current to pass through the winding, so the solenoid will not operate. • Seized plunger (and/or connected components): the solenoid will only move the plunger if all components are free to move.

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Index Electrical systems - 55 Fuel injection system - 010 Fuel shutoff solenoid - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Fuel tank system - 011

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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

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Electrical systems - Fuel tank system

Fuel level sensor - General specification L218 L220

WE WE

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 L218 L220

WE WE

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

tiometer, 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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Index Electrical systems - 55 Fuel tank system - 011 Fuel level sensor - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fuel level sensor - Overview Potentiometers (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - 55 Engine cooling system - 012

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Contents Electrical systems - 55 Engine cooling system - 012

TECHNICAL DATA Engine coolant temperature sensor General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Engine cooling system

Engine coolant temperature sensor - General specification L218 L220

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)

Index Electrical systems - 55 Engine cooling system - 012 Engine coolant temperature sensor - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Engine intake and exhaust system - 014

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Contents Electrical systems - 55 Engine intake and exhaust system - 014

SERVICE Air cleaner restriction sensor Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Electrical systems - Engine intake and exhaust system

Air cleaner restriction sensor - Remove L218 L220

WE WE

1. Locate and open rear engine hood (1) and service door (2).

93107449A1

931002032

931002030

2. Remove hardware (1) from air filter housing (2).

3. Remove hose clamp (1) from air cleaner assembly (2).

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4. Remove clip (1) securing connector X-508. Disconnect connector X-508 from the air filter restriction switch B-016 (2).

931002030

5. Unscrew the air filter restriction switch B-016 (1) by hand from air cleaner assembly (2).

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Electrical systems - Engine intake and exhaust system

Air cleaner restriction sensor - Install L218 L220

WE WE

1. Install the air filter restriction switch (1) into the air cleaner assembly.

931002030

931002032

2. Connect the connector (1) to the air filter switch, and insert clip (2).

3. Place hose clamp (1) over hose and connect to air cleaner assembly (2). Tighten the hose clamp.

4. Insert hardware (1), and attach air cleaner assembly (2) to mount.

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Index Electrical systems - 55 Engine intake and exhaust system - 014 Air cleaner restriction sensor - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Air cleaner restriction sensor - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Engine control system - 015

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FUNCTIONAL DATA Engine timing sensors Overview Speed and position sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Engine control system

Engine timing sensors - Overview Speed and position sensors L218 L220

WE WE

Most of the speed and position sensors used are 2 and 3-wire active devices (requires an electrical source to function). Therefore, a source and ground are supplied to the sensor. Non-contact sensing of a target (ferrous material) is performed by the sensor in different ways, generally electro-magnetic coupling, which affects the source (typically a switch like affect, from one level to another). The altered source may or may not be conditioned by the sensor. The controller monitoring the sensor uses the sensor signal (affected source) to produce on and off signals for digital processing. For speed sensing this would relate to how many pulses (off to on or on to off transitions) during an established period of time and for position sensing the level of the signal (on or off). These sensors can not be effectively checked out-of-circuit with only a DVOM. If the sensor is faulty and the sensor circuit is complete, use the diagnostic capability of the display monitor to test the sensor functionality in the circuit.

40011026

Sensor Adjustment When installing a new sensor, adjust the sensor to obtain a clearance of 3 mm (1/8 in) to the target metal.

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Index Electrical systems - 55 Engine control system - 015 Engine timing sensors - Overview Speed and position sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Hydrostatic drive control system - 019

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Contents Electrical systems - 55 Hydrostatic drive control system - 019

FUNCTIONAL DATA Hydrostatic drive control sensors Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Hydrostatic control solenoids Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Hydrostatic drive control sensors Remove – Right hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install – Right hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Remove Left hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install Left hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Hydrostatic control solenoids Remove – Right-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install – Right-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Remove – Left-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install – Left-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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Electrical systems - Hydrostatic drive control system

Hydrostatic drive control sensors - Overview L218 L220

WE WE

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 - Overview L218 L220

WE WE

1Z0O2004112134

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 - Remove – Right hand swash plate sensor L218 L220

WE Electro hydraulic controls WE Electro hydraulic 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 L218 L220

WE Electro hydraulic controls WE Electro hydraulic 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 L218 L220

WE Electro hydraulic controls WE Electro hydraulic 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 L218 L220

WE Electro hydraulic controls WE Electro hydraulic 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 control solenoids - Remove – Right-hand side L218 L220

WE Electro hydraulic controls WE Electro hydraulic 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 L218 L220

WE Electro hydraulic controls WE Electro hydraulic controls

NOTE: This procedure covers how to install the right hand forward and right hand reverse drive solenoids located on the electro-hydraulic hydrostatic pump. 1. 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.

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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 L218 L220

WE Electro hydraulic controls WE Electro hydraulic 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 L218 L220

WE Electro hydraulic controls WE Electro hydraulic controls

NOTE: This procedure covers how to install the left hand forward and left hand reverse drive solenoids located on the electro-hydraulic hydrostatic pump. 1. 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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Index Electrical systems - 55 Hydrostatic drive control system - 019 Hydrostatic control solenoids - Install – Left-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Hydrostatic control solenoids - Install – Right-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Hydrostatic control solenoids - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydrostatic control solenoids - Remove – Left-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Hydrostatic control solenoids - Remove – Right-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hydrostatic drive control sensors - Install – Right hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydrostatic drive control sensors - Install Left hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Hydrostatic drive control sensors - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydrostatic drive control sensors - Remove – Right hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydrostatic drive control sensors - Remove Left hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Electrical systems - 55 Parking brake electrical system - 031

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Contents Electrical systems - 55 Parking brake electrical system - 031

FUNCTIONAL DATA Brake control solenoids Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Pressure sensor Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Electrical systems - Parking brake electrical system

Brake control solenoids - Overview L218 L220

WE WE

1Z0O2004112133

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Electrical systems - Parking brake electrical system

Pressure sensor - Remove L218 L220

WE Electro hydraulic controls WE Electro hydraulic controls

NOTE: Removing the charge pressure switch is the same procedure for the EH brake valve and EH 2speed brake valve. This procedure uses the EH 2speed brake valve. 1. Locate the brake valve.

931002289

931001731

2. Locate the charge pressure switch, port PS1. Disconnect the connector (1) from the harness.

3. Unscrew the pressure sensor from the valve body.

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Electrical systems - Parking brake electrical system

Pressure sensor - Install L218 L220

WE Electro hydraulic controls WE Electro hydraulic controls

NOTE: Installing the charge pressure switch is the same procedure for the EH brake valve and EH 2speed brake valve. This procedure uses the EH 2speed brake valve. 1. Thread and tighten the charge pressure switch into the brake valve body port PS1. 2. Connect the charge pressure connector to the electrical harness.

931001731

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Index Electrical systems - 55 Parking brake electrical system - 031 Brake control solenoids - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pressure sensor - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pressure sensor - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - 55 Hydraulic system control - 036

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Contents Electrical systems - 55 Hydraulic system control - 036

TECHNICAL DATA Hydraulic fluid temperature control sensor General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Hydraulic system control

Hydraulic fluid temperature control sensor - General specification L218 L220

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)

Index Electrical systems - 55 Hydraulic system control - 036 Hydraulic fluid temperature control sensor - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Harnesses and connectors - 100

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Contents Electrical systems - 55 Harnesses and connectors - 100

TECHNICAL DATA Fuse and relay box General specification Relay and Fuse Identification - Medium Mechanical Machines (*) . . . . . . . . . . . . . . 6

FUNCTIONAL DATA Wire harnesses Electrical schematic sheet 01 Main Power Distribution - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . 8 Electrical schematic sheet 02 Accessory Power Distribution - Mechanical Units (*) . . . . . . . . . . . . . . . . . 10 Electrical schematic sheet 03 Ignition/ Charging System - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . 12 Electrical schematic sheet 04 Grounding System - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Electrical schematic sheet 05 Engine ISM - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Electrical schematic sheet 06 Engine ISM - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Electrical schematic sheet 07 Engine ISM - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Electrical schematic sheet 08 Throttle Sensors - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Electrical schematic sheet 09 Auxiliary Hydraulic Interlock Switch - Mechanical Units (*) . . . . . . . . . . . . 24 Electrical schematic sheet 10 Bulkhead Connection - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . 26 Electrical schematic sheet 11 Left Hand Cab Console - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . 28 Electrical schematic sheet 12 Left Hand Control Handle - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . 30 Electrical schematic sheet 13 Right Hand Control Handle - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . 32 Electrical schematic sheet 11 Left Hand Cab Console - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . 34 Electrical schematic sheet 12 Left Hand Control Handle - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . 36 Electrical schematic sheet 13 Right Hand Control Handle - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . 38 Electrical schematic sheet 14 Seat - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Electrical schematic sheet 15 EH Aux PWM - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Electrical schematic sheet 16 Lamps - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Electrical schematic sheet 17 Indicators - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Electrical schematic sheet 18 EU Light Adapter - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Electrical schematic sheet 19 Boom And Road Lights - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . 50 Electrical schematic sheet 20 Wipers/ Washers - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Electrical schematic sheet 21 Instrument Cluster - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Electrical schematic sheet 22 HVAC - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Electrical schematic sheet 23 Radio - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 (*) See content for specific models 47711684 06/05/2014

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Electrical schematic sheet 24 Multifunction Connectors - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . 60 Electrical schematic sheet 25 Telematics - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Electrical schematic sheet 26 Multifunction Jumper - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . 64 Electrical schematic sheet 27 Diagnostic Connector - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . 66 Electrical schematic sheet 28 Boom Lock Valve - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Electrical schematic sheet 01 Main Power Distribution - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Electrical schematic sheet 02 Accessory Power Distribution - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . 72 Electrical schematic sheet 03 Ignition/ Charging System - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Electrical schematic sheet 04 Grounding System - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Electrical schematic sheet 05 Engine ISM HPCR - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Electrical schematic sheet 06 Engine ISM HPCR - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Electrical schematic sheet 07 Engine ISM HPCR - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Electrical schematic sheet 08 Throttle Sensors - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Electrical schematic sheet 09 ET Pump/ Hydraulics - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Electrical schematic sheet 10 Hydraulic Interlocks - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Electrical schematic sheet 11 Loader Valve And Sensors - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Electrical schematic sheet 12 Bulkhead Connection - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Electrical schematic sheet 13 Bulkhead Connection - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Electrical schematic sheet 14 Bulkhead Connection - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Electrical schematic sheet 15 Left Hand Cab Console - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Electrical schematic sheet 16 Left Control Handle - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Electrical schematic sheet 17 Right Hand Control Handle - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . 102 Electrical schematic sheet 15 Left Hand Cab Console - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Electrical schematic sheet 16 Left Hand Control Handle - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Electrical schematic sheet 17 Right Hand Control Handle - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . 108 Electrical schematic sheet 18 Right Hand Control Handle - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . 110 Electrical schematic sheet 19 Unit Control Module - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Electrical schematic sheet 20 Unit Control Module - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Electrical schematic sheet 21 Lamps - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Electrical schematic sheet 22 Indicators - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Electrical schematic sheet 23 EU Light Adapter - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Electrical schematic sheet 24 Boom Road Lights - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Electrical schematic sheet 25 Wipers/ Washers - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Electrical schematic sheet 26 Instrument Cluster - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Electrical schematic sheet 27 HVAC - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Electrical schematic sheet 28 Radio - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Electrical schematic sheet 29 Multifunction On/ Off - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Electrical schematic sheet 29 Multifunction On/ Off - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Electrical schematic sheet 30 Multifunction Connectors - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Electrical schematic sheet 31 Telematics - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Electrical schematic sheet 32 Multifunction Jumper - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

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Electrical schematic sheet 33 2nd Aux - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Electrical schematic sheet 34 Diagnostic Connector - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Wire connectors Component Diagram 00 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Component diagram 01 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Component diagram 02 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Component diagram 03 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Component diagram 05 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Component diagram 07 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Component diagram 09 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Component diagram 10 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Component diagram 11 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Component diagram 12 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Component diagram 15 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Component diagram 17 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Component diagram 19 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Component diagram 20 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Component diagram 23 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Component diagram 25 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Component diagram 27 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Component diagram 29 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 Component diagram 30 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Component diagram 31 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 Component diagram 32 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Component diagram 33 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 Component diagram 36 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 Component diagram 40 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 Component diagram 41 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 Component diagram 50 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 Component diagram 60 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 Component diagram 90 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 Component Diagram 00 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 Component diagram 01 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Component diagram 02 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 Component diagram 03 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 Component diagram 04 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 Component diagram 05 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 Component diagram 07 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 Component diagram 09 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 Component diagram 10 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 Component diagram 11 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

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Component diagram 12 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 Component diagram 15 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 Component diagram 17 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242 Component diagram 19 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 Component diagram 23 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 Component diagram 25 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 Component diagram 27 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247 Component diagram 30 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 Component diagram 31 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252 Component diagram 33 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 Component diagram 36 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257 Component diagram 40 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 Component diagram 43 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 Component diagram 50 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262 Component diagram 60 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265 Component diagram 82 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266 Component diagram 83 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 Component diagram 90 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268 Component Diagram 00 – Connectors A – T (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 Component diagram 01 – UCM Connectors CN1 – CN4 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 Component diagram 02 – Chassis/Cab Interface Connectors ECC1 – ECC7 (*) . . . . . . . . . . . . . . . . . . 286 Component diagram 03 – Fuse Power Distribution (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299 Component Diagram 00 – Connectors B – T (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 Component diagram 02 – Chassis/Cab Interface Connectors CNN1 – CO2 (*) . . . . . . . . . . . . . . . . . . . 308 Component diagram 03 – Fuse Power Distribution (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319

Fuse and relay box Relay - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325 Fuse - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328

SERVICE Wire harnesses Repair (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331 Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

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Fuse and relay box - General specification Relay and Fuse Identification - Medium Mechanical Machines L218 L220

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

Component Name Lights Relay #1 Lights Relay #2 Crank Relay ECU Main Relay Main Power Relay Engine Glow Relay Front Electric Relay Accessory Relay Option Relay

K-001 K-002 K-007 K-008 K-009 K-016 K-017 K-018 K-019

HVAC Fuse Compressor Fuse Crank Fuse Side Lamps Fuse LH Tail Lamp Fuse RH Tail Lamp Fuse Instrument Cluster Fuse Ignition Fuse Acc/Beacon Fuse Accessory Fuse Unswitched Battery Fuse Rear Work Lamps Fuse Front Work Lamps Fuse Wiper/Washer Fuse FE Hot Fuse FE #1, #2, #3 Fuse High Flow/ Coupler Fuse FE On/Off Fuse Flasher/Brake Fuse LH Boom Fuse ECU Relay ECU Backup Power Fuse RH Boom Fuse ECU Main Fuse Relay Ground Fuse Relay Ground Fuse Telematics

F-001 F-002 F-003 F-004 F-005 F-006 F-007 F-008 F-009 F-010 F-011 F-012 F-013 F-014 F-015 F-016 F-017 F-018 F-019 F-020 F-021 F-022 F-023 F-024 F-025 F-026 F-027

Component ID

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Wire harnesses - Electrical schematic sheet 01 Main Power Distribution - Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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RAIL13SSL0403JA

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Wire harnesses - Electrical schematic sheet 02 Accessory Power Distribution - Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

RAIL13SSL0404JA

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Wire harnesses - Electrical schematic sheet 03 Ignition/ Charging System - Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

RAIL13SSL0405JA

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Wire harnesses - Electrical schematic sheet 04 Grounding System Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

RAIL13SSL0406JA

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Wire harnesses - Electrical schematic sheet 05 Engine ISM - Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

RAIL13SSL0407JA

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Wire harnesses - Electrical schematic sheet 06 Engine ISM - Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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RAIL13SSL0408JA

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Wire harnesses - Electrical schematic sheet 07 Engine ISM - Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

RAIL13SSL0409JA

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Wire harnesses - Electrical schematic sheet 08 Throttle Sensors Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

RAIL13SSL0410JA

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Wire harnesses - Electrical schematic sheet 09 Auxiliary Hydraulic Interlock Switch - Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

RAIL13SSL0411JA

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Wire harnesses - Electrical schematic sheet 10 Bulkhead Connection - Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

RAIL13SSL0412JA

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Wire harnesses - Electrical schematic sheet 11 Left Hand Cab Console - Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

RAIL13SSL0543JA

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Wire harnesses - Electrical schematic sheet 12 Left Hand Control Handle - Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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RAIL13SSL0414JA

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Wire harnesses - Electrical schematic sheet 13 Right Hand Control Handle - Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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RAIL13SSL0416JA

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Wire harnesses - Electrical schematic sheet 11 Left Hand Cab Console - Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

RAIL13SSL0544JA

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 12 Left Hand Control Handle - Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

RAIL13SSL0415JA

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 13 Right Hand Control Handle - Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

RAIL13SSL0417JA

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Wire harnesses - Electrical schematic sheet 14 Seat - Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

RAIL13SSL0418JA

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Wire harnesses - Electrical schematic sheet 15 EH Aux PWM Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

RAIL13SSL0419JA

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Wire harnesses - Electrical schematic sheet 16 Lamps - Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

RAIL13SSL0420JA

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Wire harnesses - Electrical schematic sheet 17 Indicators - Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

RAIL13SSL0421JA

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Wire harnesses - Electrical schematic sheet 18 EU Light Adapter Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

RAIL13SSL0422JA

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Wire harnesses - Electrical schematic sheet 19 Boom And Road Lights - Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

RAIL13SSL0423JA

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Wire harnesses - Electrical schematic sheet 20 Wipers/ Washers Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

RAIL13SSL0424JA

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Wire harnesses - Electrical schematic sheet 21 Instrument Cluster Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

RAIL13SSL0425JA

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Wire harnesses - Electrical schematic sheet 22 HVAC - Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

RAIL13SSL0426JA

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Wire harnesses - Electrical schematic sheet 23 Radio - Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

RAIL13SSL0427JA

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Wire harnesses - Electrical schematic sheet 24 Multifunction Connectors - Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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RAIL13SSL0428JA

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Wire harnesses - Electrical schematic sheet 25 Telematics - Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Mechanical hydraulic controls WE Mechanical hydraulic controls

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 26 Multifunction Jumper - Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Mechanical hydraulic controls WE Mechanical hydraulic controls

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 27 Diagnostic Connector - Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Mechanical hydraulic controls WE Mechanical hydraulic controls

Electrical systems - Harnesses and connectors

RAIL13SSL0431JA

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 28 Boom Lock Valve Mechanical Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Mechanical hydraulic controls WE Mechanical hydraulic controls

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 01 Main Power Distribution EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Electro hydraulic controls WE Electro hydraulic controls

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 02 Accessory Power Distribution - EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Electro hydraulic controls WE Electro hydraulic controls

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 03 Ignition/ Charging System - EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Electro hydraulic controls WE Electro hydraulic controls

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 04 Grounding System EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Electro hydraulic controls WE Electro hydraulic controls

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 05 Engine ISM HPCR - EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Electro hydraulic controls WE Electro hydraulic controls

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 06 Engine ISM HPCR - EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Electro hydraulic controls WE Electro hydraulic controls

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 07 Engine ISM HPCR - EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Electro hydraulic controls WE Electro hydraulic controls

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 08 Throttle Sensors - EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Electro hydraulic controls WE Electro hydraulic controls

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 09 ET Pump/ Hydraulics EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Electro hydraulic controls WE Electro hydraulic controls

Electrical systems - Harnesses and connectors

RAIL13SSL0441JA

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 10 Hydraulic Interlocks EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Electro hydraulic controls WE Electro hydraulic controls

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 11 Loader Valve And Sensors - EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Electro hydraulic controls WE Electro hydraulic controls

Electrical systems - Harnesses and connectors

RAIL13SSL0443JA

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 12 Bulkhead Connection EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Electro hydraulic controls WE Electro hydraulic controls

Electrical systems - Harnesses and connectors

RAIL13SSL0444JA

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 13 Bulkhead Connection EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Electro hydraulic controls WE Electro hydraulic controls

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 14 Bulkhead Connection EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Electro hydraulic controls WE Electro hydraulic controls

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 15 Left Hand Cab Console EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Electro hydraulic controls WE Electro hydraulic controls

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 16 Left Control Handle EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 17 Right Hand Control Handle - EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Electro hydraulic controls WE Electro hydraulic controls

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 15 Left Hand Cab Console EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 16 Left Hand Control Handle - EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Electro hydraulic controls WE Electro hydraulic controls

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 17 Right Hand Control Handle - EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 18 Right Hand Control Handle - EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 19 Unit Control Module EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Electro hydraulic controls WE Electro hydraulic controls

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 20 Unit Control Module EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Electro hydraulic controls WE Electro hydraulic controls

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 21 Lamps - EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 22 Indicators - EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 23 EU Light Adapter - EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 24 Boom Road Lights EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 25 Wipers/ Washers - EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Electro hydraulic controls WE Electro hydraulic controls

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 26 Instrument Cluster EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Electro hydraulic controls WE Electro hydraulic controls

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 27 HVAC - EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Electro hydraulic controls WE Electro hydraulic controls

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 28 Radio - EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 29 Multifunction On/ Off EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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WE Electro hydraulic controls WE Electro hydraulic controls

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 29 Multifunction On/ Off EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 30 Multifunction Connectors - EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 31 Telematics - EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 32 Multifunction Jumper EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

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Wire harnesses - Electrical schematic sheet 33 2nd Aux - EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

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Wire harnesses - Electrical schematic sheet 34 Diagnostic Connector EH Units L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Electrical systems - Harnesses and connectors

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Wire connectors - Component Diagram 00 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-001 - ENGINE RELAY BOX CONNECTOR X-001 - ENGINE RELAY BOX PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A30 256 (RD) CRANK RELAY CRANK FUSE X-FUSE1 E12 A85 900A (GY) CRANK RELAY COIL GROUND X-002 PIN 92 A86 622B (OR) CRANK RELAY COIL POWER X-002 PIN 54 A87 520 RD START MOTOR POWER X-126 PIN 1 A87A B30 B85 B86 B87 B87A 606 RD BATTERY + C30 C85 112C GY ECU MAIN RELAY COIL GROUND X-002B PIN 5 AND 6 C86 603A (OR) ECU CONTROL POWER X-FUSE1 B6 BATTERY + C87 222 (OR) C87A

84511730

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CONNECTOR X-002A - ECU-A CONNECTOR X-002A - ECU-A WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 1 805 (OR)

INJECTOR POWER 2 X-100 PIN 1

2 3

806 (GY)

INJECTOR 4 X-100 PIN 2

4 5 6 7

364 (BL)

TEMPERATURE SENSOR GROUND X-100 PIN 3

8 9 10

338 (BL)

11 12

380 (BL)

13 14

371 (BL)

361 (BL)

366 (BL)

817 (RD)

811 (BL)

815 (BL)

DELTA P SENSOR GROUND X-100 PIN 4 EGR VALVE AND INTAKE THROTTLE COMMON GROUND X-100 PIN 5 BOOST PRESSURE SENSOR GROUND X-100 PIN 6 DOC TEMPERATURE SENSOR GROUND X-100 PIN 7 RAIL PRESSURE SENSOR GROUND X-100 PIN 8 G SENSOR SHIELD (CAM SENSOR) X-100 PIN 9 G SENSOR GROUND (CAM SENSOR) X-100 PIN 10 NE SENSOR GROUND (CRANK SENSOR) X-100 PIN 11

20 21 22

379 (PK)

369 (PK)

382 (PK)

807 (OR)

808 (GY)

27 28 29 30 31

363 (YE)

EGR +5 V X-100 PIN 12 BOOST PRESSURE SENSOR POWER X-100 PIN 13 INTAKE THROTTLE +5 V X-100 PIN 14 INJ POWER 2 X-100 PIN 15 INJECTOR 2 X-100 PIN 16

FUEL TEMPERATURE SIGNAL X-100 PIN 17 47711684 06/05/2014

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CONNECTOR X-002A - ECU-A WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 32 33 381 (YE)

EGR POSITION SENSOR OUT X-100 PIN 18 DOC INLET TEMPERATURE SENSOR SIGNAL X-100 PIN 19 DOC OUTLET TEMPERATURE SENSOR SIGNAL X-100 PIN 20

360 (YE)

362 (YE)

36 37

327 (YE)

DELTA P SENSOR SIGNAL X-100 PIN 21

38 39

365 (YE)

367A (YE)

367B (YE)

813 (YE)

814 (YE)

WATER TEMPERATURE SENSOR SIGNAL X-100 PIN 22 RAIL PRESSURE SENSOR SIGNAL X-100 PIN 23 RAIL PRESSURE SENSOR SIGNAL X-100 PIN 24 G SENSOR SIGNAL OUT (CAM SENSOR) X-100 PIN 25 NE SENSOR SIGNAL (CRANK SENSOR) X-100 PIN 26

44 45

368 (PK)

RAIL PRESSURE SENSOR POWER X-100 PIN 27

46 47 48 49

803 (OR)

INJECTOR POWER 1 X-100 PIN 28

50 51

810 (GY)

INJECTOR 3 X-100 PIN 29

52 53 54 55 56 57 58 59 60 61

370 (YE)

BOOST PRESSURE SENSOR SIGNAL X-100 PIN 30

62 63

383 (YE)

ETC POSITION SENSOR OUT X-100 PIN 31

64 65 66 67

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CONNECTOR X-002A - ECU-A WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 68 69 70 71 72 73 809 (OR)

INJECTOR POWER 1 X-100 PIN 32 INJECTOR 1 X-100 PIN 33

804 (GY)

75 76 77 78

121 WH

EGR ECU K-LINE X-DIAG PIN E

79 80

384 (YE)

601D (OR)

WATER IN FUEL SWITCH SIGNAL X-011 PIN 1 STOP SWITCH ECU KEYSWITCH ON

82 83 84 85 86 87 88 89 90 91 92 93 94 95 96

641 (WH)

GLOW RELAY COIL POWER

900 (GY)

CRANK RELAY COIL GROUND

84549330

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CONNECTOR X-002B - ECU-B CONNECTOR X-002B - ECU-B WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 1 2 3 4 5 6 7

908E (BK) 908G (BK) 908B (BK) 908F (BK) 104B (OR) 104C (OR) 374 (BL)

8 9

812 (PK)

10 11 12 13 14 15 16 17 18 19 20

908A (BK) 373 (YE)

21 22

337 (PK)

23 24 25 26 27 28

372 (YE)

29 30 31

818 (BK)

32 33 34 35 36 37 38 39 40 41 42 43 44

112A (GY) 112B (GY) 503C (YE) 504C (GN) 375 (BL)

ECU GROUND ECU GROUND ECU GROUND ECU GROUND B+ ECU B+ ECU HIGH PRESSURE PUMP GROUND X-100 PIN 34 G SENSOR POWER (CAM SENSOR) X-100 PIN 45 ECU GROUND HIGH PRESSURE PUMP +5V X-100 PIN 35 DELTA P SENSOR POWER X-100 PIN 36 INLET AIR TEMPERATURE SENSOR SIGNAL X-100 PIN 37 INJECTOR SHIELD GROUND X-100 PIN 38 ECU MAIN RELAY COIL GROUND ECU MAIN RELAY COIL GROUND CAN 2 HI CAN 2 LO ETC- INTAKE THROTTLE X-036 PIN 1

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CONNECTOR X-002B - ECU-B WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 45 376 (BL) 46 47 48 49 50 51 52 53

607 (OR) 601B (OR) 601C (OR) 507A YE 508A GN 602 (YE)

54 55 56 57

622A (OR) 377 (WH)

378 (WH)

EGR- EGR VALVE MX-035 PIN 1 BATTERY + KEY SWITCH ON KEY SWITCH ON CAN 1 HI (SERVICE TOOL) CAN 1 LO (SERVICE TOOL) OIL PRESSURE SWITCH SIGNAL X-100 PIN 44 ENGINE START SWITCH ETC+ INTAKE THROTTLE M+ X-036 PIN 2 EGR+ EGR VALVE M+ X-035 PIN 5

84549331

CONNECTOR X-003 - ENGINE GLOW RELAY CONNECTOR X-003 - ENGINE GLOW RELAY PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 641A (WH) GLOW RELAY COIL POWER RELAY TERMINAL 86 2 954A BK GLOW RELAY COIL GROUND RELAY TERMINAL 85 3 605 (RD) GLOW PLUG POWER RELAY TERMINAL 30 4 5 605A (OR) GLOW PLUG POWER RELAY TERMINAL 87

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CONNECTOR X-008 - ECU RELAY DIODE CONNECTOR X-008 - ECU MAIN RELAY DIODE WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 1 603B (OR) 2 112D GY

ECU CONTROL POWER ECU MAIN RELAY COIL GROUND

87695582

CONNECTOR X-008A - ECU RELAY DIODE HOLDER CONNECTOR X-008A - ECU RELAY DIODE HOLDER PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 603B (OR) ECU CONTROL POWER 2 112D GY ECU MAIN RELAY COIL GROUND

84535086

CONNECTOR X-009 - CRANK RELAY DIODE CONNECTOR X-009 - CRANK RELAY DIODE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 622C (OR) CRANK RELAY DIODE SP-622 2 900B (GY) CRANK RELAY COIL GROUND

87695582

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Electrical systems - Harnesses and connectors

CONNECTOR X-009A - CRANK RELAY DIODE HOLDER CONNECTOR X-009A - CRANK RELAY DIODE HOLDER PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 2

84535086

CONNECTOR X-2SPD - 2 SPEED VALVE SOLENOID CONNECTOR X-2SPD - 2 SPEED VALVE SOLENOID PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 564 WH 2 SPEED VALVE SOLENOID SIGNAL B 953 (BK) 2 SPEED VALVE SOLENOID GROUND

87693821

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CONNECTOR X-5A - ALTERNATOR CONNECTOR X-5A - ALTERNATOR WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 1 244 YE 2 3

127 (OR) 127 OR

ALTERNATOR LAMP TELEMATICS ENGINE ON ALTERNATOR EXCITE ENGINE SPEED SIGNAL

84165069

CONNECTOR X-9 - IGNITION SWITCH CONNECTOR X-9 - IGNITION SWITCH PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 2 138 (OR) ACCESSORY RELAY SIGNAL X-FUSE D10 3 140 (RD) UNSWITCHED BATTERY 4 624 (WH) INSTRUMENT CLUSTER X-C23 PIN 3 5 132 (OR) INSTRUMENT CLUSTER X-C23 PIN 10

87693713

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 01 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-010 - GLOW RELAY DIODE CONNECTOR X-010 - GLOW RELAY DIODE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 641B (WH) GLOW RELAY DIODE 2 944 BK GLOW RELAY DIODE

87695582

CONNECTOR X-011 - WATER IN FUEL SWITCH CONNECTOR X-011 - WATER IN FUEL SWITCH PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 384 (YE) WATER IN FUEL SWITCH SIGNAL 2 908D (WH) WATER IN FUEL SWITCH GROUND 3 133E OR WATER IN FUEL SWITCH POWER

87709663

CONNECTOR X-14 - FUEL LEVEL SENDER CONNECTOR X-14 - FUEL LEVEL SENDER PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 956 (BK) FUEL LEVEL SENDER GROUND B 234 RD FUEL LEVEL SENDER SIGNAL X-CC1A/1B PIN 8

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87693821

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CONNECTOR X-15 - ACCESSORY BACKFEED DIODE CONNECTOR X-15 - ACCESSORY BACKFEED DIODE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 137 (WH) ACCESSORY BACKFEED DIODE X-C23 PIN 29 B 153 (WH) ACCESSORY BACKFEED DIODE SP-009

84120021

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Wire connectors - Component diagram 02 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-20A - HAND THROTTLE CONNECTOR X-20A - HAND THROTTLE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 544 (YE) HAND THROTTLE SIGNAL B 1071 (BK/WH) HAND THROTTLE SENSOR GROUND C 260 (PK) HAND THROTTLE SENSOR SUPPLY

84398823

CONNECTOR X-20A - FOOT THROTTLE CONNECTOR X-20A - FOOT THROTTLE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 545 (YE) FOOT THROTTLE SIGNAL B 1066 (BK/WH) FOOT THROTTLE SENSOR GROUND C 211 (PK) FOOT THROTTLE SENSOR SUPPLY

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Wire connectors - Component diagram 03 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-30 - CAB/RH LAMP JUMPER INTERFACE CONNECTOR X-30 - CAB/RH LAMP JUMPER INTERFACE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 798 (VT) SP-016 X-30CAB/RH LAMP JUMPER INTERFACE 2 793 (VT) SP-015 X-30CAB/RH LAMP JUMPER INTERFACE 3 779 (VT) X-30CAB/RH LAMP JUMPER INTERFACE SP-019 4 926 (BK) X-30CAB/RH LAMP JUMPER 939 (BK) INTERFACE SP-014 X-30CAB/RH LAMP JUMPER INTERFACE SP-173

87694154

CONNECTOR X-31 - CAB/LH LAMP JUMPER INTERFACE CONNECTOR X-31 - CAB/LH LAMP JUMPER INTERFACE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 799 (VT) SP-016 X-31CAB/LH LAMP JUMPER INTERFACE 2 794 (VT) X-31CAB/LH LAMP JUMPER INTERFACE SP-015 3 773 (VT) SP-018 X-31CAB/LH LAMP JUMPER INTERFACE 4 927 (BK) X-31CAB/LH LAMP JUMPER INTERFACE SP-026

87694154

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Wire connectors - Component diagram 05 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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 756 933 315 323

(OR) (BK) (RD) (YE)

X-58CAB/SEAT INTERFACE SP-058 SP-172 X-58CAB/SEAT INTERFACE SP-012 X-58CAB/SEAT INTERFACE SP-086 X-58CAB/SEAT INTERFACE

87694154

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 07 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-078 - FUEL PUMP CONNECTOR X-078 - FUEL PUMP PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 600 (OR) FUEL PUMP SWITCHED BATTERY

87688695

CONNECTOR X-74 - HVAC CONDENSER FAN CONNECTOR X-74 - HVAC CONDENSER FAN PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 1084 (BK) HVAC CONDENSER FAN GROUND B 237 WH HVAC CONDENSER FAN POWER

87692877

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CONNECTOR X-77 - SIDE LAMP DIA SOCKET CONNECTOR X-77 - SIDE LAMP DIA SOCKET WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 1 1085 (BK) 2

238 (VT)

X-77SIDE LAMP DIA SOCKET SP-027 X-77SIDE LAMP DIA SOCKET SP-015

84398826

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Wire connectors - Component diagram 09 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-93 - RH PUMP SWASH PLATE SENSOR CONNECTOR X-93 - RH PUMP SWASH PLATE SENSOR PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 1055 (BK/WH) RH PUMP SWASH PLATE SENSOR GROUND 2 223 (PK) RH PUMP ANGLE SENSOR REFERENCE #1 3 575 (YE) RH PUMP ANGLE #2 4 576 (YE) RH PUMP ANGLE #1 5 221 (PK) RH PUMP ANGLE SENSOR REFERENCE #2 6 1074 (BK/WH) RH PUMP ANGLE SENSOR GROUND #2

87694112

CONNECTOR X-94 - LH PUMP SWASH PLATE SENSOR CONNECTOR X-94 - LH PUMP SWASH PLATE SENSOR PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 1054 (BK/WH) LH PUMP SWASH PLATE SENSOR GROUND 2 222 (PK) LH PUMP ANGLE SENSOR REFERENCE #1 3 574 (YE) LH PUMP ANGLE #1 4 573 (YE) LH PUMP ANGLE #2 5 209 (PK) LH PUMP ANGLE SENSOR REFERENCE #2 6 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 CONNECTOR X-95 - DRIVE PATTERN SELECTOR SWITCH PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 522 (YE) CONTROL PATTERN H 2 3 521 (YE) CONTROL PATTERN NEUTRAL 4 5 199 (OR) CONTROL PATTERN INPUT POWER 6 523 (YE) CONTROL PATTERN ISO 7 197 (OR) PATTERN INDICATOR ISO POWER 8 1024 (BL) PATTERN INDICATOR H LS OUTPUT9 1023 (BL) PATTERN INDICATOR ISO LS OUTPUT 10 198 (OR) PATTERN INDICATOR H POWER

84159859

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Electrical systems - Harnesses and connectors

CONNECTOR X-97 - CAB/DOME LAMP JUMPER CONNECTOR X-97 - CAB/DOME LAMP JUMPER WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 1 800 (OR) 151 (OR) 2

916 (BK)

DOME LAMP POWER RADIO/DOME LAMP/ HAVC RELAY POWER DOME LAMP GROUND

87695582

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Wire connectors - Component diagram 10 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-100 - ENGINE CONNECTOR X-100 - ENGINE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 805 (OR) INJECTOR POWER 2 X-002A PIN 1 2 806 (GY) INJECTOR 2 X-002A PIN 3 3 364 (BL) TEMPERATURE SENSOR GROUND X-002A PIN 7 4 338 (BL) DELTA P SENSOR GROUND X-002A PIN 10 5 380 (BL) EGR VALVE/ INTAKE THROTTLE GROUND X-002A PIN 12 6 371 (BL) BOOST PRESSURE SENSOR GROUND X-002A PIN 14 7 361 (BL) DOC TEMPERATURE SENSOR GROUND X-002A PIN 15 8 366 (BL) RAIL PRESSURE SENSOR GROUND X-002A PIN 16 9 817 (RD) G SENSOR/ NE SENSOR SHIELD 10 811 (BL) G SENSOR (CAM SENSOR) GROUND X-002A PIN 18 11 815 (BL) NE SENSOR GROUND (CRANK SENSOR) X-002A PIN 19 12 379 (PK) EGR V +5V X-002A PIN 22 13 369 (PK) BOOST PRESSURE SENSOR POWER X-002A PIN 23 14 382 (PK) ETC V +5V X-002A PIN 24 15 807 (OR) INJECTOR POWER 3 X-002A PIN 25 16 808 (GY) INJECTOR 3 X-002A PIN 26 17 363 (YE) FUEL TEMPERATURE SENSOR SIGNAL X-002A PIN 31 18 381 (YE) EGR POSITION SENSOR OUT X-002A PIN 33 19 360 (YE) DOC INLET TEMPERATURE SENSOR X-002A PIN 34 20 362 (YE) DOC OUTLET TEMPERATURE SENSOR SIGNAL X-002A PIN 35 21 327 (YE) DELTA P SENSOR OUT X-002A PIN 37 47711684 06/05/2014

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CONNECTOR X-100 - ENGINE WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 22 365 (YE)

367A (YE)

367B (YE)

813 (YE)

814 (YE)

368 (PK)

803 (OR)

810 (GY)

370 (YE)

383 (YE)

809 (OR)

804 (GY)

374 (BL)

373 (YE)

337 (PK)

372 (YE)

38 39

818 (BK) 375 (BL)

376 (BL)

377 (WH)

378 (WH)

43 44

602 (YE)

812 (PK)

46 47

WATER TEMPERATURE SENSOR SIGNAL X-002A PIN 39 RAIL PRESSURE SENSOR SIGNAL X-002A PIN 40 RAIL PRESSURE SENSOR SIGNAL X-002A PIN 41 G SENSOR (CAM SENSOR) X-002A PIN 42 NE SENSOR SIGNAL (CRANK SENSOR) X-002A PIN 43 RAIL PRESSURE SENSOR POWER X-002A PIN 27 INJECTOR POWER 1 X-002A PIN 49 INJECTOR 4 X-002A PIN 51 BOOST PRESSURE SENSOR SIGNAL X-002A PIN 61 INTAKE THROTTLE SIGNAL X-002A PIN 63 INJECTOR POWER 4 X-002A PIN 73 INJECTOR 1 X-002A PIN 74 HIGH PRESSURE PUMP GROUND X-002B PIN 7 FUEL PUMP SCV DRIVER HIGH X-002B PIN 20 DELTA P SENSOR POWER X-002B PIN 36 INLET AIR TEMPERATURE SENSOR X-002B PIN 28 INJECTOR CASE GROUND ETC V DC MOTOR (-) X-002B PIN 44 EGR V DC MOTOR (-) X-002B PIN 45 ETC V DC MOTOR (+) X-002B PIN 57 EGR V DC MOTOR (+) X-002B PIN 58 OIL PRESSURE SWITCH SIGNAL X-002B PIN 53 G SENSOR POWER (CAM SENSOR) X-002B PIN 9 -

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84567364

CONNECTOR X-101 - ON ROAD LIGHT CONFIGURATOR CONNECTOR X-101 - ON ROAD LIGHT CONFIGURATOR PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 702 (VT) X-101ON ROAD LIGHT CONFIGURATOR SP-024

84120008

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CONNECTOR X-101A - ON ROAD LIGHT CONFIGURATOR STANDARD CONNECTOR X-101A - ON ROAD LIGHT CONFIGURATOR STANDARD PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 710 (VT) X-FUSE1POWER DISTRIBUTION-EH CHASSIS X-101AON ROAD LIGHT CONFIGURATOR STANDARD

84120010

CONNECTOR X-101B - ON ROAD LIGHT CONFIGURATOR OPTION CONNECTOR X-101B - ON ROAD LIGHT CONFIGURATOR OPTION PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 711 (VT) SP-057 X-101BON ROAD LIGHT CONFIGURATOR OPTION

84120010

CONNECTOR X-104 - LAP BAR SWITCH CONNECTOR X-104 - LAP BAR SWITCH PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 316 (RD) LAP BAR SWITCHED UNSWITCHED BATTERY POWER 2 314 (YE) LAP BAR/ SEAT BELT SIGNAL CLUSTER INPUT

87382906

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 11 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-111 - CONDENSER RELAY [CAB] PIN NUMBER 1 2 3 4 5

CONNECTOR X-111 - CONDENSER RELAY [CAB] WIRE NUMBER CIRCUIT REFERENCE 839 (RD) 1087 (BK)

CONDENSER RELAY POWER CONDENSER RELAY GROUND

237 (WH) 840 (WH)

HVAC CONDENSER FAN POWER CONDESNER RELAY SIGNAL

87692860

CONNECTOR X-113 - FE #2 SWITCH CONNECTOR X-113 - FE #2 SWITCH PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A B C D 425 (VT) LH HANDLE MULTIFUNCTION #2 UP E 359 (OR) LH HANDLE MULTIFUNCTION #2, #3 POWER F 427 (RD) LH HANDLE MULTIFUNCTION #2 DOWN

87697780

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Wire connectors - Component diagram 12 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-126 - STARTER

84161819

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Wire connectors - Component diagram 15 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-155B - TURN SIGNAL INDICATOR RIGHT CONNECTOR X-155B - TURN SIGNAL INDICATOR RIGHT PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 771 (VT) TURN SIGNAL INDICATOR RIGHT

87697629

CONNECTOR X-156B - TURN SIGNAL INDICATOR LEFT CONNECTOR X-156B - TURN SIGNAL INDICATOR LEFT PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 772 (YE) TURN SIGNAL INDICATOR LEFT

87697629

CONNECTOR X-157B - TURN SIGNAL INDICATOR GROUND CONNECTOR X-157B - TURN SIGNAL INDICATOR GROUND PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 915 (BK) TURN SIGNAL INDICATOR GROUND SP-025

87697629

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 17 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-178 - BEACON LAMP SOCKET CONNECTOR X-178 - BEACON LAMP SOCKET PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 928 (BK) BEACON LAMP SOCKET GROUND 2 761 (VT) BEACON LAMP SWITCH OUTPUT

84398826

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Wire connectors - Component diagram 19 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-194 - GLOW PLUG CONNECTOR X-194 - GLOW PLUG PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 605A (OR) X-003ENGINE GLOW RELAY X-194GLOW PLUG

84159853

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Wire connectors - Component diagram 20 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-200 - CHASSIS/REAR LAMP JUMPER INTERFACE CONNECTOR X-200 - CHASSIS/REAR LAMP JUMPER INTERFACE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 766 (VT) LH REAR TURN SIGNAL POWER 2 763 (VT) RH REAR TURN SIGNAL POWER2 3 717 (VT) LH REAR POSITION LAMP 4 718 (VT) RH REAR POSITION LAMP 5 721 VT BRAKE LAMP SIGNAL POWER 6 975 (BK) REAR LAMPS GROUND

87382918

CONNECTOR X-201 CONNECTOR CONNECTOR X-201 - CONNECTOR PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 730 (VT) LH REAR TURN SIGNAL POWER 2 733 (VT) RH REAR TURN SIGNAL POWER2 3 731 (VT) LH REAR POSITION LAMP 897 VT 4 1000 (BK) REAR LAMP GROUNDS CONNECTOR X-203 - REAR LAMP JUMPER PIN NUMBER 1 2 3 4 5 6

CONNECTOR X-203 REAR LAMP JUMPER WIRE NUMBER CIRCUIT REFERENCE 735 736 717 718 737 975

(VT) (VT) (VT) (VT) VT (BK)

LH REAR TURN SIGNAL POWER RH REAR TURN SIGNAL POWER2 LH REAR POSITION LAMP RH REAR POSITION LAMP BRAKE LAMP SIGNAL POWER REAR LAMPS GROUND

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 23 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-230 - CHASSIS OPTIONS/ LH BOOM LIGHTS INTERCONNECT CONNECTOR X-230 - CHASSIS OPTIONS/ LH BOOM LIGHTS INTERCONNECT PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 712 (VT) LH BOOM ROAD LAMPS SIGNAL B 767 (VT) LH BOOM TURN SIGNAL POWER C D 979 (BK) RH BOOM TURN SIGNAL POWER

87697724

CONNECTOR X-231 - CHASSIS OPTION/ RH BOOMLIGHTS INTERCONNECT CONNECTOR X-231 - CHASSIS OPTION/ RH BOOMLIGHTS INTERCONNECT PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 713 VT RH BOOM ROAD LAMPS SIGNAL B 764 (VT) RH BOOM TURN SIGNAL POWER C D 980 (BK) RH BOOM LAMPS GROUND

87697724

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Electrical systems - Harnesses and connectors

CONNECTOR X-232 - LH FRONT ROAD LAMP CONNECTOR X-232 - LH FRONT ROAD LAMP WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER A 712 VT B 767 (VT) C D

979 (BK)

LH BOOM TURN SIGNAL POWER LH BOOM LAMP TURN SIGNAL POWER LH BOOM LAMPS GROUND

CONNECTOR X-233 - RH FRONT ROAD LAMP CONNECTOR X-233 - RH FRONT ROAD LAMP PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 713 VT RH BOOM ROAD LAMPS SIGNAL B 764 (VT) RH BOOM TURN SIGNAL POWER C D 980 (BK) RH BOOM LAMPS GROUND

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 25 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-252 - TEMP CONTROL SWITCH CONNECTOR X-252 - TEMP CONTROL SWITCH PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 823 (PK) SP-091 X-252TEMP CONTROL SWITCH 2 824 (YE) X-252TEMP CONTROL SWITCH X-ECC3AEH CHASSIS/CAB INTERFACE -33 912 (BK) X-252TEMP CONTROL SWITCH SP-014

87714670

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 27 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-270 - BLOWER SWITCH PIN NUMBER 1 2 3 4 5

CONNECTOR X-270 - BLOWER SWITCH WIRE NUMBER CIRCUIT REFERENCE 825 821 828 827 850

OR OR WH WH WH

HVAC CLUTCH BLOWER SWITCH POWER HVAC FAN LOW HVAC FAN MEDIUM HVAC FAN HIGH

CONNECTOR X-271 - WATER VALVE CONNECTOR X-271 - WATER VALVE WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER A B C D

822 OR 1013 (BK) 824 YE

E F

HVAC WATER VALVE POWER SP-179 X-271WATER VALVE HVAC TEMPERATURE CONTROL SIGNAL -

87694714

CONNECTOR X-275 - A/C SWITCH CONNECTOR X-275 - A/C SWITCH PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 825 (OR) HVAC CLUTCH B 913 (BK) HVAC COMPRESSOR CLUTCH SWITCH GROUND C 829 (WH) AC SWITCH OUT

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 29 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-298 - EH UCM WAKEUP DIODE CONNECTOR X-270 - BLOWER SWITCH PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 334 OR MAIN POWER RELAY UCM WAKEUP B 333 YE UCM WAKEUP DIODE OUT

84120021

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 30 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-300 - HYDRAULIC COUPLER SWITCH CONNECTOR X-300 - HYDRAULIC COUPLER SWITCH PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 2 751 (OR) HYDRAULIC COUPLER SWITCH IN 3 752 (WH) HYDRAULIC COUPLER SIGNAL 4 5 6 7 8 9 918 (BK) HYDRAULIC COUPLER SWITCH INDICATOR GROUND 10

84159859

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Electrical systems - Harnesses and connectors

CONNECTOR X-301 - BEACON LAMP SWITCH CONNECTOR X-301 - BEACON LAMP SWITCH WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER A 919 (BK) B C D E

761 (VT) 796 (VT)

BEACON SWITCH INDICATOR GROUND

BEACON SWITCH OUTPUT BEACON POWER

87697780

CONNECTOR X-302 - HAZARD LAMP SWITCH CONNECTOR X-302 - HAZARD LAMP SWITCH PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 776 (VT) HAZARD SW LH TURN SIGNAL OUTPUT B 784 (OR) LH HAZARD FLASHER POWER IN C 920 (BK) HAZARD SWITCH INDICATOR GROUND E 785 (OR) RH HAZARD FLASHER POWER IN F 778 (VT) HAZARD SW RH TURN SIGNAL OUTPUT

84159858

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Electrical systems - Harnesses and connectors

CONNECTOR X-303 - HI FLOW SWITCH CONNECTOR X-303 - HI FLOW SWITCH WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER A 755 (WH) B C D E

753 (OR) 750 (WH) 921 (BK)

HIGH PERFORMANCE HIGH FLOW SIGNAL HIGH FLOW SWITCH IN STANDARD HIGH FLOW SIGNAL HIGH FLOW SWITCH INDICATOR GROUND

87693037

CONNECTOR X-306 - LOADER LOCKOUT SW CONNECTOR X-306 - LOADER LOCKOUT SW PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 312 (YE) LOADER LOCK SWITCH NORMALLY CLOSED OUTPUT (VALVE ON) B 311 (OR) LOADER LOCKOUT SWITCH IN C 398 (YE) LOADER LOCK SWITCH NORMALLY OPEN OUTPUT (VALVE OFF) D E 924 (BK) LOADER LOCK SWITCH INDICATOR GROUND

87693037

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 31 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-310 - 2 SPD INDICATOR PIN NUMBER 1 2 3 4 5 6 7 8 9 10

CONNECTOR X-310 - 2 SPD INDICATOR WIRE NUMBER CIRCUIT REFERENCE 565 (VT) 917 (BK) -

2 SPEED UCM INPUT 2 SPEED INDICATOR GROUND -

84159859

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Electrical systems - Harnesses and connectors

CONNECTOR X-311 - LAMP SELECTOR SWITCH CONNECTOR X-311 - LAMP SELECTOR SWITCH WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER A 790 (VT) B 791 (VT) C 792 (VT) D

123 (OR)

WORK LAMP SIGNAL ROAD LAMP SIGNAL WORK LAMP AND SIDE LAMP SIGNAL LAMP SWITCH POWER

87697741

CONNECTOR X-316 - IGNITION BACKFEED DIODE CONNECTOR X-316 - IGNITION BACKFEED DIODE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 133A OR MAIN POWER RELAY SIGNAL B 144 (OR) MAIN POWER RELAY SIGNAL

84120021

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Electrical systems - Harnesses and connectors

CONNECTOR X-317 - SELF LEVEL SWITCH CONNECTOR X-317 - SELF LEVEL SWITCH WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER A 404 (WH) B C D E

405 (OR)

922 (BK)

SELF LEVEL SWITCH OUTPUT POWER SELF LEVEL SWITCH POWER

SELF LEVEL SWITCH INDICATOR GROUND

87693037

CONNECTOR X-318 - SELF LEVEL VALVE CONNECTOR X-318 - SELF LEVEL VALVE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 404 WH SELF LEVEL SWITCH OUTPUT POWER 2 949 (BK) SELF LEVEL VALVE GROUND

87695582

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 32 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-323 - CHASSIS OPTIONS/MULTIFUNCTION INTERCONNECT CONNECTOR X-323 - CHASSIS OPTIONS/MULTIFUNCTION INTERCONNECT PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 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 HANDLE MULTIFUNCTION #2 UP 6 417 RD HANDLE MULTIFUNCTION #2 DOWN 7 982 (BK) MULTIFUNCTION GROUND 8 856 WH AUX ELEC ON/OFF SWITCH 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 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-330 - RIGHT SPEAKER CONNECTOR X-330 - RIGHT SPEAKER PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 451 (WH) X-335RADIO CONNECTOR X-330RIGHT SPEAKER

87697629

CONNECTOR X-331 - RIGHT SPEAKER CONNECTOR X-331 - RIGHT SPEAKER PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 450 (BL) X-335RADIO CONNECTOR X-331RIGHT SPEAKER

87697629

CONNECTOR X-332 - LEFT SPEAKER CONNECTOR X-332 - LEFT SPEAKER PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 453 (WH) X-335RADIO CONNECTOR X-332LEFT SPEAKER

87697629

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Electrical systems - Harnesses and connectors

CONNECTOR X-333 - LEFT SPEAKER PIN WIRE NUMBER NUMBER 1 452 (BL)

CONNECTOR X-333 - LEFT SPEAKER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-335RADIO CONNECTOR X-333LEFT SPEAKER

87697629

CONNECTOR X-335 - RADIO CONNECTOR PIN NUMBER 1 2 3 4 5 6 7 8 9

CONNECTOR X-335 - RADIO CONNECTOR WIRE NUMBER CIRCUIT REFERENCE

452 (BL)

LEFT SPEAKER –

451 450 453 934

RIGHT SPEAKER + RIGHT SPEAKER – LEFT SPEAKER + GROUND

(WH) (BL) (WH) (BK)

130 (OR)

RADIO POWER

84257494

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Wire connectors - Component diagram 36 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-365 - NH PARK BRAKE SWITCH CONNECTOR X-365 - NH PARK BRAKE SWITCH PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 2 194 (OR) RH CONSOLE PARK BRAKE SWITCH 3 306 (YE) RH CONSOLE PARK BRAKE SWITCH OUT 4 5 6 7 8 9 10

84159859

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Wire connectors - Component diagram 40 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-401 - RH HANDLE INTERCONNECT FE #4 CONNECTOR X-401 - RH HANDLE INTERCONNECT FE #4 PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 129 (OR) AUX ELEC ON/OFF SWITCH IN B 856 (WH) AUX ELEC ON/OFF SWITCH SIGNAL

87693431

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CONNECTOR X-403 - RH HANDLE INTERCONNECT FE/PROPORTIONAL AUX/FLOAT CONNECTOR X-403 - RH HANDLE INTERCONNECT FE/PROPORTIONAL AUX/FLOAT PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 213 (PK) PROPORTIONAL AUX SW #2 REFERENCE 5V 2 547 (YE) PROPORTIONAL AUX SWITCH OUTPUT SIGNAL #2 3 1052 (BK/WH) PROPORTIONAL AUX SWITCH #3 GROUND 4 5 352 (OR) RH HANDLE MULTIFUNCTION #1, #2 POWER 6 410 (WH) RH HANDLE MULTIFUNCTION #1 UP 7 411 (TN) RH HANDLE MULTIFUNCTION #1 DOWN 8 9 10 214 (PK) PROPORTIONAL AUX SWITCH #1 REFERENCE 5V 11 546 (YE) PROPORTIONAL AUX SWITCH OUTPUT SIGNAL 12 1053 (BK/WH) PROPORTIONAL AUX SWITCH #2 REFERENCE 13 406 (OR) FLOAT SWITCH INPUT VOLTAGE 14 531 (YE) LOADER FLOAT SWITCH 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 WIRE NUMBER CIRCUIT REFERENCE NUMBER A 324 (OR) RH GRIP PARK BRAKE SWITCH POWER B 307 (YE) RH GRIP PARK BRAKE SW OUTPUT C 832 (OR) RIDE CONTROL VALVE SOLENOID POWER D 831 (WH) RIDE CONTROL VALVE SOLENOID SIGNAL

87697723

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Electrical systems - Harnesses and connectors

CONNECTOR X-408 - LH HANDLE INTERCONNECT CONNECTOR X-408 - LH HANDLE INTERCONNECT PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 558 (OR) 2ND AUX SWITCH POWER 2 554 (WH) 2ND AUX EXTEND SW OUTPUT 3 552 (WH) 2ND AUX RETRACT SIGNAL POWER 4 891 (OR) LH GRIP HORN/ 2 SPEED POWER 5 770 (OR) LH GRIP FLASHER POWER 6 768 (VT) LH GRIP LH TURN SIGNAL OUTPUT SIGNAL 7 765 (VT) LH GRIP RH TURN SIGNAL OUTPUT SIGNAL 8 892 (WH) HORN SIGNAL POWER 9 563 (WH) 2 SPEED SW OUTPUT SIGNAL 10 353 (OR) LH HANDLE MULTIFUNCTION #2, #3 POWER 11 414 (VT) LH HANDLE MULTIFUNCTION #2 UP 12 415 (RD) LH HANDLE MULTIFUNCTION #2 DOWN 13 418 (GY) LH HANDLE MULTIFUNCTION #3 UP 14 419 (LG) LH HANDLE MULTIFUNCTION #3 DOWN

87382929

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 41 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-411 - FLASHER MODULE CONNECTOR X-411 PIN WIRE NUMBER NUMBER 1 156 RD 2 981 BK 3 769 OR

- FLASHER MODULE CIRCUIT REFERENCE FLASHER/ BRAKE POWER FLASHER GROUND FLASHER MODULE OUTPUT POWER

4 5

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Wire connectors - Component diagram 50 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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 227 929 231 220

(WH) (BK) (OR) (YE)

DOOR WIPER MOTOR SIGNAL DOOR WIPER MOTOR GROUND DOOR WIPER MOTOR PARK DOOR SWITCH BYPASS

87697724

CONNECTOR X-502A - REAR WINDOW WIPER MOTOR CONNECTOR X-502A - REAR WINDOW WIPER MOTOR PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 228 (WH) REAR WINDOW WIPER MOTOR SIGNAL B 930 (BK) REAR WINDOW WIPER MOTOR GROUND C 232 (OR) REAR WINDOW WIPER MOTOR PARK

87693712

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Electrical systems - Harnesses and connectors

CONNECTOR X-503 - WIPER/WASHER SWITCH CONNECTOR X-503 - WIPER/WASHER SWITCH WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 1 931 (BK) 2

225 (WH)

229 (OR)

5 6

224 (WH) 230 (OR)

7 8

226 (VT) 932 (BK)

WIPER/ WASHER SWITCH GROUND WIPER MOTOR AND INDICATOR LAMP POWER OUTPUT WIPER/ WASHER SWITCH MOTOR POWER IN WASHER PUMP SIGNAL WIPER/ WASHER SW PUMP POWER IN WIPER/ WASHER LAMP SIGNAL WIPER/ WASHER SWITCH INDICATOR GROUND

87716755

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CONNECTOR X-505 - CAB/DOOR SWITCH INTERFACE CONNECTOR X-505 - CAB/DOOR SWITCH INTERFACE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 250 (YE) DOOR SWITCH SIGNAL 2 1016 (BK/WH) DOOR SWITCH GROUND

87382906

CONNECTOR X-506 - FRONT WASHER PUMP CONNECTOR X-506 - FRONT WASHER PUMP PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 970 (BK) WASHER PUMP GROUND 2 224 (WH) WASHER PUMP SIGNAL

87699736

CONNECTOR X-508 - AIR FILTER RESTRICTION SWITCH CONNECTOR X-508 - AIR FILTER RESTRICTION SWITCH PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 267 YE AIR FILTER RESTRICTION/ ENGINE MALFUNCTION 2 907 (BK) AIR FILTER SWITCH GROUND

84607243

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Wire connectors - Component diagram 60 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-605 - GCU FUSE CONNECTOR X-605 - GCU FUSE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 605 (RD) X-605GCU FUSE X-003ENGINE GLOW RELAY

84399575

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Wire connectors - Component diagram 90 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-902 - FUSE RELAY GROUND PIN NUMBER A B C D E F

CONNECTOR X-902 - FUSE RELAY GROUND WIRE NUMBER CIRCUIT REFERENCE 1157 (BK) 1156 (BK) 1158 (BK) 947 (BK) 1156 BK 947 BK

OPTION RELAY COIL GROUND OPTION RELAY COIL GROUND OPTION RELAY COIL GROUND OPTION RELAY COIL GROUND OPTION RELAY COIL GROUND MAIN POWER RELAY COIL GROUND

87697790

CONNECTOR X-904 - BOOM LOCK INTERLOCK SWITCH CONNECTOR X-904 - BOOM LOCK INTERLOCK SWITCH PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 1103 YE BOOM LOCK INTERLOCK SWITCH SIGNAL C 1102 OR BOOM LOCK VALVE POWER

87695580

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Wire connectors - Component Diagram 00 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-001 - ENGINE RELAY BOX PIN NUMBER A30 A85 A86 A87 A87A B30 B85 B86 B87 B87A C30 C85 C86 C87 C87A

CONNECTOR X-001 - ENGINE RELAY BOX WIRE NUMBER CIRCUIT REFERENCE 256 (RD) 900A (GY) 622B (OR) 520 (RD)

CRANK RELAY PIN 30 CRANK RELAY COIL GROUND CRANK RELAY COIL POWER STARTER MOTOR POWER

606 (RD) 112C (GY) 603A (OR) 222 (OR)

BATTERY + ECU MAIN RELAY COIL GROUND ECU CONTROL POWER BATTERY +

84511730

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Electrical systems - Harnesses and connectors

CONNECTOR X-002A - ECU-A CONNECTOR X-002A - ECU-A WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 1 805 (OR) 2 3

806 (GY)

4 5 6 7

364 (BL)

8 9 10

338 (BL)

11 12

380 (BL)

13 14

371 (BL)

361 (BL)

366 (BL)

817 (RD)

811 (BL)

815 (BL)

20 21 22

379 (PK)

369 (PK)

382 (PK)

807 (OR)

808 (GY)

27 28 29 30

INJ POWER 2 X-100 PIN 1 INJECTOR 4 X-100 PIN 2 TEMPERATURE SENSOR GROUND X-100 PIN 3 DELTA P SENSOR GROUND X-100 PIN 4 EGR VALVE/ INTAKE THROTTLE GROUND X-100 PIN 5 BOOST PRESSURE SENSOR GROUND X-100 PIN 6 DOC TEMPERATURE SENSOR GROUND X-100 PIN 7 RAIL PRESSURE SENSOR GROUND X-100 PIN 8 G SENSOR SHIELD (CAM SENSOR) X-100 PIN 9 G SENSOR GROUND (CAM SENSOR) X-100 PIN 10 ENGINE REV1 GROUND (CRANK SENSOR) X-100 PIN 11 EGR V +5V X-100 PIN 12 BOOST PRESSURE SENSOR POWER X-100 PIN 13 INTAKE THROTTLE +5V X-100 PIN 14 INJECTOR POWER 2 X-100 PIN 15 INJECTOR 2 X-100 PIN 16 -

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Electrical systems - Harnesses and connectors

CONNECTOR X-002A - ECU-A WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 31 363 (YE)

32 33

381 (YE)

360 (YE)

362 (YE)

36 37

327 (YE)

38 39

365 (YE)

367A (YE)

367B (YE)

813 (YE)

814 (YE)

44 45

368 (PK)

46 47 48 49

803 (OR)

50 51

810 (GY)

52 53 54 55 56 57 58 59 60 61

370 (YE)

62 63

383 (YE)

FUEL TEMPERATURE SENSOR SIGNAL X-100 PIN 17 EGR POSITION SENSOR OUT X-100 PIN 18 EXHAUST TEMPERATURE SENSOR DOC INLET TEMPERATURE SENSOR X-100 PIN 19 EXHAUST TEMPERATURE SENSOR DOC OUTLET TEMPERATURE SENSOR X-100 PIN 20 DELTA P SENSOR SIGNAL X-100 PIN 21 WATER TEMPERATURE SENSOR SIGNAL X-100 PIN 22 RAIL PRESSURE SENSOR SIGNAL X-100 PIN 23 RAIL PRESSURE SENSOR SIGNAL X-100 PIN 24 G SENSOR SIGNAL (CAM SENSOR) X-100 PIN 25 ENGINE REV1 (CRANK SENSOR) X-100 PIN 26 RAIL PRESSURE SENSOR POWER X-100 PIN 27 INJECTOR POWER 1 X-100 PIN 28 INJECTOR 3 X-100 PIN 29 BOOST PRESSURE SENSOR SIGNAL X-100 PIN 30 INTAKE THROTTLE POSITION SENSOR OUT X-100 PIN 31 47711684 06/05/2014

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Electrical systems - Harnesses and connectors

CONNECTOR X-002A - ECU-A WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 65 66 67 68 69 70 71 72 73

809 (OR)

804 (GY)

75 76 77 78

121 (WH)

79 80

384 (YE)

81 82 83 84 85 86 87 88 89 90 92 93 94 95 96

601D (OR) 641 (WH) 900 (GY) -

INJECTOR POWER 1 X-100 PIN 32 INJECTOR 1 X-100 PIN 33 DIAGNOSTIC SWITCH EGR ECU K-LINE X-DIAG PIN E WATER IN FUEL SWITCH SIGNAL X-011 PIN 1 STOP SWITCH GLOW RELAY COIL POWER CRANK RELAY COIL GROUND -

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CONNECTOR X-002B - ECU-B CONNECTOR X-002B - ECU-B WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 1 2 3 4 5 6 7

908E (BK) 908G (BK) 908B (BK) 908F (BK) 104B (OR) 104C (OR) 374 (BL)

8 9

812 (PK)

10 11 12 13 14 15 16 17 18 19 20

908A (BK) 373 (YE)

21 22

337 (PK)

23 24 25 26 27 28

372 (YE)

29 30 31

818 (BK)

32 33

112A (GY)

112B (GY)

35 36 37 38 39 40 41 42 43

503C (YE) 504C (GN) -

ECU GROUND CONTROL 1 ECU GROUND CONTROL 2 ECU GROUND POWER 1 ECU GROUND POWER 2 ECU MAIN RELAY COIL POWER ECU MAIN RELAY COIL HIGH PRESSURE PUMP SENSOR GROUND X-100 PIN 34 G SENSOR POWER X-100 PIN 45 CASE GROUND FUEL PUMP SCV DRIVER HIGH X-100 PIN 35 DELTA P SENSOR POWER X-100 PIN 36 INLET AIR TEMPERATURE SENSOR X-100 PIN 37 INJECTOR SHIELD GROUND X-100 PIN 38 ECU MAIN RELAY COIL CONTROL GROUND ECU MAIN RELAY COIL CONTROL GROUND CAN 2 HIGH CAN 2 LOW -

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CONNECTOR X-002B - ECU-B WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 44 375 (BL) 45

376 (BL)

46 47 48 49 50 51 52 53

607 (OR) 601B (OR) 601C (OR) 507A (YE) 508A (GN) 602 (YE)

54 55 56 57

622A (OR) 377 (WH)

378 (WH)

ETCX-100 PIN 39 EGRX-100 PIN 40 VB POWER BACKUP B+ KEY ON SWITCH KEY ON SWITCH CAN 1 HIGH (SERVICE TOOL) CAN 1 LOW (SERVICE TOOL) OIL PRESSURE SWITCH SIGNAL X-100 PIN 44 STARTER SWITCH ETC+ X-100 PIN 41 EGR+ X-100 PIN 42

84549331

CONNECTOR X-003 - ENGINE GLOW RELAY PIN NUMBER 1 2 3 4 5

CONNECTOR X-003 - ENGINE GLOW RELAY WIRE NUMBER CIRCUIT REFERENCE 641A (WH) 954A (BK) 605 (RD)

GLOW RELAY COIL POWER GLOW RELAY COIL GROUND GLOW PLUG POWER

605A (OR)

GLOW PLUG POWER

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CONNECTOR X-008 - ECU RELAY DIODE CONNECTOR X-008 - ECU RELAY DIODE WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 1 603B (OR) 2 112D (GY)

ECU MAIN RELAY COIL DIODE ECU MAIN RELAY COIL CONTROL GROUND

87695582

CONNECTOR X-008A - ECU RELAY DIODE HOLDER CONNECTOR X-008A - ECU RELAY DIODE HOLDER PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 2

84535086

CONNECTOR X-009 - CRANK RELAY DIODE CONNECTOR X-009 - CRANK RELAY DIODE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 622C (OR) CRANK RELAY DIODE SP-622 2 900B (GY) CRANK RELAY COIL GROUND

87695582

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CONNECTOR X-009A - CRANK RELAY DIODE HOLDER CONNECTOR X-009A - CRANK RELAY DIODE HOLDER PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 2

84535086

CONNECTOR X-2SPD - 2 SPEED VALVE SOLENOID CONNECTOR X-2SPD - 2 SPEED VALVE SOLENOID PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 564 (WH) 2 SPEED VALVE SOLENOID SIGNAL B 953 (BK) 2 SPEED VALVE SOLENOID GROUND

87693821

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CONNECTOR X-5A - ALTERNATOR CONNECTOR X-5A - ALTERNATOR WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 1 244 YE 2 3

127 (OR)

ALTERNATOR LAMP TELEMATICS ENGINE ON ALTERNATOR EXCITE

84165069

87693713

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Wire connectors - Component diagram 01 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-010 - GLOW RELAY DIODE HOLDER CONNECTOR X-010 - GLOW RELAY DIODE HOLDER PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 641B (WH) GLOW RELAY DIODE 2 954B (BK) GLOW RELAY COIL GROUND

87695582

CONNECTOR X-010A - GLOW RELAY DIODE HOLDER CONNECTOR X-010A - GLOW RELAY DIODE HOLDER PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 2

84535086

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Electrical systems - Harnesses and connectors

CONNECTOR X-011 - WATER IN FUEL SWITCH CONNECTOR X-011 - WATER IN FUEL SWITCH WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 1 384 (YE) 2 908D (WH) 3 133E (OR)

WATER IN FUEL SWITCH SIGNAL WATER IN FUEL SWITCH GROUND WATER IN FUEL SWITCH POWER

87709663

CONNECTOR X-11 - A/C COMPRESSOR HVAC HIGH PRESSURE SW CONNECTOR X-11 - A/C COMPRESSOR HVAC HIGH PRESSURE SW PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 833 (WH) HVAC HIGH PRESSURE SWITCH 2 834 (WH) HVAC BINARY PRESSURE SWITCH 3 841 (WH) A/C COMPRESSOR RELAY PIN 87 POWER

87382911

CONNECTOR X-012 BOOST PRESSURE SENSOR CONNECTOR X-012 BOOST PRESSURE SENSOR PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 370 YE BOOST PRESSURE SENSOR SIGNAL X-002A PIN 61 2 371 BL BOOST PRESSURE SENSOR GROUND X-002A PIN 14 3 369 PK BOOST PRESSURE SENSOR POWER X-002A PIN 23

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Electrical systems - Harnesses and connectors

CONNECTOR X-014 OIL PRESSURE SWITCH CONNECTOR X-014 OIL PRESSURE SWITCH WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 1 602 YE

OIL PRESSURE SWITCH SIGNAL X-002B PIN 53

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CONNECTOR X-14 - FUEL LEVEL SENDER CONNECTOR X-14 - FUEL LEVEL SENDER WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER A 956 (BK) B 234 (RD)

FUEL LEVEL SENDER GROUND FUEL LEVEL SENDER TO INSTRUMENT CLUSTER

87693821

CONNECTOR X-15 - ACCESSORY BACKFEED DIODE CONNECTOR X-15 - ACCESSORY BACKFEED DIODE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 137 (WH) ACCESSORY RELAY SIGNAL FROM INSTRUMENT CLUSTER B 153 (WH) ACCESSORY RELAY SIGNAL

84120021

CONNECTOR X-016 DOC INLET TEMPERATURE SENSOR CONNECTOR X-016 DOC INLET TEMPERATURE SENSOR PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 360 YE DOC INLET TEMPERATURE SIGNAL X-002A PIN 34 2 361A BL DOC INLET TEMPERATURE SENSOR GROUND X-002A PIN 15

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Electrical systems - Harnesses and connectors

CONNECTOR X-017 DOC OUTLET TEMPERATURE SENSOR CONNECTOR X-017 DOC OUTLET TEMPERATURE SENSOR PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 362 YE DOC OUTLET TEMPERATURE SIGNAL X-002A PIN 35 2 361B BL DOC OUTLET TEMPERATURE SENSOR GROUND X-002A PIN 15

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 02 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-020 INLET AIR TEMPERATURE CONNECTOR X-020 INLET AIR TEMPERATURE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 371 YE INLET AIR TEMPERATURE SENSOR SIGNAL X-002B PIN 28 2 366B BL INLET AIR TEMPERATURE SENSOR GROUND CONNECTOR X-20 - FOOT THROTTLE SENSOR CONNECTOR X-20 - FOOT THROTTLE SENSOR PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 545 (YE) FOOT THROTTLE SIGNAL B 1066 (BK/WH) FOOT THROTTLE GROUND C 211 (PK) FOOT THROTTLE SENSOR SUPPLY VOLTAGE

84398823

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84398823

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CONNECTOR X-20AA - CAP

84539352

CONNECTOR X-021 WATER TEMPERATURE SENSOR CONNECTOR X-021 WATER TEMPERATURE SENSOR PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 365 YE WATER TEMPERATURE SIGNAL X-002A PIN 39 2 364A BL WATER TEMPERATURE SENSOR GROUND X-002A PIN 7 CONNECTOR X-022 G SENSOR (CAM ANGLE SENSOR) CONNECTOR X-022 G SENSOR (CAM ANGLE SENSOR) PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 371 YE G SENSOR OUTPUT X-002A PIN 42 2 812 PK G SENSOR POWER 3 811 BL G SENSOR GROUND X-002A PIN 18

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Electrical systems - Harnesses and connectors

CONNECTOR X-023 NE SENSOR (CRANK ANGLE SENSOR) CONNECTOR X-023 NE SENSOR (CRANK ANGLE SENSOR) PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 814 YE ENGINE REV1 (CRANK ANGLE) X-002A PIN 43 2 815 BL ENGINE REV1 GROUND X-002A PIN 19 CONNECTOR X-026 DELTA P SENSOR CONNECTOR X-026 DELTA P SENSOR PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 2 327 YE DELTA P SENSOR OUT X-002A PIN 37 3 4 337 PK DELTA P SENSOR POWER 5 338 BL DELTA P SENSOR GROUND X-002A PIN 10 6

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 03 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-30 - CAB HARNESS/RH LAMP JUMPER INTERFACE [CAB] CONNECTOR X-30 - CAB HARNESS/RH LAMP JUMPER INTERFACE [CAB] PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 798 (VT) RH WORK LAMP POWER 2 793 (VT) RH SIDE LAMP POWER 3 779 (VT) RH CAB TURN SIGNAL POWER 4 926 (BK) RH CAB LAMPS GROUND 939 (BK) CAB LAMPS/DOOR WIPER MOTOR/WIPER WASHER SW/WIPER WASHER SW INDICATOR GROUND

87694154

CONNECTOR X-031 RAIL PRESSURE SENSOR CONNECTOR X-031 RAIL PRESSURE SENSOR PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 368 PK RAIL PRESSURE SENSOR POWER X-002A PIN 45 2 367 YE RAIL PRESSURE SENSOR SIGNAL X-002A PIN 40 3 366A BL SENSOR GROUND X-002A PIN 16 CONNECTOR X-31 - CAB HARNESS/LH LAMP JUMPER INTERFACE [CAB] CONNECTOR X-31 - CAB HARNESS/LH LAMP JUMPER INTERFACE [CAB] PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 799 (VT) LH WORK LAMP POWER 2 794 (VT) LH SIDE LAMP POWER 3 773 (VT) LH CAB TURN SIGNAL POWER 4 927 (BK) LH CAB LAMPS GROUND

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87694154

CONNECTOR X-032 FUEL TEMPERATURE SENSOR CONNECTOR X-032 FUEL TEMPERATURE SENSOR PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 363 YE DOC OUTLET TEMPERATURE SIGNAL X-002A PIN 31 2 364B BL FUEL TEMPERATURE SENSOR GROUND X-002A PIN 7

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CONNECTOR X-033 HIGH PRESSURE PUMP CONNECTOR X-033 HIGH PRESSURE PUMP WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 1 373 YE 2

374 BL

FUEL PUMP SCV DRIVER HIGH X-002B PIN 20 HIGH PRESSURE PUMP GROUND

CONNECTOR X-035 EGR VALVE CONNECTOR X-035 EGR VALVE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 376 GY EGR V DC MOTOR (-) X-002B PIN 45 2 379 PK EGR V +5V X-002A PIN 22 3 380A BL SENSOR GROUND X-002A PIN 12 4 381 YE EGR POSITION SENSOR OUT X-002A PIN 33 5 378 WH EGR V DC MOTOR (+) X-002B PIN 58 CONNECTOR X-036 INTAKE THROTTLE CONNECTOR X-036 INTAKE THROTTLE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 375 GY ETC V DC MOTOR (-) X-002B PIN 44 2 377 WH ETC V DC MOTOR (+) X-002B PIN 57 3 380B BL SENSOR GROUND X-002A PIN 12 4 5 381 YE ETC V +5V X-002A PIN 24 6 383 YE ETC POSITION SENSOR OUT X-002A PIN 33

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Wire connectors - Component diagram 04 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-42 - MECHANICAL BACKUP SWITCH CONNECTOR X-42 - MECHANICAL BACKUP SWITCH PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 893 (OR) BACKUP ALARM SWITCH POWER 2 894 (WH) BACKUP ALARM SWITCH TO SWITCH

87695584

CONNECTOR X-43 - MECHANICAL BACKUP SWITCH CONNECTOR X-43 - MECHANICAL BACKUP SWITCH PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 894 (WH) BACKUP ALARM SWITCH TO SWITCH 2 895 (WH) BACKUP ALARM SIGNAL

87695584

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Electrical systems - Harnesses and connectors

CONNECTOR X-44 - CONNECTOR CONNECTOR X-44 - CONNECTOR WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER A 733 VT B 999 BK 734 VT C

RH TAIL LAMP POWER RH STOP/ TAIL LAMPS GROUND BRAKE LAMPS

CONNECTOR X-49 - CONNECTOR CONNECTOR X-49 - CONNECTOR WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER A 734 VT B 734 VT C

RH STOP/ TAIL LAMPS GROUND

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Wire connectors - Component diagram 05 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-58 - CAB/SEAT HARNESS INTERFACE CONNECTOR X-58 - CAB/SEAT HARNESS INTERFACE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 756 (OR) SEAT ACCESSORY POWER 2 933 (BK) SEAT ACCESSORY GROUND 3 315 (RD) SEAT SWITCH UNSWITCHED POWER 4 323 (YE) SEAT SWITCH CLUSTER INPUT

87694154

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Wire connectors - Component diagram 07 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-078 - FUEL PUMP CONNECTOR X-078 - FUEL PUMP PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 600 (OR) SP-037 X-078FUEL PUMP

87688695

CONNECTOR X-74 - HVAC CONDENSER FAN CONNECTOR X-74 - HVAC CONDENSER FAN PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 1084 (BK) HVAC CONDENSER FAN GROUND B 237 (WH) HVAC CONDENSER FAN POWER

87692877

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CONNECTOR X-75 - A/C COMPRESSOR HVAC HIGH PRESSURE SW CONNECTOR X-75 - A/C COMPRESSOR HVAC HIGH PRESSURE SW PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 833 (WH) HVAC HIGH PRESSURE SWITCH 2 834 (WH) HVAC BINARY PRESSURE SWITCH 3 841 (WH) A/C COMPRESSOR RELAY PIN 87 POWER CONNECTOR X-76 - HVAC HIGH PRESSURE SWITCH CONNECTOR X-76 - HVAC HIGH PRESSURE SWITCH PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 833 WH PRESSURE SWITCH 2 834 WH BINARY PRESSURE SWITCH TO COMPRESSOR RELAY PIN 85 CONNECTOR X-77 - SIDE LAMP DIA SOCKET CONNECTOR X-77 - SIDE LAMP DIA SOCKET PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 1085 (BK) SP-027 X-77SIDE LAMP DIA SOCKET 2 238 (VT) SP-015 X-77SIDE LAMP DIA SOCKET

84398826

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Wire connectors - Component diagram 09 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-97 - CAB/DOME LAMP JUMPER CONNECTOR X-97 - CAB/DOME LAMP JUMPER PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 800 (OR) DOME LAMP POWER1 151 (OR) RADIO/ DOME LAMP/ HVAC RELAY POWER 2 916 (BK) DOME LAMP GROUND

87695582

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Wire connectors - Component diagram 10 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-100 - ENGINE CONNECTOR X-100 - ENGINE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 805 (OR) INJECTOR POWER 2 X-002A PIN 1 2 806 (GY) INJECTOR 2 X-002A PIN 3 3 364 (BL) TEMPERATURE SENSOR GROUND X-002A PIN 7 4 338 (BL) DELTA P SENSOR GROUND X-002A PIN 10 5 380 (BL) EGR VALVE/ INTAKE THROTTLE GROUND X-002A PIN 12 6 371 (BL) BOOST PRESSURE SENSOR GROUND X-002A PIN 14 7 361 (BL) DOC TEMPERATURE SENSOR GROUND X-002A PIN 15 8 366 (BL) RAIL PRESSURE SENSOR GROUND X-002A PIN 16 9 817 (RD) G SENSOR/ NE SENSOR SHIELD X-002A PIN 17 10 811 (BL) G SENSOR (CAM SENSOR) GROUND X-002A PIN 18 11 815 (BL) NE SENSOR GROUND (CRANK SENSOR) X-002A PIN 19 12 379 (PK) EGR V +5V X-002A PIN 22 13 369 (PK) BOOST PRESSURE SENSOR POWER X-002A PIN 23 14 382 (PK) ETC V +5V X-002A PIN 24 15 807 (OR) INJECTOR POWER 2 X-002A PIN 25 16 808 (GY) INJECTOR 2 X-002A PIN 26 17 363 (YE) FUEL TEMPERATURE SENSOR SIGNAL X-002A PIN 31 18 381 (YE) EGR POSITION SENSOR OUT X-002A PIN 33 19 360 (YE) DOC INLET TEMPERATURE SENSOR X-002A PIN 34 20 362 (YE) DOC OUTLET TEMPERATURE SENSOR SIGNAL X-002A PIN 35

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CONNECTOR X-100 - ENGINE WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 21 327 (YE) 22

365 (YE)

367A (YE)

367B (YE)

813 (YE)

814 (YE)

368 (PK)

803 (OR)

810 (GY)

370 (YE)

383 (YE)

809 (OR)

804 (GY)

374 (BL)

373 (YE)

337 (PK)

372 (YE)

818 (BK)

375 (BL)

376 (BL)

377 (WH)

378 (WH)

43 44

602 (YE)

812 (PK)

46 47

DELTA P SENSOR OUT X-002A PIN 37 WATER TEMPERATURE SENSOR SIGNAL X-002A PIN 39 RAIL PRESSURE SENSOR SIGNAL X-002A PIN 40 RAIL PRESSURE SENSOR SIGNAL X-002A PIN 41 G SENSOR (CAM SENSOR) X-002A PIN 42 NE SENSOR SIGNAL (CRANK SENSOR) X-002A PIN 43 RAIL PRESSURE SENSOR POWER X-002A PIN 27 INJECTOR POWER 1 X-002A PIN 49 INJECTOR 3 X-002A PIN 51 BOOST PRESSURE SENSOR SIGNAL X-002A PIN 61 INTAKE THROTTLE SIGNAL X-002A PIN 63 INJECTOR POWER 1 X-002A PIN 73 INJECTOR 1 X-002A PIN 74 HIGH PRESSURE PUMP GROUND X-002B PIN 7 FUEL PUMP SCV DRIVER HIGH X-002B PIN 20 DELTA P SENSOR POWER X-002B PIN 22 INLET AIR TEMPERATURE SENSOR X-002B PIN 28 INJECTOR SHIELD GROUND X-002B PIN 31 ETC V DC MOTOR (-) X-002B PIN 44 EGR V DC MOTOR (-) X-002B PIN 45 ETC V DC MOTOR (+) X-002B PIN 57 EGR V DC MOTOR (+) X-002B PIN 58 OIL PRESSURE SWITCH SIGNAL X-002B PIN 53 G SENSOR POWER (CAM SENSOR) X-002B PIN 9 -

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CONNECTOR X-101 - ON ROAD LIGHT CONFIGURATOR CONNECTOR X-101 - ON ROAD LIGHT CONFIGURATOR PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 702 (VT) X-101ON ROAD LIGHT CONFIGURATOR SP-024

84120008

84120010

CONNECTOR X-104 - LAP BAR SWITCH CONNECTOR X-104 - LAP BAR SWITCH PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 316 (RD) LAP BAR SWITCH UNSWITCHED BATTERY POWER 2 314 (YE) INSTRUMENT CLUSTER INPUT

87382906

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Wire connectors - Component diagram 11 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-111 - CONDENSER RELAY [CAB] CONNECTOR X-111 - CONDENSER RELAY [CAB] PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 839 (RD) CONDENSER RELAY POWER 2 1087 (BK) CONDENSER RELAY GROUND 4 5

237 (WH) 840 (WH)

HVAC CONDENSER FAN POWER CONDENSER RELAY SIGNAL

87692860

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CONNECTOR X-113 - FE #2 SWITCH CONNECTOR X-113 - FE #2 SWITCH WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER A B C D 425 (VT) E

359 (OR)

427 (RD)

LH HANDLE MULTIFUNCTION #2 UP LH HANDLE MULTIFUNCTION #2, #3 POWER LH HANDLE MULTIFUNCTION #2 DOWN

87697780

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CONNECTOR X-114 LEFT HAND CONTROL HANDLE CONNECTOR X-114 LEFT HAND CONTROL HANDLE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 558 OR 2ND AUX SWITCH POWER 2 554 WH 2ND AUX EXTEND SWITCH OUTPUT 3 552 WH 2ND AUX RETRACT SIGNAL POWER 4 5 770 OR LH GRIP FLASHER POWER 6 768 VT LH GRIP LH TURN SIGNAL OUTPUT 7 765 VT LH GRIP RH TURN SIGNAL OUTPUT 8 246 OR AUX ELEC ON/OFF SWITCH IN 9 857 WH AUX ELEC ON/OFF SWITCH SIGNAL 10 358 OR LH HANDLE MULTIFUNCTION #2, #3 POWER 11 424 VT LH HANDLE MULTIFUNCTION #2 UP 12 426 RD LH HANDLE MULTIFUNCTION #2 DOWN 13 418 GY LH HANDLE MULTIFUNCTION #3 UP 14 419 LG LH HANDLE MULTIFUNCTION #3 DOWN

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CONNECTOR X-117 RIGHT HAND CONTROL HANDLE CONNECTOR X-117 RIGHT HAND CONTROL HANDLE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 352 OR RH HANDLE MULTIFUNCTION #1, #2 POWER 2 410 WH RH HANDLE MULTIFUNCTION #1 UP 3 411 TN RH HANDLE MULTIFUNCTION #1 DOWN 4 5 412 VT RH HANDLE MULTIFUNCTION #2 UP 6 413 RD RH HANDLE MULTIFUNCTION #2 DOWN 7 8 9 247 OR AUX ELEC ON/OFF SWITCH IN 10 858 WH AUX ELEC ON/OFF SWITCH SIGNAL

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Wire connectors - Component diagram 12 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-126 - STARTER CONNECTOR X-126 - STARTER PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 520 (RD) X-001ENGINE RELAY BOX X-126STARTER

84161819

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Wire connectors - Component diagram 15 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-155B - TURN INDI RIGHT CONNECTOR X-155B - TURN INDI RIGHT PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 771 (VT) SP-019 X-155BTURN INDI RIGHT

87697629

CONNECTOR X-156B - TURN INDI LEFT CONNECTOR X-156B - TURN INDI LEFT PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 772 (YE) SP-018 X-156BTURN INDI LEFT

87697629

CONNECTOR X-157B - TURN INDI GROUND CONNECTOR X-157B - TURN INDI GROUND PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 915 (BK) X-157BTURN INDI GROUND SP-025

87697629

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Wire connectors - Component diagram 17 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-178 - BEACON LAMP SOCKET CONNECTOR X-178 - BEACON LAMP SOCKET PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 928 (BK) BEACON SWITCH OUTPUT 2 761 (VT) BEACON GROUND

84398826

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Wire connectors - Component diagram 19 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-194 - GLOW PLUG CONNECTOR X-194 - GLOW PLUG PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 605A (OR) X-003ENGINE GLOW RELAY X-194GLOW PLUG

84159853

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Wire connectors - Component diagram 23 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-230 - CHASSIS OPTIONS/LH BOOM LIGHTS INTERCONNECT CONNECTOR X-230 - CHASSIS OPTIONS/LH BOOM LIGHTS INTERCONNECT PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 712 (VT) SP-059 X-230CHASSIS OPTIONS/LH BOOM LIGHTS INTERCONNECT B 767 (VT) X-230CHASSIS OPTIONS/LH BOOM LIGHTS INTERCONNECT SP-051 C D 979 (BK) X-230CHASSIS OPTIONS/LH BOOM LIGHTS INTERCONNECT SP-174

87697724

CONNECTOR X-231 - CHASSIS OPTION/RH BOOM LIGHTS INTERCONNECT CONNECTOR X-231 - CHASSIS OPTION/RH BOOM LIGHTS INTERCONNECT PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 713 (VT) X-231CHASSIS OPTION/RH BOOM LIGHTS INTERCONNECT SP-060 B 764 (VT) SP-052 X-231CHASSIS OPTION/RH BOOM LIGHTS INTERCONNECT C D 980 (BK) SP-178 X-231CHASSIS OPTION/RH BOOM LIGHTS INTERCONNECT

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87697724

CONNECTOR X-232 - LH FRONT ROAD LAMP CONNECTOR X-232 - LH FRONT ROAD LAMP PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 712 VT LH BOOM TURN SIGNAL POWER B 767 (VT) LH BOOM LAMP TURN SIGNAL POWER C D 979 (BK) LH BOOM LAMPS GROUND CONNECTOR X-233 - RH FRONT ROAD LAMP CONNECTOR X-233 - RH FRONT ROAD LAMP PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 713 VT RH BOOM ROAD LAMPS SIGNAL B 764 (VT) RH BOOM TURN SIGNAL POWER C D 980 (BK) RH BOOM LAMPS GROUND

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Wire connectors - Component diagram 25 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-252 - TEMP CONTROL SW CONNECTOR X-252 - TEMP CONTROL SW PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 823 (PK) TEMPERATURE SWITCH POWER 2 824 (YE) HVAC TEMPERATURE CONTROL SIGNAL 3 912 (BK) HVAC TEMPERATURE SWITCH GROUND

87714670

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Wire connectors - Component diagram 27 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-270 - BLOWER SWITCH PIN NUMBER 1 2 3 4 5

CONNECTOR X-270 - BLOWER SWITCH WIRE NUMBER CIRCUIT REFERENCE 825 821 828 827 850

OR OR WH WH WH

HVAC CLUTCH BLOWER SWITCH POWER HVAC FAN LOW HVAC FAN MEDIUM HVAC FAN HIGH

CONNECTOR X-271 - WATER VALVE CONNECTOR X-271 - WATER VALVE WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER A B C D

822 OR 1013 (BK) 824 YE

E F

HVAC WATER VALVE POWER SP-179 X-271WATER VALVE HVAC TEMPERATURE CONTROL SIGNAL -

87694714

CONNECTOR X-275 - A/C SWITCH CONNECTOR X-275 - A/C SWITCH PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 825 (OR) HVAC CLUTCH B 913 (BK) HVAC COMPRESSOR CLUTCH SWITCH GROUND C 829 (WH) AC SWITCH OUT

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Wire connectors - Component diagram 30 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

84159859

CONNECTOR X-301 - BEACON LAMP SWITCH CONNECTOR X-301 - BEACON LAMP SWITCH PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 919 (BK) BEACON SWITCH INDICATOR GROUND B C D 761 (VT) BEACON SWITCH OUTPUT E 796 (VT) BEACON POWER

87697780

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CONNECTOR X-302 - HAZARD LAMP SWITCH CONNECTOR X-302 - HAZARD LAMP SWITCH WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER A 776 (VT) B C

784 (OR) 920 (BK)

E F

785 (OR) 778 (VT)

HAZARD SW LH TURN SIGNAL OUTPUT LH HAZARD FLASHER POWER IN HAZARD SWITCH INDICATOR GROUND RH HAZARD FLASHER POWER IN HAZARD SW RH TURN SIGNAL OUTPUT

84159858

CONNECTOR X-303 - HI FLOW SWITCH CONNECTOR X-303 - HI FLOW SWITCH PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 755 (WH) HIGH PERFORMANCE HIGH FLOW SIGNAL B 753 (OR) HIGH FLOW SWITCH IN C 750 (WH) STANDARD HIGH FLOW SIGNAL D E 921 (BK) HIGH FLOW SWITCH INDICATOR GROUND

87693037

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CONNECTOR X-306 - LOADER LOCKOUT SW CONNECTOR X-306 - LOADER LOCKOUT SW WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER A 312 (YE)

B C

311 (OR) 398 (YE)

D E

924 (BK)

LOADER LOCK SWITCH NORMALLY CLOSED OUTPUT (VALVE ON) LOADER LOCKOUT SWITCH IN LOADER LOCK SWITCH NORMALLY OPEN OUTPUT (VALVE OFF) LOADER LOCK SWITCH INDICATOR GROUND

87693037

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Wire connectors - Component diagram 31 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-310 - 2SPEED INDICATOR CONNECTOR X-310 - 2SPEED INDICATOR WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 1 2 3 4 5 6 7

565 (VT)

8 9 10

917 (BK) -

X-CC3AMECHANICAL CAB/CHASSIS INTERFACE -3[CAB] X-3102SPEED INDICATOR SP-025 X-3102SPEED INDICATOR -

84159859

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CONNECTOR X-311 - LIGHT SELECTOR SWITCH CONNECTOR X-311 - LIGHT SELECTOR SWITCH WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER A 790 (VT)

791 (VT)

792 (VT)

123 (OR)

X-CC1AMECHANICAL CAB/CHASSIS INTERFACE -1[CAB] X-311LIGHT SELECTOR SWITCH X-CC1AMECHANICAL CAB/CHASSIS INTERFACE -1[CAB] X-311LIGHT SELECTOR SWITCH X-CC3AMECHANICAL CAB/CHASSIS INTERFACE -3[CAB] X-311LIGHT SELECTOR SWITCH X-CC3AMECHANICAL CAB/CHASSIS INTERFACE -3[CAB] X-311LIGHT SELECTOR SWITCH

87697741

CONNECTOR X-316 - IGNITION BACKFEED DIODE CONNECTOR X-316 - IGNITION BACKFEED DIODE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 133A (OR) X-316IGNITION BACKFEED DIODE X-CC2BMECHANICAL CHASSIS/CAB INTERFACE 2 B 144 (OR) X-FUSE1POWER DISTRIBUTIONCHASSIS X-316IGNITION BACKFEED DIODE

84120021

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CONNECTOR X-317 - SELF LEVEL SWITCH CONNECTOR X-317 - SELF LEVEL SWITCH WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER A 404 (WH)

B E

405 (OR) 922 (BK)

X-CC3AMECHANICAL CAB/CHASSIS INTERFACE -3[CAB] X-317SELF LEVEL SWITCH X-317SELF LEVEL SWITCH SP-058 SP-026 X-317SELF LEVEL SWITCH

87693037

CONNECTOR X-318 - SELF LEVEL VALVE CONNECTOR X-318 - SELF LEVEL VALVE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 404 (WH) X-CC3AMECHANICAL CAB/CHASSIS INTERFACE -3[CAB] X-317SELF LEVEL SWITCH 2 949 (BK) X-318SELF LEVEL VALVE SP-178

87695582

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Wire connectors - Component diagram 33 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-330 - RIGHT SPEAKER CONNECTOR X-330 - RIGHT SPEAKER PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 451 (WH) X-335RADIO CONNECTOR X-330RIGHT SPEAKER

87697629

CONNECTOR X-331 - RIGHT SPEAKER CONNECTOR X-331 - RIGHT SPEAKER PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 450 (BL) X-335RADIO CONNECTOR X-331RIGHT SPEAKER

87697629

CONNECTOR X-332 - LEFT SPEAKER CONNECTOR X-332 - LEFT SPEAKER PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 453 (WH) X-335RADIO CONNECTOR X-332LEFT SPEAKER

87697629

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Electrical systems - Harnesses and connectors

CONNECTOR X-333 - LEFT SPEAKER CONNECTOR X-333 - LEFT SPEAKER WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 1 452 (BL)

X-335RADIO CONNECTOR X-333LEFT SPEAKER

87697629

CONNECTOR X-335 - RADIO CONNECTOR CONNECTOR X-335 - RADIO CONNECTOR PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 2 452 (BL) X-335RADIO CONNECTOR X-333LEFT SPEAKER 4 451 (WH) X-335RADIO CONNECTOR X-330RIGHT SPEAKER 5 450 (BL) X-335RADIO CONNECTOR X-331RIGHT SPEAKER 6 453 (WH) X-335RADIO CONNECTOR X-332LEFT SPEAKER 7 934 (BK) X-335RADIO CONNECTOR SP-026 9 130 (OR) X-335RADIO CONNECTOR SP-021

84257494

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Wire connectors - Component diagram 36 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-365 - NH PARK BRAKE SWITCH CONNECTOR X-365 - NH PARK BRAKE SWITCH PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 2 305 (YE) RH CONSOLE PARK BRAKE SWITCH 3 306 (YE) PARK BRAKE SWITCHOUT 4 5 6 7 8 9 10

84159859

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 40 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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 WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 324 (OR) RH GRIP PARK BRAKE SWITCH POWER 2 307 (YE) RH GRIP PARK BRAKE SWITCH OUTPUT 3 4 832 (OR) RIDE CONTROL VALVE SOLENOID SWITCH POWER 5 831 (WH) RIDE CONTROL VALVE SOLENOID SWITCH GROUND 6 7 8 699 (PK) EH AUX PROPORTIONAL SWITCH SIGNAL OUTPUT 9 1010 (BK/WH) EH AUX PROPORTIONAL SWITCH SIGNAL GROUND 10 331 (OR) EH AUX PROPORTIONAL SWITCH SIGNAL REFERENCE VOLTAGE

87382922

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Electrical systems - Harnesses and connectors

CONNECTOR X-405 - LH HANDLE INTERCONNECT HORN/TWO SPEED CONNECTOR X-405 - LH HANDLE INTERCONNECT HORN/TWO SPEED PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 891 (OR) LH GRIP HORN/2 SPEED SWITCH POWER B 892 (WH) HORN POWER SIGNAL C D 563 (WH) 2 SPEED SWITCH OUTPUT SIGNALD

87697723

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 43 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-430 - EH AUX PWM CONTROLLER CONNECTOR X-430 - EH AUX PWM CONTROLLER PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 319 (OR) EH AUX POWER 2 901 (BK/WH) CLEAN ENGINE GROUND 3 889 (WH) EH AUX EXTEND SIGNAL 4 890 (WH) EH AUX RETRACT SIGNAL 5 1009 (BL) EH AUX VALVE SIGNAL RETURN 6 699 (PK) EH AUX PROPORTIONAL SWITCH SIGNAL OUTPUT 7 1010 (BK/WH) EH AUX PROPORTIONAL SWITCH GROUND 8 331 (OR) EH AUX PROPORTIONAL SWITCH REFERENCE VOLTAGE

87700325

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Electrical systems - Harnesses and connectors

CONNECTOR X-432 - PROPORTIONAL AUX VALVE RETRACT CONNECTOR X-432 - PROPORTIONAL AUX VALVE RETRACT PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 890 (WH) EH AUX RETRACT VALVE 2 914 (BL) EH AUX RETRACT GROUND

87695582

CONNECTOR X-433 - PROPORTIONAL AUX VALVE EXTEND CONNECTOR X-433 - PROPORTIONAL AUX VALVE EXTEND PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 889 (WH) EH AUX EXTEND SIGNAL 2 911 (BL) EH AUX EXTEND GROUND

87695582

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 50 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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 227 929 231 220

(WH) (BK) (OR) (YE)

DOOR WIPER MOTOR SIGNAL DOOR WIPER MOTOR GROUND DOOR WIPER MOTOR PARK DOOR SWITCH BYPASS

87697724

87693712

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Electrical systems - Harnesses and connectors

CONNECTOR X-503 - WIPER/WASHER SWITCH CONNECTOR X-503 - WIPER/WASHER SWITCH WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 1 931 (BK) 2

225 (WH)

229 (OR)

5 6

224 (WH) 230 (OR)

7 8

226 (VT) 932 (BK)

87716755

CONNECTOR X-505 - CAB/DOOR SWITCH INTERFACE CONNECTOR X-505 - CAB/DOOR SWITCH INTERFACE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 250 (YE) DOOR SWITCH SIGNAL 2 1016 (BK/WH) DOOR SWITCH GROUND

87382906

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Electrical systems - Harnesses and connectors

CONNECTOR X-506 - FRONT WASHER PUMP CONNECTOR X-506 - FRONT WASHER PUMP WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 1 970 (BK) 2 224 (WH)

WASHER PUMP GROUND WASHER PUMP SIGNAL

87699736

CONNECTOR X-508 - AIRFLT CONNECTOR X-508 - AIRFLT PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 267 YE AIR FILTER RESTRICTION/ ENGINE MALFUNCTION 2 907 (BK) AIR FILTER SWITCH GROUND

84607243

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 60 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-605 - GCU FUSE CONNECTOR X-605 - GCU FUSE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 605 (RD) X-605GCU FUSE X-003ENGINE GLOW RELAY

84399575

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Wire connectors - Component diagram 82 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-827 INJECTOR 1 CONNECTOR X-827 INJECTOR 1 PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 803 OR INJECTOR POWER 1 X-002A PIN 49 2 804 GY INJECTOR 1 X-002A PIN 74 CONNECTOR X-828 INJECTOR 2 CONNECTOR X-828 INJECTOR 2 PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 805 OR INJECTOR POWER 2 X-002A PIN 1 2 806 GY INJECTOR 2 X-002A PIN 3 CONNECTOR X-829 INJECTOR 3 CONNECTOR X-829 INJECTOR 3 PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 807 OR INJECTOR POWER 3 X-002A PIN 25 2 808 GY INJECTOR 3 X-002A PIN 26

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Wire connectors - Component diagram 83 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-830 INJECTOR 4 CONNECTOR X-830 INJECTOR 4 PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 809 OR INJECTOR POWER 4 X-002A PIN 73 2 810 GY INJECTOR 4 X-002A PIN 51

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Wire connectors - Component diagram 90 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-902 - X-902 CONNECTOR X-902 - X-902 WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER A B C D

1157 (BK) 1156 (BK) 1158 (BK) 947 (BK)

E F

FRONT CHASSIS GROUND B FRONT CHASSIS GROUND B OPTION RELAY COIL GROUND MAIN POWER RELAY COIL GROUND

87697790

CONNECTOR X-903 CONNECTOR X-903 PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 1155 (BK) OPTION RELAY COIL GROUND B 1154 (BK) OPTION RELAY COIL GROUND C D E F

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CONNECTOR X-904 - BOOM LOCK INTERLOCK SWITCH CONNECTOR X-904 - BOOM LOCK INTERLOCK SWITCH PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 1103 (WH) BOOM LOCK VALVE DRIVE B 1102 (OR) BOOM LOCK VALVE POWER C

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CONNECTOR X-905 - BOOM LOCK VALVE CONNECTOR X-905 - BOOM LOCK VALVE WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 1 1103 (WH) 2 1104 (BK)

BOOM LOCK VALVE DRIVE BOOM LOCK VALVE GROUND

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Wire connectors - Component Diagram 00 – Connectors A – T L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-AUX_EXT 2ND AUX EXTEND CONNECTOR X-AUX_EXT 2ND AUX EXTEND PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 544 WH 2ND AUX EXTEND SWITCH OUTPUT 2 958 BK 2ND AUX EXTEND GND

SL57_87695582

CONNECTOR X-AUX_RET 2ND AUX RETRACT CONNECTOR X-AUX_RET 2ND AUX RETRACT PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 552 WH 2ND AUX RETRACT SIGNAL POWER 2 959 BK 2ND AUX RETRACT GND

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Electrical systems - Harnesses and connectors

CONNECTOR X-BRK BRAKE VALVE SOLENOID CONNECTOR X-BRK BRAKE VALVE SOLENOID WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 1 258 WH 2 960 BK

PARK BRAKE VALVE SIGNAL BRAKE SOLENOID GROUND

SL57_87695582

CONNECTOR X-BRKPRS BRAKE PRESSURE SWITCH CONNECTOR X-BRKPRS BRAKE PRESSURE SWITCH PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 535 YE PARK BRAKE PRESSURE SWITCH 2 1064 BK PARK BRAKE PRESSURE SWITCH GROUND 3

SL57_87680689

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Electrical systems - Harnesses and connectors

CONNECTOR X-CPLR HYDRAULIC COUPLER VALVE SOLENOID CONNECTOR X-CPLR HYDRAULIC COUPLER VALVE SOLENOID PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 752 WH HYDRAULIC COUPLER SIGNAL (X-ECC5B/5A PIN 8) 2 978 BK COUPLER VALVE SOLENOID GROUND

SL57_87695582

CONNECTOR X-HFLO HIGH FLOW VALVE SOLENOID CONNECTOR X-HFLO HIGH FLOW VALVE SOLENOID PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 750 WH STANDARD HIGH FLOW SIGNAL 2 976 BK HIGH FLOW VALVE SOLENOID GND

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Electrical systems - Harnesses and connectors

CONNECTOR X-PLTLK PILOT INTERLOCK CONNECTOR X-HFLO HIGH FLOW VALVE SOLENOID PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A 536 WH LOADER PILOT INTERLOCK B 1063 BL LOADER PILOT INTERLOCK GROUND

87691549

CONNECTOR X-PORT_LK PORT LOCK CONNECTOR X-PORT_LK PORT LOCK PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 304 WH HYDRAULIC LOADER INTERLOCK SIGNAL 2 976 BK HYDRAULIC LOADER INTERLOCK GND

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Electrical systems - Harnesses and connectors

CONNECTOR X-RDCTRL RIDE CONTROL VALVE SOLENOID CONNECTOR X-RDCTRL RIDE CONTROL VALVE SOLENOID PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 831 WH RIDE CONTROL VALVE SOLENOID SIGNAL 2 951 BK RIDE CONTROL VALVE GROUND

SL57_87695582

CONNECTOR X-RRJMPRA CHASSIS/REAR LAMP JUMPER INTERFACE CONNECTOR X-RRJMPRA CHASSIS/REAR LAMP JUMPER INTERFACE PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 706 VT REAR WORK LAMP FUSE OUT 2 704 VT TAIL LAMP SPLICE RH TAIL LAMP FUSE OUT 3 703 VT LAMP FUSE OUT 4 950 BK REAR LAMP GROUND

87382914

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CONNECTOR X-TELE TELEMATICS 12 PIN CONNECTOR PIN NUMBER 1 2 3 4 5 6 7 8 9 10 11 12

CONNECTOR X-TELE TELEMATICS WIRE NUMBER CIRCUIT REFERENCE 925 BK/WH 802 OR 503D YE 503D GN

TELEMATICS GROUND TELEMATICS IGNITION POWER CAN HI CAN LO

244 YE

ALTERNATOR LAMP TELEMATICS ENGINE ON

308 YE 336 RD

VEHICLE WORKING CONDITION TELEMATICS UNSWITCHED BATTERY

87700156

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CONNECTOR X-TELE TELEMATICS 16 PIN CONNECTOR CONNECTOR X-TELE TELEMATICS WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER A 336 RD B C D E F G H J K L M N P R S

802 OR 244 YE

TELEMATICS UNSWITCHED BATTERY

308 YE

TELEMATICS IGNITION POWER ALTERNATOR LAMP TELEMATICS ENGINE ON VEHICLE WORKING CONDITION

925 BK/WH

TELEMATICS GROUND

503D YE 504D GN

CAN HI CAN LO

205A

87696550

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Wire connectors - Component diagram 01 – UCM Connectors CN1 – CN4 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-CN1A UCM CONNECTOR PIN NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

CONNECTOR X-CN1A UCM CONNECTOR WIRE NUMBER CIRCUIT REFERENCE 1075 BK/WH

UCM GROUND

1076 BK/WH 202 PK 200 PK

UCM GROUND SENSOR SUPPLY 1 SENSOR SUPPLY 3

1018 BL 525 YE

BUCKET RETURN UCM WAKE-UP

124 YE

ENGINE RPM SIGNAL

1022 BL 189 RD

REV DRIVE RETURN UCM UNSWITCHED BATTERY

1020 BL

PROPORTIONAL AUX RETURN

515 WH

PROPORTIONAL AUX RETRACT

240 OR

5V REF SUPPLY

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CONNECTOR X-CN1B UCM CONNECTOR PIN NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

CONNECTOR X-CN1B UCM CONNECTOR WIRE NUMBER CIRCUIT REFERENCE 1026 BK/WH

UCM GROUND

1025 BK/WH

UCM GROUND

560 GN

RH UA2 Y SENSOR OUTPUT

521 YE

CONTROL PATTERN NEUTRAL

128 OR

SWITCHED POWER PROP AUX EXTEND SWITCHED POWER PROP AUX RETRACT

126 OR

28 29 30 31 32 33 34

580 579 166 201 514

VT VT OR OR WH

BRAKE LAMP CIRCUIT OUTPUT #2 BRAKE LAMP CIRCUIT OUTPUT #1 SWITCHED POWER BRAKE LAMP RH UA2 SENSOR OUTPUT PROPORTIONAL AUX EXTEND

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Electrical systems - Harnesses and connectors

CONNECTOR X-CN2A UCM CONNECTOR PIN NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

CONNECTOR X-CN2A UCM CONNECTOR WIRE NUMBER CIRCUIT REFERENCE

164 165 536 537

OR OR WH WH

LEFT PUMP REVERSE POWER RIGHT PUMP REVERSE POWER LOADER PILOT INTERLOCK LOADER PORT INTERLOCK

159 OR 518WH

SW POWER PORT/ PILOT LOCK PUMP RIGHT REVERSE

163 OR 517 WH

SW POWER PORT/ PILOT LOCK PUMP LEFT REVERSE

1103 YE

BOOM LOCK SIGNAL

1077 BK/WH

UCM GROUND

1024 BL

PATTERN INDICATOR H LS OUTPUT

1027 BK/WH

UCM GROUND

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CONNECTOR X-CN2B UCM CONNECTOR CONNECTOR X-CN2B UCM CONNECTOR WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 1 503E YE 2 1023 BL 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

CAN HI PATTERN INDICATOR ISO LS OUTPUT

1019 BL

LOADER RETURN

154 OR 504E GN

SW POWER LOADER CONTROL CAN LO

535 YE 562 GN

PARK BRAKE PRESSURE SWITCH LH UA2 X SENSOR OUTPUT

158 OR

SWITCHED POWER LOADER CONTROL

522 523 754 398

622D WH 1021 BL 1028 BK/WH 531 YE 547 YE

CONTROL PATTERN H CONTROL PATTERN ISO PARK BRAKE SWITCH LOADER LOCKOUT SWITCH N/O OUTPUT ENGINE START INPUT DRIVE FORWARD RETURN UCM GROUND LOADER FLOAT SWITCH INPUT PROPORTIONAL AUX SWITCH #2

568 GN 576 YE 575 YE 1029 BK/WH

LH UA2 Y SENSOR OUTPUT RH PUMP ANGLE #1 RH PUMP ANGLE #2 UCM GROUND

YE YE YE YE

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CONNECTOR X-CN3A UCM CONNECTOR PIN NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

CONNECTOR X-CN3A UCM CONNECTOR WIRE NUMBER CIRCUIT REFERENCE

168 OR 169 OR 258 WH

SWITCHED POWER PARK BRAKE SWITCHED POWER PARK BRAKE PARK BRAKE VALVE SIGNAL

170 OR

SWITCHED POWER TWO SPEED

574 YE 573 YE 548 GN

LH PUMP ANGLE #1 LH PUMP ANGLE #2 RH UA2 X SENSOR OUT

171 OR

SWITCHED POWER TWO SPEED

1030 BK/WH 120 OR 512 WH 303 WH

UCM GROUND PUMP FORWARD POWER LOADER LOWER SIGNAL HYDRAULIC LOADER INTERLOCK SIGNAL

564 WH 1031 BK/WH

2 SPEED VALVE SOLENOID UCM GROUND

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CONNECTOR X-CN3B UCM CONNECTOR PIN NUMBER 1 2 3 4 5 6 7 8 9 10 11 12

CONNECTOR X-CN3B UCM CONNECTOR WIRE NUMBER CIRCUIT REFERENCE

167 OR

SW POWER BACKUP ALARM

513 WH

LOADER RAISE SIGNAL

142 OR 147 OR

SW POWER BUCKET CONTROL SW POWER BUCKET CONTROL

755 WH 570 YE

571 YE

14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

572 YE

HIGH FLOW SIGNAL CONTROL VALVE BUCKET POSITION CONTROL VALVE LOADER POSITION CONTROL VALVE AUX POSITION

510 WH 895 WH 312 YE

BUCKET RETRACT SIGNAL BACKUP ALARM SIGNAL LOADER LOCK SWITCH N/C OUT

1032 BK/WH

UCM GROUND

526 YE

SEAT SW OPERATOR INTERLOCK

519 WH 516 WH 1033 BK/WH

PUMP RIGHT FORWARD PUMP LEFT FORWARD UCM GROUND

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Electrical systems - Harnesses and connectors

CONNECTOR X-CN4A UCM CONNECTOR CONNECTOR X-CN4A UCM CONNECTOR WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 1 0060 OR

SWITCHED POWER BUCKET CONTROL

2 3 4 5 6 7 8

0061 OR

SWITCHED POWER BUCKET CONTROL

9 10

527 YE

SEAT BELT OPERATOR INTERLOCK

561 WH 569 WH 511 WH 1034 BK/WH

RH UA1 Y SENSOR OUT LH UA1 Y SENSOR OUT BUCKET EXTEND SIGNAL UCM GROUND

549 WH 567 WH 1035 BK/WH

RH UA1 X SENSOR OUT LH UA1 SENSOR OUT UCM GROUND

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

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CONNECTOR X-CN4B UCM CONNECTOR PIN NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

CONNECTOR X-CN4B UCM CONNECTOR WIRE NUMBER CIRCUIT REFERENCE

423 YE

EHF INTERLOCK

541 YE

2 SPEED UCM INPUT

546 YE

PROPORTIONAL AUX SWITCH #1

1036 BK/WH

UCM GROUND

1037 BK/WH

UCM GROUND

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Wire connectors - Component diagram 02 – Chassis/Cab Interface Connectors ECC1 – ECC7 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-ECC1A CHASSIS/CAB INTERFACE HARNESS CONNECTOR X-ECC1A CHASSIS/CAB INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 797 VT LIGHT RELAY #1 WORK LAMP POWER 2 795 VT SIDE LAMP POWER SIGNAL 3 503 YE CAN HI 4 504 GN CAN LO 5 791 VT LAMP SW ROAD LAMP SIGNAL 6 314 YE LAP BAR/ SEAT BELT CLUSTER INPUT 7 910 BK/WH INSTRUMENT CLUSTER GROUND 8 234 YE FUEL LEVEL SENDER 9 357 OR MAIN POWER RELAY IGNITION FUSE 10 115 RD BEACON AND ACCESSORY FUSE OUTPUT 11 264 YE HYDRAULIC OIL TEMP SENSOR 12 310 RD UNSWITCHED BATTERY POWER 13 545 YE FOOT THROTTLE SIGNAL 14 790 VT LAMP SW WORK LAMP SIGNAL

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Electrical systems - Harnesses and connectors

CONNECTOR X-ECC1B CHASSIS/CAB INTERFACE HARNESS CONNECTOR X-ECC1B CHASSIS/CAB INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 798 VT LIGHT RELAY #1 WORK LAMP POWER 2 795 VT SIDE LAMP POWER SIGNAL 3 503A YE CAN HI 4 504A GN CAN LO 5 791 VT ROAD LAMP SIGNAL 6 314 YE LAP BAR/ SEAT BELT CLUSTER INPUT 7 966 BK/WH CLEAN GROUND 8 234 YE FUEL LEVEL SENDER 9 357 OR MAIN POWER RELAY IGNITION FUSE 10 115 RD BEACON AND ACCESSORY FUSE OUTPUT 11 264 YE HYDRAULIC OIL TEMP SENSOR 12 310 RD UNSWITCHED BATTERY POWER 13 545 YE FOOT THROTTLE SIGNAL 14 790 VT LAMP SW WORK LAMP SIGNAL

84398821

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Electrical systems - Harnesses and connectors

CONNECTOR X-ECC2A CHASSIS/CAB INTERFACE HARNESS CONNECTOR X-ECC2A CHASSIS/CAB INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 134 OR WIPER/ SEAT ACC/ RADIO/ DOME LAMP/ DEFROST SW/ HVAC RELAY SELF LEVEL SW POWER 2 3 329 YE SEAT SWITCH UCM INPUT 4 309 OR INSTRUMENT CLUSTER SWITCH POWER 5 303 WH HYDRAULIC LOADER INTERLOCK SIGNAL 6 261 YE HYDRAULIC OIL FILTER 7 267 YE AIR FILTER/ ENGINE MALFUNCTION 8 1066 BK/WH FOOT THROTTLE SENSOR GROUND 9 843 OR HVAC FUSE TO HVAC BOX-VOLTAGE DROP PARALLEL CIRCUIT 10 622 WH START RELAY SIGNAL 11 133 OR MAIN POWER RELAY SIGNAL 12 175 WH EH ACC RELAY CHASSIS INTERFACE SIGNAL 13 211 PK FOOT THROTTLE SENSOR SUPPLY 14 822 OR HVAC WATER VALVE POWER

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Electrical systems - Harnesses and connectors

CONNECTOR X-ECC2B CHASSIS/CAB INTERFACE HARNESS CONNECTOR X-ECC2B CHASSIS/CAB INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 134 OR WIPER/ SEAT ACC/ RADIO/ DOME LAMP/ DEFROST SW/ HVAC RELAY SELF LEVEL SW POWER 2 3 329 YE SEAT SWITCH UCM INPUT 4 309 OR INSTRUMENT CLUSTER SWITCH POWER 5 303 WH HYDRAULIC LOADER INTERLOCK SIGNAL 6 261 YE HYDRAULIC OIL FILTER 7 267 YE AIR FILTER/ ENGINE MALFUNCTION 8 1066 BK/WH FOOT THROTTLE SENSOR GROUND 9 843 OR HVAC FUSE TO HVAC BOX-VOLTAGE DROP PARALLEL CIRCUIT 10 622 WH START RELAY SIGNAL 11 133A OR MAIN POWER RELAY SIGNAL 12 175 WH EH ACC RELAY CHASSIS INTERFACE SIGNAL 13 211 PK FOOT THROTTLE SENSOR SUPPLY 14 822 OR HVAC WATER VALVE POWER

87382926

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Electrical systems - Harnesses and connectors

CONNECTOR X-ECC3A CHASSIS/CAB INTERFACE HARNESS CONNECTOR X-ECC3A CHASSIS/CAB INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 404 WH SELF LEVEL SW OUTPUT POWER 2 248 YE EGR K-LINE 3 824 YE HVAC TEMPERATURE CONTROL SIGNAL 4 1090 BK/WH UJM SENSOR GROUNDS 5 792 VT LAMP SW WORK AND SIDE LAMP SIGNAL 6 1023 BL PATTERN INDICATOR ISO LS OUTPUT 7 833 WH THERMOSTAT TO BINARY PRESSURE SW 8 1024 BL PATTERN INDICATOR H LS OUTPUT 9 754 YE PARK BRAKE SW 10 123 OR LAMP SW POWER 11 541 YE 2 SPEED UCM INPUT 12 531 YE LOADER FLOAT SW INPUT 13 834 WH BINARY PRESSURE SW TO COMPRESSOR RELAY PIN 86 14 844 OR HVAC FUSE TO HVAC BOX-VOLTAGE DROP PARA

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Electrical systems - Harnesses and connectors

CONNECTOR X-ECC3B CHASSIS/CAB INTERFACE HARNESS CONNECTOR X-ECC3B CHASSIS/CAB INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 404 WH SELF LEVEL SW OUTPUT POWER 2 121 YE EGR K-LINE 3 824 YE HVAC TEMPERATURE CONTROL SIGNAL 4 1090 BK/WH UJM SENSOR GROUNDS 5 792 VT LAMP SW WORK AND SIDE LAMP SIGNAL 6 1023 BL PATTERN INDICATOR ISO LS OUTPUT 7 833 WH THERMOSTAT TO BINARY PRESSURE SW 8 1024 BL PATTERN INDICATOR H LS OUTPUT 9 754 YE PARK BRAKE SW 10 123 OR UNSWITCHED BATTERY POWER 11 541 YE 2 SPEED UCM INPUT 12 531 YE LOADER FLOAT SW INPUT 13 834 WH BINARY PRESSURE SW TO COMPRESSOR RELAY PIN 86 14 844 OR HVAC FUSE TO HVAC BOX-VOLTAGE DROP PARA

84394890

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Electrical systems - Harnesses and connectors

CONNECTOR X-ECC4A CHASSIS/CAB INTERFACE HARNESS CONNECTOR X-ECC4A CHASSIS/CAB INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 769 OR FLASHER MODULE OUTPUT POWER 2 774 VT LH TURN SIGNAL CHASSIS POWER 3 398 YE LOADER LOCKOUT SW N/O OUTPUT (VALVE OFF) 4 521 YE CONTROL PATTERN NEUTRAL 5 237 WH HVAC CONDENSER FAN POWER 6 780 VT RH TURN SIGNAL CHASSIS POWER 7 841 OR A/C COMPRESSOR RELAY PIN 87 POWER 8 836 RD COMPRESSOR/CONDENSER FAN FUSE 9 522 YE CONTROL PATTERN H 10 233 OR WIPER/WASHER SW POWER 11 523 YE CONTROL PATTERN ISO 12 312 YE LOADER LOCK SW N/C OUTPUT (VALVE ON) 13 548 GN RH UA2 X SENSOR OUTPUT 14 560 GN RH UA2 Y SENSOR OUTPUT

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Electrical systems - Harnesses and connectors

CONNECTOR X-ECC4B CHASSIS/CAB INTERFACE HARNESS CONNECTOR X-ECC4B CHASSIS/CAB INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 769 OR FLASHER MODULE OUTPUT POWER 2 774 VT LH TURN SIGNAL CHASSIS POWER 3 398 YE LOADER LOCKOUT SW N/O OUTPUT (VALVE OFF) 4 521 YE CONTROL PATTERN NEUTRAL 5 237 WH HVAC CONDENSER FAN POWER 6 780 VT RH TURN SIGNAL CHASSIS POWER 7 841 OR A/C COMPRESSOR RELAY PIN 87 POWER 8 836 RD COMPRESSOR/CONDENSER FAN FUSE 9 522 YE CONTROL PATTERN H 10 233 OR WIPER/WASHER SW POWER 11 523 YE CONTROL PATTERN ISO 12 312 YE LOADER LOCK SW N/C OUTPUT (VALVE ON) 13 548 GN RH UA2 X SENSOR OUTPUT 14 560 GN RH UA2 Y SENSOR OUTPUT

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Electrical systems - Harnesses and connectors

CONNECTOR X-ECC5A CHASSIS/CAB INTERFACE HARNESS CONNECTOR X-ECC5A CHASSIS/CAB INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 129 OR AUX ELEC ON/OFF SW IN 2 856 WH AUX ELEC ON/OFF SW SIGNAL 3 549 WH RH UA1 X SENSOR OUTPUT 4 744 OR HIGH FLOW/ HYDRAULIC COUPLER SW POWER 5 752 WH HYDRAULIC COUPLER SIGNAL 6 755 WH HIGH PERFORMANCE HIGH FLOW SIGNAL 7 831 WH RIDE CONTROL VALVE SOLENOID SIGNAL 8 750 WH STANDARD HIGH FLOW SIGNAL 9 561 WH RH UA1 Y SENSOR OUTPUT 10 1051 BK/WH UJM SENSOR GROUNDS 11 562 GN UA2 X SENSOR OUTPUT 12 568 GN UA2 Y SENSOR OUTPUT 13 554 WH 2ND AUX EXTEND SW OUTPUT 14 552 WH 2ND AUX RETRACT SIGNAL POWER

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Electrical systems - Harnesses and connectors

CONNECTOR X-ECC5B CHASSIS/CAB INTERFACE HARNESS CONNECTOR X-ECC5B CHASSIS/CAB INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 129 OR AUX ELEC ON/OFF SW IN 2 856 WH AUX ELEC ON/OFF SW SIGNAL 3 549 WH RH UA1 X SENSOR OUTPUT 4 744 OR HIGH FLOW/ HYDRAULIC COUPLER SW POWER 5 752 WH HYDRAULIC COUPLER SIGNAL 6 755 WH HIGH PERFORMANCE HIGH FLOW SIGNAL 7 831 WH RIDE CONTROL VALVE SOLENOID SIGNAL 8 750 WH STANDARD HIGH FLOW SIGNAL 9 561 WH RH UA1 Y SENSOR OUTPUT 10 1051 BK/WH UJM SENSOR GROUNDS 11 562 GN LH UA2 X SENSOR OUTPUT 12 568 GN LH UA2 Y SENSOR OUTPUT 13 554 WH 2ND AUX EXTEND SW OUTPUT 14 552 WH 2ND AUX RETRACT SIGNAL POWER

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Electrical systems - Harnesses and connectors

CONNECTOR X-ECC6A CHASSIS/CAB INTERFACE HARNESS CONNECTOR X-ECC6A CHASSIS/CAB INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 567 WH LH UA1 X SENSOR OUTPUT 2 569 WH LH UA1 Y SENSOR OUTPUT 3 354 OR HANDLE MULTIFUNCTION #1, #2, #3 POWER 4 410 WH RH HANDLE MULTIFUNCTION #1 UP 5 411 TN RH HANDLE MULTIFUNCTION #1 DOWN 6 416 VT HANDLE MULTIFUNCTION #2 UP 7 417 RD HANDLE MULTIFUNCTION #2 DOWN 8 418 GY LH HANDLE MULTIFUNCTION #3 UP 9 419 LG LH HANDLE MULTIFUNCTION #3 DOWN 10 892 WH HORN POWER SIGNAL 11 546 YE PROPORTIONAL AUX SW OUTPUT SIGNAL #1 12 210 PK CAB SENSOR SUPPLY 1 13 200 PK SENSOR SUPPLY 3 14 547 YE PROPORTIONAL AUX SW OUTPUT SIGNAL #2

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Electrical systems - Harnesses and connectors

CONNECTOR X-ECC6B CHASSIS/CAB INTERFACE HARNESS CONNECTOR X-ECC6B CHASSIS/CAB INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 567 WH LH UA1 X SENSOR OUTPUT 2 569 WH LH UA1 Y SENSOR OUTPUT 3 407 OR HANDLE MULTIFUNCTION #1, #2, #3 POWER 4 410 WH RH HANDLE MULTIFUNCTION #1 UP 5 411 TN RH HANDLE MULTIFUNCTION #1 DOWN 6 416 VT HANDLE MULTIFUNCTION #2 UP 7 417 RD HANDLE MULTIFUNCTION #2 DOWN 8 418 GY LH HANDLE MULTIFUNCTION #3 UP 9 419 LG LH HANDLE MULTIFUNCTION #3 DOWN 10 892 WH HORN POWER SIGNAL 11 546 YE PROPORTIONAL AUX SW OUTPUT SIGNAL #1 12 210 PK CAB SENSOR SUPPLY 1 13 200 PK SENSOR SUPPLY 3 14 547 YE PROPORTIONAL AUX SW OUTPUT SIGNAL #2

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Electrical systems - Harnesses and connectors

CONNECTOR X-ECC7A CHASSIS/CAB INTERFACE HARNESS CONNECTOR X-ECC7A CHASSIS/CAB INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 2 507A WH CAN 2 HI 3 508A BL CAN 2 LO 4 CONNECTOR X-ECC7B CHASSIS/CAB INTERFACE HARNESS CONNECTOR X-ECC7B CHASSIS/CAB INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 205C YE REGENERATION INHIBIT SW 2 507 WH CAN 2 HI 3 508 BL CAN 2 LO 4

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 03 – Fuse Power Distribution L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

CONNECTOR X-FUSE1 POWER DISTRIBUTION CONNECTOR X-FUSE1 POWER DISTRIBUTION PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER A1 830 OR HVAC RELAY FUSE POWER A2 820 OR HVAC RELAY FUSE POWER A3 119 RD TELEMATICS UNSWITCHED BATTERY A4 336 RD TELEMATICS UNSWITCHED BATTERY A5 401 RD MULTIFUNCTION FUSE IN A6 420 OR MULTIFUNCTION FUSE POWER A7 707 VT LIGHT RELAY #2 PIN 87 SIDE LAMP SWITCH REAR WORK LAMP OUTPUT A8 A9 945 BK LIGHT RELAY #2 PIN 85 COIL GROUND A10 116 RD LIGHT RELAY #1 PIN 87 UNSWITCHED POWER A11 710 VT ROAD LAMP CONFIGURATION FRONT WORK LAMP CONTROL SIGNAL TERMINAL 87A A12 946 BK LIGHT RELAY #1 PIN 85 COIL GROUND B1 183 OR UCM BACKUP ALARM FUSE IN B2 167 OR SWITCH POWER BACKUP ALARM B3 403 OR AUX ELEC ON/OFF FUSE IN B4 129 OR AUX ELEC ON/OFF SW IN B5 402 OR HANDLE MF #1, #2, #3 FUSE IN B6 407 OR HANDLE MF #1, #2, #3 POWER B7 709 WH LAMP SWITCH WORK AND SIDE LAMP SIGNAL AND SIDE LAMP FUSE OUT TERMINAL 86 B8 B9 113 RD LIGHT RELAY #2 PIN 30 UNSWITCHED POWER B10 325 WH LIGHTS RELAY #1 TERMINAL 86 B11 B12 788 VT LIGHT RELAY #1 PIN 30 FUSE (FRONT WORK LAMP POWER) C1 135 OR ACCESSORY RELAY PIN 87 OUTPUT POWER C2 134 OR WIPER/ SEAT ACC/ RADIO/ DOME LAMP/DFRST SW/HVAC RELAY/ SELF LEVEL SW POWER C3 350 OR MAIN POWER RELAY PIN 87 OUTPUT C4 351 OR MAIN POWER RELAY IGNITION FUSE C5 835 OR COMPRESSOR/ CONDENSER FAN FUSE C6 836 OR COMPRESSOR/ CONDENSER FAN FUSE

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CONNECTOR X-FUSE1 POWER DISTRIBUTION WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER C7 136 OR

MAIN POWER RELAY PIN 87 OUTPUT

C8 C9

947 BK

C10

125 OR

C11 C12

948 BK

D1 D2 D3

160 RD 310 RD 326 OR

300 OR

114 RD

115 RD

D7 D8 D9 D10 D11 D12 E1

144 OR

ACCESSORY RELAY PIN 85 COIL GROUND UNSWITCHED BATTERY POWER UNSWITCHED BATTERY POWER MAIN POWER RELAY IGNITION FUSE MAIN POWER RELAY PIN 87 OUTPUT BEACON AND ACCESSORY FUSE OUTPUT BEACON AND ACCESSORY FUSE OUTPUT MAIN POWER RELAY SIGNAL

118 RD 139 OR

MAIN POWER RELAY TERMINAL 30 ACCESSORY RELAY TERMINAL 86

117 OR 788 VT

797 VT

792 VT

708 VT

E5 E6 E7

705 VT 706 VT 701 VT

703 VT

700 VT

E10

704 VT

E11 E12

255 RD 256 RD

ACCESSORY RELAY TERMINAL 30 LIGHT RELAY #1 PIN 30 TO FUSE (FRONT WORK LAMP POWER) LIGHT RELAY #1 FRONT WORK LAMP POWER LAMP SWITCH WORK AND SIDE LAMP SIGNAL LAMP SW WORK AND SIDE LAMP SIGNAL AND SIDE LAMP FUSE OUT REAR WORK LAMPS REAR WORK LAMPS TAIL LAMP SPLICE LH TAIL FUSE IN TAIL LAMP SPLICE LH TAIL LAMP FUSE OUT TAIL LAMP SPLICE RH TAIL LAMP FUSE IN TAIL LAMP SPLICE RH TAIL LAMP FUSE OUT CRANK RELAY PIN 30 POWER CRANK RELAY PIN 30 POWER

MAIN POWER RELAY PIN 85 COIL GROUND ACCESSORY RELAY PIN 87 OUTPUT POWER

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CONNECTOR X-FUSE2 POWER DISTRIBUTION PIN NUMBER A1 A2 A3 A4 A5 A6 A7

CONNECTOR X-FUSE2 POWER DISTRIBUTION WIRE NUMBER CIRCUIT REFERENCE 173 172 184 185 187 122 190

OR OR OR OR OR OR OR

UCM BRAKE LAMP FUSE IN SWITCHED POWER BRAKE LAMP UCM PARK BRAKE FUSE IN SWITCHED POWER PARK BRAKE UCM PUMP REVERSE FUSE IN SPLICE SP-152 UCM POWER RELAY PIN 87 OUTPUT

A8 A9

1067 BK

A10

743 OR

A11 A12

972 BK

B1 B2 B3 B4 B5 B6 B7

174 177 203 120 181 178 335

B8 B9

193 RD

B10

141 WH

B11 B12 C1 C2 C3

104 356 603 180

C4 C5

182 OR 188 RD

189 RD

C7 C8 C9 C10

400 OR

FRONT ELECTRIC RELAY TERMINAL 87

C11 C12

974 BK

D1 D2 D3 D4

355 354 204 176

FRONT ELECTRIC RELAY COIL GROUND TERMINAL 85 BATTERY + ECU BACKUP POWER UCM BUCKET FUSE IN SPLICE SP-111

OR OR OR OR OR OR WH

RD RD RD OR

RD RD OR OR

UCM POWER RELAY PIN 85 GROUND HIGH FLOW/ HYDRAULIC COUPLER SWITCH POWER OPTION RELAY TERMINAL 87 OPTION RELAY COIL GROUND TERMINAL 85 PROPORTIONAL AUX FUSE IN SPLICE SP-109 UCM PUMP FORWARD FUSE IN PUMP FORWARD POWER UCM LOADER FUSE IN SPLICE SP-110 UCM POWER RELAY PIN 86 SIGNAL UCM POWER RELAY PIN 30 UNSWITCHED POWER OPTION RELAY SIGNAL TERMINAL 86 OPTION RELAY TERMINAL 30 BATTERY + ECU MAIN RELAY COIL POWER UCM PORT/PILOT INTERLOCK FUSE IN SPLICE SP-112 UCM UNSWITCHED BATTERY FUSE IN UCM UNSWITCHED BATTERY FUSE OUT

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CONNECTOR X-FUSE2 POWER DISTRIBUTION WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER D5 243 OR D6 D7 D8 D9 D10

233 OR

WIPER/WASHER SWITCH POWER FROM ACC RELAY WIPER/WASHER SWITCH POWER

146 WH

FRONT ELECTRIC RELAY COIL SIGNAL TERMINAL 86

D11 D12

103 RD

E1 E2 E3 E4 E5

145 OR 104A OR 186 OR 179 OR 714 VT

E6 E7

716 VT 715 VT

E8 E9

719 VT 157 RD

E10 E11

156 RD 743 OR

E12

744 OR

FRONT ELECTRIC RELAY TERMINAL 30 MAIN ECU POWER MAIN ECU POWER UCM 2SPD FUSE IN UCM 2SPD FUSE OUT ROAD LAMP CONFIGURATION BOOM LAMP CONTROL SIGNAL LH BOOM ROAD LAMPS SIGNAL ROAD LAMP CONFIGURATION BOOM LAMP CONTROL SIGNAL RH BOOM ROAD LAMPS SIGNAL CHASSIS OPTIONS HARNESS BATTERY POWER FLASHER/BRAKE POWER HIGH FLOW/ HYDRAULIC COUPLER SWITCH POWER HIGH FLOW/ HYDRAULIC COUPLER SWITCH POWER

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Wire connectors - Component Diagram 00 – Connectors B – T L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-BRK BRAKE VALVE SOLENOID CONNECTOR X-BRK BRAKE VALVE SOLENOID PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 258 WH PARK BRAKE VALVE SIGNAL 2 960 BK BRAKE SOLENOID GROUND

SL57_87695582

CONNECTOR X-PORT_LK PORT LOCK CONNECTOR X-PORT_LK PORT LOCK PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 304 WH HYDRAULIC LOADER INTERLOCK SIGNAL 2 976 BK HYDRAULIC LOADER INTERLOCK GND

SL57_87695582

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87382914

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CONNECTOR X-TELE TELEMATICS 12 PIN CONNECTOR PIN NUMBER 1 2 3 4 5 6 7 8 9 10 11 12

CONNECTOR X-TELE TELEMATICS WIRE NUMBER CIRCUIT REFERENCE 925 BK/WH 802 OR 503D YE 503D GN

TELEMATICS GROUND TELEMATICS IGNITION POWER CAN HI CAN LO

244 YE

ALTERNATOR LAMP TELEMATICS ENGINE ON

308 YE 336 RD

VEHICLE WORKING CONDITION TELEMATICS UNSWITCHED BATTERY

87700156

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CONNECTOR X-TELE TELEMATICS 16 PIN CONNECTOR CONNECTOR X-TELE TELEMATICS WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER A 336 RD B C D E F G H J K L M N P R S

802 OR 244 YE

TELEMATICS UNSWITCHED BATTERY

308 YE

TELEMATICS IGNITION POWER ALTERNATOR LAMP TELEMATICS ENGINE ON VEHICLE WORKING CONDITION

925 BK/WH

TELEMATICS GROUND

503D YE 504D GN

CAN HI CAN LO

205A

87696550

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Wire connectors - Component diagram 02 – Chassis/Cab Interface Connectors CNN1 – CO2 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-CC1A CHASSIS/CAB INTERFACE HARNESS CONNECTOR X-CC1A CHASSIS/CAB INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 797 VT LAMP POWER 2 795 VT POWER SIGNAL 3 248 YE EGR ECU K-LINE 4 503 YE CAN HI 5 791 VT ROAD LAMP SIGNAL 6 205C YE TELE CRANK DIS 7 910 BK/WH INSTRUMENT CLUSTER GROUND 8 234 YE FUEL LEVEL SENDER 9 319 OR EH AUX POWER 10 115 RD BEAC AND ACC FUSE OP 11 264 YE HYDRAULIC OIL TEMP SENDER 12 310 RD UNSWITCHED BATTERY POWER 13 545 YE FOOT THROTTLE SIGNAL 14 790 VT LAMP SWITCH WORK LAMP SIGNAL

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CONNECTOR X-CC1B CHASSIS/CAB INTERFACE HARNESS CONNECTOR X-CC1B CHASSIS/CAB INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 797 VT WORK LAMP POWER 2 795 VT SIDE LAMP POWER SIGNAL 3 248 YE DIAG SW TO ECU 4 503A YE CAN HI 5 791 VT ROAD LAMP SIGNAL 6 7 910 BK/WH INSTRUMENT CLUSTER GROUND 8 234 RD FUEL LEVEL SENDER 9 319 OR EH AUX POWER 10 115 RD BEAC AND ACC FUSE OP 11 264 YE UNSWITCHED BATTERY TO HYDRAULIC OIL TEMP SENDER 12 310 RD UNSWITCHED BATTERY POWER 13 545 YE FOOT THROTTLE SIGNAL 14 790 VT LAMP SWITCH WORK LAMP SIGNAL

84398821

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CONNECTOR X-CC2A CHASSIS/CAB INTERFACE HARNESS CONNECTOR X-CC2A CHASSIS/CAB INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 134 OR UNSWITCHED BATTERY POWER 2 3 258 WH PARK BRAKE VALVE SIGNAL 4 309 OR INSTRUMENT CLUSTER SWITCHED POWER 5 303 WH HYDRAULIC LOADER INTERLOCK SIGNAL 6 261 YE HYDRAULIC OIL FILTER 7 267 YE AIR FILTER/ ENGINE MALFUNCTION 8 1066 BK/WH FOOT THROTTLE SENSOR GROUND 9 843 RD HVAC FUSE TO HVAC BOX 10 622 OR ENGINE START SWITCH 11 133A OR MAIN POWER RELAY POWER 12 139 OR ACCESSORY RELAY SIGNAL 13 211 PK FOOT THROTTLE SENSOR SUPPLY 14 822 OR HVAC WATER VALVE POWER

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CONNECTOR X-CC2B CHASSIS/CAB INTERFACE HARNESS CONNECTOR X-CC2B CHASSIS/CAB INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 134 OR UNSWITCHED BATTERY POWER 2 3 258 WH PARK BRAKE VALVE SIGNAL 4 309 OR INSTRUMENT CLUSTER SWITCHED POWER 5 303 WH HYDRAULIC LOADER INTERLOCK SIGNAL 6 261 YE HYDRAULIC OIL FILTER 7 267 YE AIR FILTER/ ENGINE MALFUNCTION 8 1066 BK/WH FOOT THROTTLE SENSOR GROUND 9 843 RD HVAC FUSE TO HVAC BOX 10 622 OR ENGINE START SWITCH 11 133 OR MAIN POWER RELAY POWER 12 139 OR ACCESSORY RELAY SIGNAL 13 211 PK FOOT THROTTLE SENSOR SUPPLY 14 822 OR HVAC WATER VALVE POWER

87382926

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CONNECTOR X-CC3A CHASSIS/CAB INTERFACE HARNESS CONNECTOR X-CC3A CHASSIS/CAB INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 404 WH SELF LVL SWITCH POWER 2 565 VT 2 SPEED INDICATOR 3 824 YE HVAC TEMPERATURE CONTROL SIGNAL 4 504 GN CAN LO 5 792 VT LAMP SWITCH WORK AND SIDE LAMP SIGNAL 6 841 WH A/C COMPRESSOR RELAY PIN 87 POWER 7 833 WH PRESSURE SWITCH 8 844 OR HVAC FUSE TO HVAC BOX 9 307 YE RH GRIP PARK BRAKE SWITCH OUTPUT 10 123 OR UNSWITCHED BATTERY POWER 11 237 WH HVAC CONDENSER FAN POWER 12 836 RD COMP/ CONDENSER FAN FUSE 13 834 WH BINARY PRESSURE SWITCH TO COMP RELAY PIN 86 14 233 OR WIPER/WASHER SWITCHED POWER

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CONNECTOR X-CC3B CHASSIS/CAB INTERFACE HARNESS CONNECTOR X-CC3B CHASSIS/CAB INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 404 WH SELF LVL SWITCH POWER 2 565 VT 2 SPEED INDICATOR 3 824 YE HVAC TEMPERATURE CONTROL SIGNAL 4 504A GN CAN LO 5 792 VT LAMP SWITCH WORK AND SIDE LAMP SIGNAL 6 841 WH A/C COMPRESSOR RELAY PIN 87 POWER 7 833 WH PRESSURE SWITCH 8 844 OR HVAC FUSE TO HVAC BOX 9 307 YE RH GRIP PARK BRAKE SWITCH OUTPUT 10 123 OR UNSWITCHED BATTERY POWER 11 237 WH HVAC CONDENSER FAN POWER 12 836 RD COMP/ CONDENSER FAN FUSE 13 834 WH BINARY PRESSURE SWITCH TO COMP RELAY PIN 86 14 233 OR WIPER/WASHER SWITCHED POWER

84394890

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CONNECTOR X-ECC7A CHASSIS/CAB INTERFACE HARNESS CONNECTOR X-ECC7A CHASSIS/CAB INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 2 507 WH CAN 2 HI 3 508 BL CAN 2 LO 4 CONNECTOR X-ECC7B CHASSIS/CAB INTERFACE HARNESS CONNECTOR X-ECC7B CHASSIS/CAB INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 205C YE 2 507A WH CAN 2 HI 3 508A BL CAN 2 LO 4

SL57_87382915

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CONNECTOR X-CO1A CHASSIS/OPTIONS INTERFACE HARNESS CONNECTOR X-CO1A CHASSIS/OPTIONS INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 782 OR FLASHER POWER OUT 2 774 VT LH TURN SIGNAL CHASSIS POWER 3 4 5 311 WH LOADER LOCKOUT SWITCH IN 6 780 VT RH TURN SIGNAL CHASSIS POWER 7 312 WH LOADER LOCK SWITCH OUT 8 9 10 141 WH OPTIONS RELAY SIGNAL

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CONNECTOR X-CO1B CHASSIS/OPTIONS INTERFACE HARNESS CONNECTOR X-CO1B CHASSIS/OPTIONS INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 782 OR FLASHER POWER OUT 2 774 VT LH TURN SIGNAL CHASSIS POWER 3 4 5 311 WH LOADER LOCKOUT SWITCH IN 6 780 VT RH TURN SIGNAL CHASSIS POWER 7 312 WH LOADER LOCK SWITCH OUT 8 9 10 141 WH OPTIONS RELAY SIGNAL

SL57_87382925

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CONNECTOR X-CO2A CHASSIS/OPTIONS INTERFACE HARNESS CONNECTOR X-CO2A CHASSIS/OPTIONS INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 425 VT LH HANDLE MULTIFUNCTION #2 UP 2 359 OR LH HANDLE MULTIFUNCTION #2, #3 POWER 3 427 RD LH HANDLE MULTIFUNCTION #2 DOWN 4 751 OR HYDRAULIC COUPLER SW IN 5 752 WH HYDRAULIC COUPLER SIGNAL 6 7 753 OR HIGH FLOW SWITCH IN 8 750 WH STANDARD HIGH FLOW SIGNAL 9 10

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CONNECTOR X-CO2B CHASSIS/OPTIONS INTERFACE HARNESS CONNECTOR X-CO2B CHASSIS/CAB INTERFACE HARNESS PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 425 VT LH HANDLE MULTIFUNCTION #2 UP 2 359 OR AUX ELEC ON/OFF SIGNAL 3 427 RD LH HANDLE MULTIFUNCTION #2 DOWN 4 751 OR UNSWITCHED BATTERY POWER 5 752 WH HYDRAULIC COUPLER SIGNAL 6 7 753 OR UNSWITCHED BATTERY POWER 8 750 WH STANDARD HIGH FLOW SIGNAL 9 10

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Wire connectors - Component diagram 03 – Fuse Power Distribution L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

CONNECTOR X-FUSE1 POWER DISTRIBUTION PIN NUMBER A1 A2 A3 A4 A5 A6 A7

CONNECTOR X-FUSE1 POWER DISTRIBUTION WIRE NUMBER CIRCUIT REFERENCE RD RD RD OR OR OR VT

HVAC FUSE POWER HVAC FUSE POWER BATTERY POWER ECU BACKUP POWER BATTERY + ECU MAIN POWER COIL POWER LIGHT RELAY #2 PIN 87 SIDE LAMP SWITCH REAR WORK LAMP OUTPUT

A8 A9

945 BK

A10 A11

116 RD 710 VT

A12 B1 B2

946 BK 243 OR 233 OR

114A RD

336 RD

B5 B6

604 RD 603 OR

709 VT

LIGHTS RELAY #2 COIL GROUND TERMINAL 85 LIGHT UNSWITCHED POWER ROAD LAMP CONFIG FRONT WORK LAMP CONTROL SIGNAL LIGHTS RELAY #1 COIL GROUND SWITCH POWER WIPER/ WASHER SWITCHED POWER TELEMATICS UNSWITCHED BATTERY TELEMATICS UNSWITCHED BATTERY ECU RELAY POWER ECU MAIN RELAY COIL CONTROL POWER LAMP FUSE OUT LIGHTS RELAY #2 TERMINAL 86

B8 B9 B10 B11 B12

830 820 608 607 222 104 707

113 RD 325 VT

LIGHT UNSWITCHED POWER LIGHTS RELAY #1 TERMINAL 86

788 VT

LIGHTS RELAY #1 PIN 30 TO FUSE (FRONT WORK LAMP POWER) ACCESSORY FUSE IN UNSWITCHED BATTERY POWER UNSWITCHED BATTERY MAIN POWER RELAY IGNITION FUSE COMPRESSOR FUSE IN COMP/ CONDENSER FAN FUSE UNSWITCHED BATTERY SIGNAL MAIN POWER RELAY TERMINAL 87

C1 C2 C3 C4

135 134 350 351

OR OR OR OR

C5 C6 C7

835 RD 836 RD 136 OR

C8 C9

947 BK

C10

125 OR

MAIN POWER RELAY COIL GROUND TERMINAL 85 UNSWITCHED BATTERY POWER ACCESSORY RELAY TERMINAL 87

C11

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CONNECTOR X-FUSE1 POWER DISTRIBUTION WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 948 BK C12 D1 D2 D3 D4

160 310 326 300

RD RD OR OR

114 RD

115 RD

D7 D8 D9

144 OR

D10

139 OR

D11 D12

117 RD

788 VT

E2 E3

797 VT 792 VT

E4 E5 E6 E7 E8 E9 E10

708 705 706 701 703 700 704

E11 E12

255 RD 256 RD

118 RD

VT VT VT VT VT VT VT

ACCESSORY RELAY COIL GROUND TERMINAL 85 UNSWITCHED BATTERY POWER UNSWITCHED BATTERY POWER UNSWITCHED BATTERY POWER INSTRUMENT CLUSTER UNSWITCHED BATTERY POWER ACCESSORY/ BEACON FUSE POWER IN ACCESSORY/ BEACON FUSE POWER OUT MAIN POWER RELAY SIGNAL MAIN POWER RELAY PIN 30 UNSWITCHED BATTERY ACC RELAY UNSWITCHED POWER TERMINAL 30 ACC RELAY UNSWITCHED POWER TERMINAL 30 LIGHT RELAY #1 PIN 30 TO FUSE (FRONT WORK LAMP POWER) WORK LAMP POWER LAMP SWITCH WORK AND SIDE LAMP SIGNAL LAMP FUSE OUT REAR WORK LAMP FUSE IN REAR WORK LAMP FUSE OUT LAMP FUSE IN LAMP FUSE OUT LAMP FUSE IN TAIL LAMP SPLICE RH TAIL LAMP FUSE OUT CRANK RELAY CRANK RELAY PIN 30

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CONNECTOR X-FUSE2 POWER DISTRIBUTION CONNECTOR X-FUSE2 POWER DISTRIBUTION WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 743 OR

FRONT ELECTRIC RELAY UNSWITCHED BATTERY POWER TERMINAL 87

A11 A12

972 BK

OPTION RELAY COIL GROUND OPTION RELAY TERMINAL 85

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10

148 WH

OPTION RELAY COIL SIGNAL TERMINAL 86

B11 B12

100B RD

356 OR

420 OR

OPTION RELAY UNSWITCHED BATTERY RELAY TERMINAL 30 UNSWITCHED BATTERY POWER FE HOT IN UNSWITCHED BATTERY POWER FE HOT OUT

C3 C4 C5 C6 C7 C8 C9 C10

149 OR

UNSWITCHED BATTERY POWER FRONT ELECTRIC RELAY TERMINAL 87

C11 C12

974 BK

355 OR

354 OR

FRONT ELECTRIC RELAY COIL GROUND TERMINAL 85 UNSWITCHED BATTERY POWER FE #1, #2, #3 IN UNSWITCHED BATTERY POWER FE #1, #2, #3 OUT

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CONNECTOR X-FUSE2 POWER DISTRIBUTION WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER D7 D8 D9 D10 146 WH D11 D12

100A RD

145 OR

129 OR

E3 E4 E5

714 VT

716 VT

715 VT

719 VT

101 RD

E10

156 RD

E11

743 OR

E12

744 OR

FRONT ELECTRIC RELAY COIL SIGNAL TERMINAL 86 FRONT ELECTRIC RELAY UNSWITCHED POWER TERMINAL 30 UNSWITCHED BATTERY POWER FE ON/OFF FUSE IN UNSWITCHED BATTERY POWER FE ON/OFF FUSE OUT

LH BOOM ROAD LAMP FUSE POWER IN LH BOOM ROAD LAMP FUSE POWER OUT RH BOOM ROAD LAMP FUSE POWER IN RH BOOM ROAD LAMP FUSE POWER OUT FLASHER/ BRAKE FUSE POWER IN FLASHER/ BRAKE FUSE POWER OUT UNSWITCHED BATTERY POWER HIGH FLOW/ COUPLER FUSE IN UNSWITCHED BATTERY POWER HIGH FLOW/ COUPLER FUSE OUT

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Fuse and relay box Relay - Overview L218 L220

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 L218 L220

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 localisation 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

Fuse and relay configuration for the fuse block located in the cab area.

RAIL13SSL0616EA

RAIL13SSL0617EA

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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 5 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.

Relay configuration for the relay block located in the engine area. 1. Crank relay 2. ECU relay

RAIL13SSL0094AA

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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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Wire harnesses - Repair L218 L220

WE WE

NOTE: For Wiring Harness replacement, see Wire harnesses - Replace (55.100) 1. Temporary Wiring Harness Repair The following method to repair wiring is a temporary expedient only. Wiring should be replaced as soon as possible. Do not attempt to repair the wire on any system sensors as these are sealed and should only be replaced with a new component. NOTE: When conducting a cable repair it is important that only RESIN CORED SOLDER is used. Use of other types of solder may result in further cable damage. 2. To carry out a temporary repair, proceed as follows:Locate damaged portion of cable then cut away outer protective cover on both sides of the damaged area.

1Z0O2004112111

1Z0O2004112112

1Z0O2004112113

3. Peel back the cable from both ends of the damaged area and carefully cut away the inner cable cover at the damaged area and strip about 13 mm ( 1/2 in) of insulation from the wires. Do not cut away any wire strands. Using a suitable solvent, clean about 2 in ( 50 mm) from each cover end. Clean the grey cable cover and the individual leads. Twist two bare leads together for each damaged lead, being careful to match wire colours, then solder the leads using resin cored solder. Tape each repaired lead with vinyl insulation tape.

4. Wind a layer of vinyl insulation tape up to the grey cable cover at each end of the repair section. Make a paper trough, then apply silicon rubber compound (non hardening sealant) over the repaired section up to the cover ends. Sufficient sealant must be used to fill the ends of the cut away area.

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5. Allow the compound to cure then cover the area with insulating tape taking the tape well over each end of the repair. An overlap of at least 2 in ( 50 mm) of tape at each end is necessary. Check to ensure the repair is satisfactory and secure the repaired cable so that repeat damage is avoided. NOTE: This is a temporary repair only. Ensure the damaged cable is replaced as soon as possible to prevent ingress of water or chemicals.

1Z0O2004112114

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Wire harnesses - Replace L218 L220

WE WE

NOTE: For Wiring Harness repair, see Wire harnesses - Repair (55.100) 1. If a wire within the harness is found to be beyond repair or is open circuit, a jumper wire may be installed as a temporary repair until such time when a new harness assembly can be installed. Use the following procedure to install an additional wire: Locate the faulty wire using the procedures described in the fault code charts. Disconnect the affected connectors. If fitted carefully roll back the seal between the connector and harness outer covering. Remove the pins from the connector blocks of the affected wire using the appropriate removal tool found in the harness repair kit. NOTE: Use the instructions supplied with the kit to ensure correct pin removal.

1Z0O2004112115

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2. From the harness repair kit select the correct pin for the connectors. Obtain locally the correct cross-sectional size wire and measure out the length required by following the harness routing. Join the new wire to the new pins as described in the harness repair kit and install one of the pins into its connector. If possible attempt to run the new wire within the existing harness outer covering, if this is not possible run the wire along the harness, securing regularly with suitable ties. With the wire correctly routed instal the second terminal into its connector block. Replace the connector seal if removed. To ensure that the repair has been effective check for continuity of the new wire using a suitable multi-meter. NOTE: This is a temporary repair only. Ensure the damaged cable is replaced as soon as possible to prevent ingress of water or chemicals.

1Z0O2004112116

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Index Electrical systems - 55 Harnesses and connectors - 100 Wire harnesses - Electrical schematic sheet 02 Accessory Power Distribution - Mechanical Units (*) . . . . . . . . . 10 Wire harnesses - Electrical schematic sheet 03 Ignition/ Charging System - Mechanical Units (*) . . . . . . . . . . . . 12 Wire harnesses - Electrical schematic sheet 04 Grounding System - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . 14 Wire harnesses - Electrical schematic sheet 05 Engine ISM - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . 16 Wire harnesses - Electrical schematic sheet 06 Engine ISM - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . 18 Wire harnesses - Electrical schematic sheet 07 Engine ISM - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . 20 Wire harnesses - Electrical schematic sheet 08 Throttle Sensors - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . 22 Wire harnesses - Electrical schematic sheet 09 Auxiliary Hydraulic Interlock Switch - Mechanical Units (*) . . . . 24 Wire harnesses - Electrical schematic sheet 10 Bulkhead Connection - Mechanical Units (*) . . . . . . . . . . . . . . . . 26 Wire harnesses - Electrical schematic sheet 11 Left Hand Cab Console - Mechanical Units (*) . . . . . . . . . . . . . . . 28 Wire harnesses - Electrical schematic sheet 12 Left Hand Control Handle - Mechanical Units (*) . . . . . . . . . . . . . 30 Wire harnesses - Electrical schematic sheet 13 Right Hand Control Handle - Mechanical Units (*) . . . . . . . . . . . 32 Wire harnesses - Electrical schematic sheet 11 Left Hand Cab Console - Mechanical Units (*) . . . . . . . . . . . . . . . 34 Wire harnesses - Electrical schematic sheet 12 Left Hand Control Handle - Mechanical Units (*) . . . . . . . . . . . . . 36 Wire harnesses - Electrical schematic sheet 13 Right Hand Control Handle - Mechanical Units (*) . . . . . . . . . . . 38 Wire harnesses - Electrical schematic sheet 14 Seat - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Wire harnesses - Electrical schematic sheet 15 EH Aux PWM - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . 42 Wire harnesses - Electrical schematic sheet 16 Lamps - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Wire harnesses - Electrical schematic sheet 17 Indicators - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Wire harnesses - Electrical schematic sheet 18 EU Light Adapter - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . 48 Wire harnesses - Electrical schematic sheet 19 Boom And Road Lights - Mechanical Units (*) . . . . . . . . . . . . . . . 50 Wire harnesses - Electrical schematic sheet 20 Wipers/ Washers - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . 52 Wire harnesses - Electrical schematic sheet 21 Instrument Cluster - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . 54 Wire harnesses - Electrical schematic sheet 22 HVAC - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Wire harnesses - Electrical schematic sheet 23 Radio - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Wire harnesses - Electrical schematic sheet 24 Multifunction Connectors - Mechanical Units (*) . . . . . . . . . . . . . 60 Wire harnesses - Electrical schematic sheet 25 Telematics - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Wire harnesses - Electrical schematic sheet 26 Multifunction Jumper - Mechanical Units (*) . . . . . . . . . . . . . . . . . 64 Wire harnesses - Electrical schematic sheet 27 Diagnostic Connector - Mechanical Units (*) . . . . . . . . . . . . . . . . 66 Wire harnesses - Electrical schematic sheet 28 Boom Lock Valve - Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . 68 Wire harnesses - Electrical schematic sheet 01 Main Power Distribution - EH Units (*) . . . . . . . . . . . . . . . . . . . . . 70 Wire harnesses - Electrical schematic sheet 02 Accessory Power Distribution - EH Units (*) . . . . . . . . . . . . . . . . 72 Wire harnesses - Electrical schematic sheet 03 Ignition/ Charging System - EH Units (*) . . . . . . . . . . . . . . . . . . . . 74

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Wire harnesses - Electrical schematic sheet 04 Grounding System - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Wire harnesses - Electrical schematic sheet 05 Engine ISM HPCR - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Wire harnesses - Electrical schematic sheet 06 Engine ISM HPCR - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Wire harnesses - Electrical schematic sheet 07 Engine ISM HPCR - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Wire harnesses - Electrical schematic sheet 08 Throttle Sensors - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Wire harnesses - Electrical schematic sheet 09 ET Pump/ Hydraulics - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . 86 Wire harnesses - Electrical schematic sheet 10 Hydraulic Interlocks - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . 88 Wire harnesses - Electrical schematic sheet 11 Loader Valve And Sensors - EH Units (*) . . . . . . . . . . . . . . . . . . . 90 Wire harnesses - Electrical schematic sheet 12 Bulkhead Connection - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . 92 Wire harnesses - Electrical schematic sheet 13 Bulkhead Connection - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . 94 Wire harnesses - Electrical schematic sheet 14 Bulkhead Connection - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . 96 Wire harnesses - Electrical schematic sheet 15 Left Hand Cab Console - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . 98 Wire harnesses - Electrical schematic sheet 16 Left Control Handle - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . 100 Wire harnesses - Electrical schematic sheet 17 Right Hand Control Handle - EH Units (*) . . . . . . . . . . . . . . . . . . 102 Wire harnesses - Electrical schematic sheet 15 Left Hand Cab Console - EH Units (*) . . . . . . . . . . . . . . . . . . . . . 104 Wire harnesses - Electrical schematic sheet 16 Left Hand Control Handle - EH Units (*) . . . . . . . . . . . . . . . . . . . 106 Wire harnesses - Electrical schematic sheet 17 Right Hand Control Handle - EH Units (*) . . . . . . . . . . . . . . . . . . 108 Wire harnesses - Electrical schematic sheet 18 Right Hand Control Handle - EH Units (*) . . . . . . . . . . . . . . . . . . 110 Wire harnesses - Electrical schematic sheet 19 Unit Control Module - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . 112 Wire harnesses - Electrical schematic sheet 20 Unit Control Module - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . 114 Wire harnesses - Electrical schematic sheet 21 Lamps - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Wire harnesses - Electrical schematic sheet 22 Indicators - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Wire harnesses - Electrical schematic sheet 23 EU Light Adapter - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Wire harnesses - Electrical schematic sheet 24 Boom Road Lights - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . 122 Wire harnesses - Electrical schematic sheet 25 Wipers/ Washers - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Wire harnesses - Electrical schematic sheet 26 Instrument Cluster - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . 126 Wire harnesses - Electrical schematic sheet 27 HVAC - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Wire harnesses - Electrical schematic sheet 28 Radio - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Wire harnesses - Electrical schematic sheet 29 Multifunction On/ Off - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . 132 Wire harnesses - Electrical schematic sheet 29 Multifunction On/ Off - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . 134 Wire harnesses - Electrical schematic sheet 30 Multifunction Connectors - EH Units (*) . . . . . . . . . . . . . . . . . . . 136 Wire harnesses - Electrical schematic sheet 31 Telematics - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Wire harnesses - Electrical schematic sheet 32 Multifunction Jumper - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . 140 Wire harnesses - Electrical schematic sheet 33 2nd Aux - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Wire harnesses - Electrical schematic sheet 34 Diagnostic Connector - EH Units (*) . . . . . . . . . . . . . . . . . . . . . . 144 Fuse and relay box - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328 Fuse and relay box - General specification Relay and Fuse Identification - Medium Mechanical Machines (*) . . . 6 Fuse and relay box Fuse - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 Fuse and relay box Relay - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325 Wire connectors - Component Diagram 00 – Connectors A – T (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

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Wire connectors - Component Diagram 00 – Connectors B – T (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 Wire connectors - Component Diagram 00 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Wire connectors - Component Diagram 00 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 Wire connectors - Component diagram 01 – UCM Connectors CN1 – CN4 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 Wire connectors - Component diagram 01 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Wire connectors - Component diagram 01 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Wire connectors - Component diagram 02 – Chassis/Cab Interface Connectors CNN1 – CO2 (*) . . . . . . . . . . . 308 Wire connectors - Component diagram 02 – Chassis/Cab Interface Connectors ECC1 – ECC7 (*) . . . . . . . . . . 286 Wire connectors - Component diagram 02 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Wire connectors - Component diagram 02 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 Wire connectors - Component diagram 03 – Fuse Power Distribution (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319 Wire connectors - Component diagram 03 – Fuse Power Distribution (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299 Wire connectors - Component diagram 03 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Wire connectors - Component diagram 03 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 Wire connectors - Component diagram 04 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 Wire connectors - Component diagram 05 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Wire connectors - Component diagram 05 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 Wire connectors - Component diagram 07 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Wire connectors - Component diagram 07 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 Wire connectors - Component diagram 09 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Wire connectors - Component diagram 09 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 Wire connectors - Component diagram 10 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Wire connectors - Component diagram 10 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 Wire connectors - Component diagram 11 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Wire connectors - Component diagram 11 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 Wire connectors - Component diagram 12 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Wire connectors - Component diagram 12 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 Wire connectors - Component diagram 15 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Wire connectors - Component diagram 15 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 Wire connectors - Component diagram 17 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Wire connectors - Component diagram 17 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242 Wire connectors - Component diagram 19 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Wire connectors - Component diagram 19 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 Wire connectors - Component diagram 20 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Wire connectors - Component diagram 23 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Wire connectors - Component diagram 23 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 Wire connectors - Component diagram 25 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Wire connectors - Component diagram 25 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 Wire connectors - Component diagram 27 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Wire connectors - Component diagram 27 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

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Wire connectors - Component diagram 29 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 Wire connectors - Component diagram 30 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Wire connectors - Component diagram 30 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 Wire connectors - Component diagram 31 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 Wire connectors - Component diagram 31 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252 Wire connectors - Component diagram 32 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Wire connectors - Component diagram 33 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 Wire connectors - Component diagram 33 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 Wire connectors - Component diagram 36 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 Wire connectors - Component diagram 36 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257 Wire connectors - Component diagram 40 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 Wire connectors - Component diagram 40 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 Wire connectors - Component diagram 41 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 Wire connectors - Component diagram 43 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 Wire connectors - Component diagram 50 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 Wire connectors - Component diagram 50 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262 Wire connectors - Component diagram 60 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 Wire connectors - Component diagram 60 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265 Wire connectors - Component diagram 82 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266 Wire connectors - Component diagram 83 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 Wire connectors - Component diagram 90 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 Wire connectors - Component diagram 90 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268 Wire harnesses - Electrical schematic sheet 01 Main Power Distribution - Mechanical Units (*) . . . . . . . . . . . . . . . 8 Wire harnesses - Repair (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331 Wire harnesses - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

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Electrical systems - 55 Battery - 302

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Contents Electrical systems - 55 Battery - 302

SERVICE Battery Check Maintenance Free (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Disconnect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Connect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Battery - Check Maintenance Free L218 L220

WE WE

During normal use of a vehicle the battery is constantly being discharged, and recharged by the vehicle electrical systems. This process causes evaporation of the battery electrolyte. Maintenance free batteries have condenser channels that allow the gases to condense into liquids again. This prevents the gases from escaping through vent holes so there is no requirement to top off the electrolyte. The following procedure will tell if a battery is fit for service or if it must be replaced. 1. Inspect the battery before testing. Many conditions can be seen and corrected before battery problems occur. Inspect the battery case for cracks and leaks. Inspect the battery posts, cables and clamps for broken wires, loose connections and corrosion. Make sure the top of the battery is clean and dry. Dirt or electrolyte on top of a battery can cause the battery to discharge. This material on the top of a battery provides a path for current to flow, permitting the battery to discharge. 2. Remove the battery from the vehicle. Clean the outside of the battery. Also, clean the battery tray. When cleaning a battery, use a solution of baking soda and water. Check and clean the battery cables if necessary. 3. Check the battery carrier to make sure the carrier is in good condition. Check the battery brackets for the correct tension. A loose battery bracket will allow the battery to vibrate. Vibration will damage the battery. Battery brackets which are too tight can buckle or crack the battery case. 4. Check the battery for raised cell covers or a warped case. This may indicate that the battery has been overheated or overcharged. 5. Using a multi-meter check the battery voltage. A reading of less than 11.6 volts indicates the battery should be charged using a battery charger. If battery voltage is unable to be raised to approximately 12.4 volts, the battery should be replaced.

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Battery - Disconnect L218 L220

WE WE

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).

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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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4. Disconnect positive battery connection (1).

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Battery - Remove L218 L220

WE WE

Battery removal 1. Remove the battery cover hardware (1) and the battery cover (2).

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931001638

2. Turn battery disconnector (1) —if equipped— to the off position (2).

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3. Disconnect the negative cable connection (1).

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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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Battery - Install L218 L220

WE WE

Battery installation 1. Confirm that the battery quick disconnector (1) is in the off position (2), as shown. NOTE: The battery disconnector is optional.

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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).

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931001639

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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.

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8. Install the battery cover (2) and secure with the hardware (1).

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Battery - Connect L218 L220

WE WE

Connect battery 1. Turn battery disconnector (1) —if equipped— to the off position (2).

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2. Connect the positive battery connection (1).

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3. Connect the negative battery connection (1).

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4. Turn the battery disconnector (1)— if equipped— to the on position (2).

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Index Electrical systems - 55 Battery - 302 Battery - Check Maintenance Free (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Battery - Connect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Battery - Disconnect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Battery - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Battery - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Electrical systems - 55 External lighting - 404

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Contents Electrical systems - 55 External lighting - 404

FUNCTIONAL DATA Work light Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overview Resistance devices (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Work light - Overview L218 L220

WE WE

Switches are a vital part of an electric circuit. Switches may be configured to provide operator or operational information to an electronic controller or switches may be used to control circuit operation indirectly by energizing a control relay or switches may control the operation of a functional device directly by completing the power or ground side of the control circuit. Switches can be configured to control a number of different functional devices at the same time and / or multiple functional devices one at a time. This is achieved by having several separate functional devices connected to a single switch terminal or by having each of the separate functional devices connected to a different terminal (multiple switch positions).

RAPH12SSL0690BA

Operator controlled switches are typically toggle, rocker or potentiometer type devices. They may contain momentary and / or maintained contact arrangements, they may have more than two positions and may incorporate warning, position and / or backlighting. Switches can be as simple as a two position maintained contact rocker type used to turn on or turn off the hazard warning lights (switch also incorporates a warning light which illuminates when the hazard warning position is actuated) or as complex as the multi-position, multifunction, maintained and momentary contact selector type used to operate the parking lights, head lights to include high and low beam control, direction indicators and horn operation. Checking the operation of most of the operator controlled switches can be accomplished by using a multi-meter to test for continuity through the appropriate switch contacts, once the switch connector has been disconnected and the switch has been actuated or de-actuated. NOTE: A growing number of mechanically controlled devices are incorporating electronics to replace mechanical contacts and to allow for non-contact sensing. These devices are referred to as Sensors rather than Switches and often cannot be continuity tested with a multi-meter.

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Work light - Overview Resistance devices L218 L220

WE WE

1Z0O2004112128

A number of electrical components alter or make use of electricity through their resistance to current flow. Resistors are components which are generally used to regulate the supply of voltage and current to other electrical components. In some cases, the purpose of resistance in an electrical circuit is to provide light or heat. Lamps and cigar lighters (where equipped) are examples. Lamps convert electricity into light, and cigar lighters convert it into heat. Both lamps and lighters make use of the same physical principle, that is Ohms Law. Where applicable, the engine grid heater and heated cab mirrors are other examples of resistance devices designed to convert electricity into heat.

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Index Electrical systems - 55 External lighting - 404 Work light - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Work light - Overview Resistance devices (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - 55 Cab controls - 512

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Contents Electrical systems - 55 Cab controls - 512

TECHNICAL DATA Instrument cluster Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Cigarette lighter Overview Resistance devices (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Instrument cluster - Configure 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.

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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. • 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 47711684 06/05/2014

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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.

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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.

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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.

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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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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. 47711684 06/05/2014

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Electrical systems - Cab controls

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.

931002267

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Electrical systems - Cab controls

User codes Once in the SETUP menu, press the START button to move to the LOCK menu. Press the POWER button to enter the LOCK menu.

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.

931002267

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Electrical systems - Cab controls

Cigarette lighter - Overview Resistance devices L218 L220

WE WE

1Z0O2004112128

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Index Electrical systems - 55 Cab controls - 512 Cigarette lighter - Overview Resistance devices (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Instrument cluster - Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Cab engine controls - 525

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Electrical systems - 55 Cab engine controls - 525

FUNCTIONAL DATA Throttle control Overview Potentiometers (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Cab engine controls

Throttle control - Overview Potentiometers L218 L220

WE WE

20095585

93095586

Rotary to linear actuators contain a potentiometer used to provide position information.

1Z0O2004112130

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Electrical systems - Cab engine controls

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Index Electrical systems - 55 Cab engine controls - 525 Throttle control - Overview Potentiometers (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Electronic modules - 640

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Electrical systems - 55 Electronic modules - 640

SERVICE Electronic module Electrical test Engine Control Unit (ECU) verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Electronic modules

Electronic module - Electrical test Engine Control Unit (ECU) verification 1. Locate the Engine Control Unit (ECU). • Disconnect the harness from the ECU. Place the key switch ON. 2. Use a multimeter to check the power supply and ground reference circuits. • ECU harness connector X-002B pin 47 to connector X-002B pin 3. • ECU harness connector X-002B pin 48 to connector X-002B pin 4. • ECU harness connector X-002B pin 46 to connector X-002B pin 31. • ECU harness connector X-002B pin 5 to connector X-002B pin 1. • ECU harness connector X-002B pin 6 to connector X-002B pin 2. • ECU harness connector X-002B pin 46 to connector X-002B pin 18. The multimeter should read between 8 - 18 V. A. If any of the readings are incorrect, continue with 3. B. If the readings are correct continue with 5. 3. Check the power supply circuits of the Engine Control Unit (ECU) at the engine harness connector. Place the key switch ON. Use a multi-meter to measure the voltage from the harness side of: • ECU harness connector X-002B pin 47 to chassis ground. • ECU harness connector X-002B pin 48 to chassis ground. • ECU harness connector X-002B pin 46 to chassis ground. • ECU harness connector X-002B pin 5 to chassis ground. • ECU harness connector X-002B pin 6 to chassis ground. The multimeter should read between 8 - 18 V. A. If any of the readings are incorrect. Repair or replace the circuit to the ECU connector. B. If the readings are correct continue with 4.

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Electrical systems - Electronic modules

4. Check the ground circuits of the Engine Control Unit (ECU) at the engine harness connector. Place the key switch OFF. Use a multi-meter to check for continuity from the harness side of: • ECU harness connector X-002B pin 3 to chassis ground. • ECU harness connector X-002B pin 4 to chassis ground. • ECU harness connector X-002B pin 31 to chassis ground. • ECU harness connector X-002B pin 1 to chassis ground. • ECU harness connector X-002B pin 2 to chassis ground. • ECU harness connector X-002B pin 18 to chassis ground. There should be continuity. A. If any of the readings are incorrect. Repair or replace the circuit to the ECU connector. B. If the readings are correct continue with 5. 5. Use the Service Tool D to check the software level. • If the incorrect software level is installed. Install the correct software level. Test the system for proper operation. • If the correct software level is installed, replace the ECU. Install the current software level. Test the system to verify repairs.

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Index Electrical systems - 55 Electronic modules - 640 Electronic module - Electrical test Engine Control Unit (ECU) verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 FAULT CODES - DTC

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Electrical systems - 55 FAULT CODES - DTC

DIAGNOSTIC 1004-Hydraulic Filter Restriction Switch - Hydraulic Filter Restricted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1009-Hydraulic Oil Temperature Sender - Over Temperature >210° F . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1025-Throttle Sensor - Out Of Range Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1026-Hand Throttle Signal Out Of Range - Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 1030-Throttle Sensor - Out Of Range Short to Ground/ Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 1031-Hand Throttle Sensor - Short To Ground/ Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 1040-Engine overspeed warning, Engine speed greater than 2750 RPM for 5 seconds . . . . . . . . . . . . . 32 1044-Fuel level sensor below 2.0 ohm for 5 seconds, shorted low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 1045-Fuel Level Sensor Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 1051-Timeout of CAN message EEC1, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 1053-Timeout of CAN message CM1BC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 1054-Timeout of CAN message engine temperature, 5 seconds without message . . . . . . . . . . . . . . . . . 42 1056-Timeout of CAN message DPFC1, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 1058-Timeout of CAN message EDC2BC, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 1059-Timeout of CAN message DM1, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 1201-Hydraulic oil filter switch open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 1205-Hydraulic Enable (EH Machines) - Hydraulic Enable Output, Short to Power (*) . . . . . . . . . . . . . . 48 1212-Calibration Functions - Ground Drive Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 50 1213-Calibration Functions - Loader Valve Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 51 1214-Calibration Functions - Throttle Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 1221-Health Monitor Functions - UCM - UCM Temperature / Current Draw Over Limit (*) . . . . . . . . . . . 53 1222-Health Monitor Functions - UCM - UCM Sustained Over Temperature Limit (*) . . . . . . . . . . . . . . . 54 1223-Health Monitor Functions - UCM - UCM Sustained Over Current Limit (*) . . . . . . . . . . . . . . . . . . . . 55 1224-Health Monitor Functions - UCM - Internal Memory or Core Monitoring Fault (*) . . . . . . . . . . . . . . 56 1225-Health Monitor Functions - UCM - EEPROM Memory Checksum Fault (*) . . . . . . . . . . . . . . . . . . . 57 1350-Hyd Enable Switch - Implausible State (Hardwire vs CAN) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 1532-Backup Alarm - Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 1533-Backup Alarm - Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 1900-UCM - UCM Ground Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 1901-UCM - UCM Supply Voltage High (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

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1902-UCM - UCM Supply Voltage Low (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 1903-UCM - UCM Supply Voltage Below Operational Limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 1904-UCM - Rail 12VB: 5V Regulators Supply Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 1905-UCM - 5VREF1 Sensor Supply Voltage Out of Range (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 1906-UCM - 5VREF3 Sensor Supply Voltage Out of Range (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 1907-UCM - Rail 12VF1: Aux Retract Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 1908-UCM - Rail 12VF2: Bucket Extend Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 1909-UCM - Rail 12VF3: Boom Raise/Lower Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 1910-UCM - Rail 12VH: Ldr Plt Interlk & Port Lock Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 1911-UCM - Rail 12VH1: Left & Right Pump Reverse Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . 86 1912-UCM - Rail 12VM: Left & Right Brake Lights & Aux Extend Input Power Off (*) . . . . . . . . . . . . . . . 88 1913-UCM - Rail 12VS1: Bucket Curl Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 1914-UCM - Rail 12VS2: Backup Alarm Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 1915-UCM - Rail 12VT1: Two Speed Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 1916-UCM - Rail 12VU1: Right & Left Pumps Forward Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . 96 1917-UCM - Rail 12VU2: Park Brake Solenoid Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 3390-Engine Air Filter Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 4043-Hydraulic Oil Temperature Sender Short To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 4044-Hydraulic Oil Temperature Sender Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 4055-Park Brake Valve (On/Off) - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 4056-Park Brake Valve (On/Off) - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 109 4057-Park Brake Valve (On/Off) - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 4061-Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit (*) . . . . . . 113 4062-Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground (*) . . . 115 4071-Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit (*) . . . . . . . 117 4072-Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground (*) . . . . 119 4081-Forward Pump Control Valves (Directional) - Common Solenoid Return Short to Power (*) . . . . 121 4082-Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground (*) . . 123 4083-Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit (*) . . . . . . 125 4309-Park Brake Button - Park Brake Button Timeout (30 sec) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 4309-Park Brake Button - Park Brake Button Timeout (30 sec) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 4361-Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit (*) . . . . . . 130 4362-Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground (*) . . . 132 4371-Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit (*) . . . . . . . 134 4372-Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground (*) . . . . 136 4381-Reverse Pump Control Valves (Directional) - Common Solenoid Return Short to Power (*) . . . . 138 4382-Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground (*) . . 140 4383-Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit (*) . . . . . . 143 4401-Park Brake (Mechanical Machines) - Park Brake Solenoid - Open Circuit (*) . . . . . . . . . . . . . . . . 145 4402-Park Brake (Mechanical Machines) - Park Brake Solenoid - Short to Power (*) . . . . . . . . . . . . . . 148 4431-Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) (*) . . . 150

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4731-Right Swash Plate Sensor - Pin A Short to Ground/ Open Circuit Right Hand Pump Angle #1 (*) 153 4732-Right Swash Plate Sensor - Pin A Short to Power Right Hand Pump Angle #1 (*) . . . . . . . . . . . . 155 4734-Right Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit Right Hand Pump Angle #2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 4735-Right Swash Plate Angle Sensor - Pin B Short to Power Right Hand Pump Angle #2 (*) . . . . . . 160 4737-Right Swash Plate Angle Sensor - In Range Fault Right Hand Pump Angle #1 and Right Hand Pump Angle #2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 4741-Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit Left Hand Angle #1 (*) . 165 4742-Left Swash Plate Angle Sensor - Pin A Short to Power Left Hand Angle #1 (*) . . . . . . . . . . . . . . . 167 4744-Left Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit Left Hand Pump Angle #2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 4745-Left Swash Plate Angle Sensor - Pin B Short to Power Left Hand Pump Angle #2 (*) . . . . . . . . . 172 4747-Left Swash Plate Angle Sensor - In Range Fault Left Hand Pump Angle #1 and Left Hand Pump Angle #2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 4752-Left Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle Left Hand Pump Angle #1 and Left Hand Pump Angle #2 (*) . . . . . . . . . . . . . . . . . . . . . . . . 177 4754-Right Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle Right Hand Pump Angle #1 and Right Hand Pump Angle #2 (*) . . . . . . . . . . . . . . . . . . . . . . 179 4781-Solenoid Valve - Solenoid Supply Open Circuit Two Speed Solenoid (*) . . . . . . . . . . . . . . . . . . . . 181 4782-Solenoid Valve - Solenoid Supply Short to Ground Two Speed Solenoid (*) . . . . . . . . . . . . . . . . . 183 4783-Solenoid Valve - Solenoid Supply Short to Power Two Speed Solenoid (*) . . . . . . . . . . . . . . . . . . 185 4951-Hydraulic Enable (Mechanical Machines) - Hydraulic Interlock Solenoid, Short to Power (*) . . . 187 4952-Hydraulic Enable (Mechanical Machines) - Hydraulic Interlock Solenoid Open Circuit (*) . . . . . . 189 5051-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . 191 5052-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . . 193 5053-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . . 195 5061-Port Lock Valve (On/Off) - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 5062-Port Lock Valve (On/Off) - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 5063-Port Lock Valve (On/Off) - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 5121-Right Joystick F-B Axis - Pin A Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . . . 203 5122-Right Joystick F-B Axis - Pin B Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . . . 207 5124-Right Joystick F-B Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211 5131-Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . 216 5132-Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . 220 5134-Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . 224 5135-Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . 228 5137-Right Joystick R-L Axis (ISO/H Pattern) - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 5141-Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 5142-Aux Thumbwheel Axis - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 5144-Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 242 5145-Aux Thumbwheel Axis - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 5147-Aux Thumbwheel Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247 5201-Left Joystick L-R Axis - Pin A Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . 250

(*) See content for specific models 47711684 06/05/2014

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5202-Left Joystick L-R Axis - Pin B Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . 254 5204-Left Joystick L-R Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 5211-Left Joystick F-B Axis - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 5212-Left Joystick F-B Axis - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 5214-Left Joystick F-B Axis - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 5215-Left Joystick F-B Axis - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 5217-Left Joystick F-B Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 5221-Loader Arm Valve (Directional) - Solenoid Raise A Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . 284 5222-Loader Arm Valve (Directional) - Solenoid Raise A Supply Short to Ground (*) . . . . . . . . . . . . . . 286 5231-Loader Arm Valve (Directional) - Solenoid Lower B Supply Open Circuit (*) . . . . . . . . . . . . . . . . . 288 5232-Loader Arm Valve (Directional) - Solenoid Lower B Supply Short to Ground (*) . . . . . . . . . . . . . . 290 5241-Boom Valve (Directional) - Common Solenoid (C) Return Short to Power (*) . . . . . . . . . . . . . . . . 292 5242-Loader Arm Valve (Directional) - Loader Arm Solenoids Short to Ground (*) . . . . . . . . . . . . . . . . . 294 5243-Boom Valve (Directional) - Common Solenoid (C) Return Open Circuit (*) . . . . . . . . . . . . . . . . . . 296 5251-Loader Bucket Valve (Directional) - Solenoid Rollback (A) Supply Open Circuit (*) . . . . . . . . . . . 298 5252-Loader Bucket Valve (Directional) - Solenoid Rollback (A) Supply Short to Ground (*) . . . . . . . . 300 5261-Bucket Valve (Directional) - Solenoid Dump (B) Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . 302 5262-Bucket Valve (Directional) - Solenoid Dump (B) Supply Short to Ground (*) . . . . . . . . . . . . . . . . . 304 5271-Bucket Valve (Directional) - Common Solenoid (C) Return Short to Power (*) . . . . . . . . . . . . . . . 306 5272-Loader Bucket Valve (Directional) - Loader Bucket Solenoids Short to Ground (*) . . . . . . . . . . . . 308 5273-Bucket Valve (Directional) - Common Solenoid (C) Return Open Circuit (*) . . . . . . . . . . . . . . . . . . 310 5281-Aux Valve (Directional) - Solenoid Forward (A) Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . 312 5282-Aux Valve (Directional) - Solenoid Forward (A) Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . 314 5291-Aux Valve (Directional) - Solenoid Reverse (B) Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . 316 5292-Aux Valve (Directional) - Solenoid Reverse (B) Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . 318 5309-Float Button - Float Button Timeout (30 sec) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 5371-EHF Pump Control PRV's (Directional) - Forward Solenoid (A) Supply Open Circuit (*) . . . . . . . 322 5372-EHF Pump Control PRV's (Directional) - Forward Solenoid (A) Supply Short to Ground (*) . . . . 324 5381-EHF Pump Control PRV's (Directional) - Reverse Solenoid (B) Supply Open Circuit (*) . . . . . . . 326 5382-EHF Pump Control PRV's (Directional) - Reverse Solenoid (B) Supply Short to Ground (*) . . . . 328 5391-EHF Pump Control PRV's (Directional) - Solenoids Return Open Circuit (*) . . . . . . . . . . . . . . . . . 330 5392-EHF Pump Control PRV's (Directional) - EHF Pumps Solenoids Short to Ground (*) . . . . . . . . . 333 5393-EHF Pump Control PRV's (Directional) - EHF Pumps Solenoids Short to Power (*) . . . . . . . . . . 335 5409-CAN Message Error - Aux Override Disabled Due To Aux Override Button Timeout (30 sec) (*) 338 5501-Loader Arm Spool Sensor - Sensor Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . 339 5502-Loader Arm Spool Sensor - Sensor Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341 5503-Hydraulic Enable (Mechanical Machines) - EH AUX Output, Short to Power (*) . . . . . . . . . . . . . . 343 5504-Bucket Valve Spool Sensor - Sensor Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . 345 5505-Bucket Valve Spool Sensor - Sensor Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347 5507-Auxiliary Valve Spool Sensor - Sensor Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . 350 5508-Auxiliary Valve Spool Sensor - Sensor Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353

(*) See content for specific models 47711684 06/05/2014

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5511-Loader Arm Spool Sensor - Implausible State Sensor vs. Loader Arm Command, Stuck Spool/ PRV (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356 5512-Bucket Valve Spool Sensor - Implausible State Sensor vs. Loader Bucket Command (*) . . . . . . 359 5513-Auxiliary Valve Spool Sensor - Implausible State Sensor vs. Auxiliary Command (*) . . . . . . . . . 361 5601-Aux Valve (Directional) - Common Solenoid Return Short to Power (*) . . . . . . . . . . . . . . . . . . . . . 364 5602-Loader Auxiliary Valve (Directional) - Loader Auxiliary Solenoids Short to Ground (*) . . . . . . . . . 367 5603-Loader Auxiliary Valve Solenoid Return Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369 5701-Pattern Switch - Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371 5703-Pattern Switch - Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374 5811-Loader Lockout Switch - Implausible State (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377 9004-Memory Error - Triple Redundant: Hour Meter - Location 1 Corrupt . . . . . . . . . . . . . . . . . . . . . . . . 380 9005-Memory Error - Triple Redundant: Hour Meter - Location 2 Corrupt . . . . . . . . . . . . . . . . . . . . . . . . 381 9006-Memory Error - Triple Redundant: Hour Meter - Location 3 Corrupt . . . . . . . . . . . . . . . . . . . . . . . . 382 9151-CAN Connection: CAN Communication Timed Out After 5 Seconds . . . . . . . . . . . . . . . . . . . . . . . 383 9152-CAN Connection - CAN Communication Timed Out After 5 Seconds . . . . . . . . . . . . . . . . . . . . . . . 384 9153-CAN Connection - EEC1 Message Timed Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385 9154-CAN Connection - TSC1 Message Timed Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386 9156-Hyd Enable Switch - Hyd Enable Button Error from AIC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387 9158-H-Pattern Indicator Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388 9159-ISO-Pattern Indicator Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390 9160-H-Pattern Indicator Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392 9161-ISO-Pattern Indicator Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395 9401-Memory Error - Double Redundant: Memory Corruption Detected and Repaired . . . . . . . . . . . . . 398 9403-Memory Error - Double Redundant: Unrecoverable Memory Corruption Operable . . . . . . . . . . . 399 9404-Memory Error - Triple Redundant: Hour Meter - Hour Meter Failure . . . . . . . . . . . . . . . . . . . . . . . . 401 9405-CAN - DM1 (EH Machines): Loss Of DM1 Message From UCM (*) . . . . . . . . . . . . . . . . . . . . . . . . 402 9406-CAN - Can Communication Lost (EH Machines): Loss Of All CAN Communication From UCM (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403 9407-Memory Error - ID Errors: Unrecoverable Hardware ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404 9408-Memory Error - ID Errors: Unrecoverable Panel ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405 9410-Loss of EGR inducement status message from EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406 [ECU] - 1010-Battery 5V reference 1 circuit low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407 [ECU] - 1011-Battery 5V reference 1 circuit high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409 [ECU] - 1012-Battery 5V reference 2 circuit low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411 [ECU] - 1013-Battery 5V reference 2 circuit high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414 [ECU] - 1014-Vehicle system voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417 [ECU] - 1015-Vehicle system voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419 [ECU] - 1041-Engine overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421 [ECU] - 1816-Capacitor charge-up circuit malfunction (Insufficient charge) . . . . . . . . . . . . . . . . . . . . . . . 423 [ECU] - 1817-Capacitor charge-up circuit malfunction (Excessive charge) . . . . . . . . . . . . . . . . . . . . . . . 425 [ECU] - 1818-Engine Control Unit (ECU) watchdog fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427 [ECU] - 3007-Coolant temperature sensor - Signal above range maximum . . . . . . . . . . . . . . . . . . . . . . . 428 (*) See content for specific models 47711684 06/05/2014

55.16 [55.DTC] / 6

[ECU] - 3008-Coolant temperature sensor - Signal below range minimum . . . . . . . . . . . . . . . . . . . . . . . 431 [ECU] - 3010-Intake manifold boost temperature sensor circuit - Signal above range maximum . . . . . 433 [ECU] - 3011-Intake manifold boost temperature sensor circuit - Signal below range minimum . . . . . . 435 [ECU] - 3015-Fuel temperature sensor - Signal above range maximum . . . . . . . . . . . . . . . . . . . . . . . . . . 437 [ECU] - 3016-Fuel temperature sensor - Signal below range minimum . . . . . . . . . . . . . . . . . . . . . . . . . . 439 [ECU] - 3019-Intake manifold boost pressure sensor circuit - Signal above range maximum . . . . . . . . 442 [ECU] - 3024-Atmospheric pressure sensor inside Engine Control Unit (ECU) - Signal above range maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444 [ECU] - 3025-Atmospheric pressure sensor inside Electronic Control Unit (ECU) - Signal below range minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445 [ECU] - 3037-Intake manifold boost pressure sensor circuit - Signal below range minimum . . . . . . . . . 446 [ECU] - 3088-Crank speed sensor - High voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448 [ECU] - 3089-Crankshaft speed sensor - Invalid signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 [ECU] - 3090-Camshaft speed sensor - No signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452 [ECU] - 3102-Rail pressure sensor - Signal below range minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454 [ECU] - 3112-Rail pressure sensor - Signal above range maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456 [ECU] - 3210-Injector bank 1 circuit (Cylinder 1 and 4) - Short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458 [ECU] - 3218-Injector bank 2 circuit (Cylinder 2 and 3) - Short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460 [ECU] - 3258-Starter relay circuit - Shorted to high source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462 [ECU] - 3259-Starter relay circuit - Shorted to low source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464 [ECU] - 3267-Engine Control Unit (ECU) fuel pump output - Shorted to high source . . . . . . . . . . . . . . . 466 [ECU] - 3268-Engine Control Unit (ECU) fuel pump output - Shorted to low source . . . . . . . . . . . . . . . . 468 [ECU] - 3293-Common rail pressure exceeds hi upper limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470 [ECU] - 3305-Common rail pressure below target pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472 [ECU] - 3309-Common rail pressure exceeds upper limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474 [ECU] - 3334-Controller Area Network (CAN) message not received from vehicle controller - TSC1-PE Active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476 [ECU] - 3691-Glow plug circuit - No load error for low voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . 478 [ECU] - 3694-Glow plug circuit. - Short circuit to ground error for low voltage system . . . . . . . . . . . . . . 480 [ECU] - 3764-Engine controller main relay circuit (Terminal 30) - Early opening defect of main relay . 482 [ECU] - 3797-Differential pressure sensor - Signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484 [ECU] - 3798-Differential pressure sensor - Signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486 [ECU] - 3830-Intake valve position - Signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488 [ECU] - 3831-Intake valve position - Signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 [ECU] - 3948-Exhaust Gas Recirculation (EGR) lift sensor 1 - Signal too high . . . . . . . . . . . . . . . . . . . . 492 [ECU] - 3949-Exhaust Gas Recirculation (EGR) lift sensor 1 - Signal too low . . . . . . . . . . . . . . . . . . . . . 494 [ECU] - 3950-Exhaust Gas Recirculation (EGR) valve stuck Open/Closed . . . . . . . . . . . . . . . . . . . . . . . 496 [ECU] - 3951-Exhaust gas temperature 1 sensor - Signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498 [ECU] - 3952-Exhaust gas temperature 1 sensor - Signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 [ECU] - 3953-Exhaust gas temperature 2 sensor - Signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502 [ECU] - 3954-Exhaust gas temperature 2 sensor - Signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504 [ECU] - 3955-Camshaft sensor error - Invalid signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506 [ECU] - 3956-Injector 1and/or 4 - Shorted to high source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508

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[ECU] - 3957-Injector 1 and/or 4 - Shorted to low source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510 [ECU] - 3958-Injector 1 and 4 - Open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512 [ECU] - 3959-Injector 2 and/or 3 - Shorted to high source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514 [ECU] - 3960-Injector 2 and/or 3 - Shorted to low source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516 [ECU] - 3961-Injector 2 and 3 - Open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518 [ECU] - 3962-Supply pump control valve Suction Control Valve (SCV) stuck . . . . . . . . . . . . . . . . . . . . . 520 [ECU] - 3963-Actual rail pressure above target . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522 [ECU] - 3964-Actual rail pressure is excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524 [ECU] - 3965-Engine stop switch stuck closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526 [ECU] - 3966-Water in fuel filter failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528 [ECU] - 3967-Injector codes not written to Engine Control Unit (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . 529 [ECU] - 3968-Incorrect injector codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530 [ECU] - 3969-Invalid injector codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531 [ECU] - 3970-Engine Control Unit (ECU) memory fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532 [ECU] - 3971-Engine Control Unit (ECU) memory error - Verify engine dataset . . . . . . . . . . . . . . . . . . . 533 [ECU] - 3972-Intake throttle motor driver circuit invalid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534 [ECU] - 3973-Exhaust Gas Recirculation (EGR) valve position does not match the target position . . . 536 [ECU] - 3974-Exhaust Gas Recirculation (EGR) motor signal - Shorted to power or ground . . . . . . . . 538 [ECU] - 3975-Intake throttle valve stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540 [ECU] - 3976-Perform maintenance on Exhaust Gas Recirculation (EGR) timing 1-1 . . . . . . . . . . . . . . 543 [ECU] - 3977-Perform maintenance on Exhaust Gas Recirculation (EGR) timing 1-2 . . . . . . . . . . . . . . 544

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Electrical systems - FAULT CODES

1004-Hydraulic Filter Restriction Switch - Hydraulic Filter Restricted Context: The Instrument Cluster measures an open circuit on the hydraulic oil filter input, X-C23 pin 2. Cause: The Instrument Cluster measures an open circuit on the hydraulic oil filter input, X-C23 pin 2. Possible failure modes: 1. Clogged hydraulic filter. 2. Signal wire has an open circuit. 3. Faulty reading from the switch. 4. Faulty instrument cluster. Solution: 1. Verify that the fault code is still active. Prior to clearing fault codes, write down all fault codes, number of occurrences and engine hours at last occurrence. (1) Use the Electronic Service Tool to clear all fault codes. (2) To check for fault code: Start and operate machine. A. Fault 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. (1) Inspect the hydraulic filter. Replace the filter if needed. A. The filter is OK and does not need to be replaced. Go to 3. B. The filter is in poor condition or is clogged. Replace the filter. Go to Step 3 to confirm elimination of the fault. 3. Verify the harness and connectors are not damaged. (1) Inspect the Instrument Cluster and Hydraulic Filter Restriction Switch connections. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) 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.

RAPH12SSL0143FA

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(1)

Instrument Cluster connector X-C23 pin 2

Schematic Legend (2)

Hydraulic filter restriction sensor

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. 4. Measure the resistance through the filter restriction switch. (1) Disconnect the oil filter switch from the harness. (2) 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 less than 10 Ω. A. The resistance is less than 10 Ω. Go to Step 5. B. The resistance is greater than 10 Ω. Replace hydraulic filter restriction switch and retest. Return to Step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. (1) Disconnect Instrument Cluster Connector X-C23. (2) Use a jumper wire with alligator clips on both end to connect X-C23 pin 2 to chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. (3) Measure the resistance from the oil filter connector X-OILFFT to chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent short condition.

RAPH12SSL0426EA

(1) (2)

Schematic Legend Digital voltmeter set to measure (3) resistance. Instrument cluster connector X-C23. (4)

Jumper wire with alligator clips connected to chassis ground. Instrument cluster

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 signal wire. Repair or replace the signal wire as required. Return to Step 1 to confirm elimination of fault. Mechanical Units F5H Wire harnesses - Electrical schematic sheet 21 (55.100.DP-C.20.E.21) Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) EH Units F5H Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Wire harnesses - Electrical schematic sheet 12 (55.100.DP-C.20.E.12) Small mechanical machines ISM engine Wire harnesses - Electrical schematic sheet 25 (55.100.DP-C.20.E.25) Small EH machines ISM engine 47711684 06/05/2014

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Medium mechanical machines ISM engine Wire harnesses - Electrical schematic sheet 21 (55.100.DP-C.20.E.21) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26)

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Electrical systems - FAULT CODES

1009-Hydraulic Oil Temperature Sender - Over Temperature >210° F Context: The Instrument Cluster monitored a Hydraulic Oil Temperature greater than 110 °C (230 °F) for a period greater than 3 seconds. Cause: The Hydraulic Oil Temperature is above 110 °C (230 °F) for a period greater than 3 seconds. 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 still active (1) To check for fault code: Start and operate machine. (2) Use the Electronic Service Tool to clear all fault codes. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. A. Fault is not recorded again. Return the machine to service. B. Fault code 1009 is recorded again. Go to Step 2. 2. Verify hydraulic oil level. (1) Check hydraulic oil level, add oil as required. Refer to 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. (1) Run engine at 1500 RPM. (2) Check fan operation. (3) Check 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 fan or clear clogs from cooling core. Repair as required. Return to Step 1 to confirm elimination of fault. 4. Check temperature sender. (1) Disconnect terminal connector from the hydraulic oil temperature sender. (2) Measure the resistance from the hydraulic oil temperature sender ground connection to chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. (3) Measure the resistance across the temperature sender. Temperature 110 °C (230 °F)

Hydraulic Oil Temperature Sensor Open Circuit Resistance Measurements Resistance in ohms (± 10%) 130 Ω 47711684 06/05/2014

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Hydraulic Oil Temperature Sensor Open Circuit Resistance Measurements 105 °C (221 °F) 151 Ω 100 °C (212 °F) 175 Ω 95 °C (203 °F) 202 Ω 92 °C (198 °F) 223 Ω 88 °C (190 °F) 258 Ω 85 °C (185 °F) 280 Ω 81 °C (178 °F) 323 Ω 78 °C (172 °F) 358 Ω 74 °C (165 °F) 412 Ω 68 °C (154 °F) 511 Ω 16 °C (61 °F) 4250 Ω A. The resistance measurement is greater than 100 Ω and less than 5,000 Ω, go to Step 5. B. The resistance reading is 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. (1) Disconnect Instrument Cluster connector X-C23. (2) Disconnect the hydraulic oil temperature sensor. (3) Measure the resistance from hydraulic oil temperature sender connector pin 1 (signal wire) 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 measurement is greater than 20,000 Ω. Temporarily replace the Instrument Cluster and retest. Go 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. Mechanical Units F5H engine Wire harnesses - Electrical schematic sheet 21 (55.100.DP-C.20.E.21) Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) EH Units F5H engine Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Wire harnesses - Electrical schematic sheet 12 (55.100.DP-C.20.E.12) Small mechanical machines ISM engine Wire harnesses - Electrical schematic sheet 25 (55.100.DP-C.20.E.25) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Medium mechanical machines ISM engine Wire harnesses - Electrical schematic sheet 21 (55.100.DP-C.20.E.21) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26)

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1025-Throttle Sensor - Out Of Range Short to Power Context: The instrument cluster has detected an problem with the throttle signal to the instrument cluster. Diagnostic Trouble Code 1030 has an error priority of White. White errors are not displayed on the instrument cluster. Engine speed is set to 1500 RPM while Diagnostic Trouble Code 1030 is active. Cause: instrument cluster has sensed higher than normal voltage on throttle input pin, X-C23 pin 22. The fault is active while the ignition switch is on and throttle voltage is greater than 5.3 V. Possible failure modes: 1. Short circuit in the throttle wiring. 2. 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 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 throttle position sensor.

RAPH12SSL0300FA

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Electrical systems - FAULT CODES

(1) (2)

Hand throttle position sensor Foot throttle position sensor

(3)

Instrument cluster

Schematic Legend (4) (5)

Connector XCC1A/1B pin 13 Connector XCC2A/2B pin 8 XCC2A/2B pin 13

A. The throttle position sensor harness is not damaged and all 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 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 throttle connector and inspect pins. Turn the ignition switch to the ON position. Measure the voltage from pin C to pin B. The voltage should be between 4.8 volts and 5.2 volts. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is correct. Go to step 4. B. The voltage is greater than 5.2 volts or less than 4.8 volts. Go to step 7. 4. Measure the voltage on the sensor signal line. Turn the ignition switch OFF. Disconnect the throttle position sensor from the harness. Disconnect the instrument cluster Connector X-C23. Turn the ignition switch ON. Measure the voltage of X-20 pin A to chassis ground. The voltage should be less than 0.5 volts. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 volts. Go to step 5. B. The voltage is greater than 0.5 volts. There is a short circuit to another voltage source. Repair or repalce the wire as required. Return to step 1 to confirm elimination of the fault. 5. Check the signal voltage from the sensor.

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RCPH10TLB053FAM

(1) (2)

Throttle Signal Legend Throttle Signal Voltage Throttle movement in degrees of travel. 0 degrees equals low idle. 20 degrees 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.

RAPH12SSL0301FA

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(1) (2)

Schematic legend Breakout Tee (3)

Throttle position sensor Instrument cluster

Connect the breakout Tee and measure the voltage from pin A to pin B (or slide Back Probes into pin A and B). Turn the ignition switch ON, engine OFF. Measure the voltage from pin A to pin B. Move the throttle from low idle to WOT (wide open throttle). The voltage should change from approximately 0.55 volts at low idle to 4.2 volts at WOT. A. The voltage changed from approximately 0.5 volts to 4.2 volts. Go to step 6. B. The voltage did not change from 0.55 volts to 4.2 volts as the throttle moved from low idle to WOT or the voltage was less than 0.5 volts at low idle. Temporarily replace the sensor and retest. Return to step 1 to confirm elimination of fault. 6. Measure the throttle signal from the sensor to the instrument cluster. Turn the ignition switch OFF. Remove the breakout harness and 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 from removed wire, pin 22 to X-C25 pin 20 (chassis ground will also work). Move the throttle from low idle to WOT (wide open throttle). The voltage should change from approximately 0.55 volts at low idle to 4.2 volts at WOT. A. The voltage changed from approximately 0.5 volts to 4.2 volts. 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 volts to 4.2 volts as the throttle moved from low idle to WOT or the voltage was less than 0.5 volts 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 25. 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 throttle position sensor. Repair or replace the harness as required. Return to step 1. B. The voltage is greater than 5.2 volts or less than 4.8 volts. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. Mechanical Units F5H engine Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08) EH Units F5H engine Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08) Small mechanical machines ISM engine Wire harnesses - Electrical schematic sheet 25 (55.100.DP-C.20.E.25) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08) Medium mechanical machines ISM engine Wire harnesses - Electrical schematic sheet 21 (55.100.DP-C.20.E.21) Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08) Medium EH machines ISM engine 47711684 06/05/2014

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08)

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Electrical systems - FAULT CODES

1026-Hand Throttle Signal Out Of Range - Short to Power Context: Diagnostic Trouble Code 1026 has an error priority of White. Engine speed is set to 1500 RPM while Diagnostic Trouble Code 1026 is active. Cause: The instrument cluster has sensed higher than normal voltage on throttle input pin, X-C23 pin 22. The fault is active while ignition switch is on and throttle voltage is greater than 5.3 V. Possible failure modes: 1. Short circuit in the throttle wiring. 2. 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 code: Start and operate 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 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 throttle position sensor.

RAPH12SSL0300FA

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Electrical systems - FAULT CODES

(1) (2)

Hand throttle position sensor Foot throttle position sensor

(3)

Instrument cluster

Schematic Legend (4) (5)

Connector XCC1A/1B pin 13 Connector XCC2A/2B pin 8 XCC2A/2B pin 13

A. The throttle position sensor harness is not damaged and all 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 as required. Return to step 1 to confirm elimination of fault. 3. Check voltage at throttle sensor. Turn the ignition switch OFF. Disconnect the throttle connector and inspect pins. Turn the ignition switch to the ON position. 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 correct. Go to step 4. B. The voltage is greater than 5.2 V or less than 4.8 V. Go to step 7. 4. Turn the ignition switch OFF. Disconnect the 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 throttle signal from the sensor.

RCPH10TLB053FAM

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Electrical systems - FAULT CODES

Throttle Signal Legend Throttle Signal Voltage Throttle movement in degrees of travel. 0 degrees equals low idle. 20 degrees equals WOT (Wide Open Throttle).

(1) (2)

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.

RAPH12SSL0301FA

(1) (2)

Throttle position sensor Instrument cluster

Schematic legend Breakout Tee (3)

Connect the breakout Tee and measure the voltage from pin C to pin B (or slide Back Probes into pin C and B). Turn the ignition switch ON, engine OFF. Measure the voltage from pin C to 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 between 0.55 V at low idle to 4.2 V at WOT. Go to step 6. B. The voltage did not change between 0.55 V and 4.2 V as the throttle moved between low idle and 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. 6. Measure the throttle signal from the sensor to the instrument cluster. Turn the ignition switch OFF. Remove the breakout harness and 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 the removed wire, pin 22 and X-C25 pin 20 (chassis ground will also work). 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 at low idle to 4.2 V at WOT. 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 throttle moved between low idle and WOT or the voltage was less than 0.5 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 25. 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 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. Small mechanical machines Wire harnesses - Electrical schematic sheet 25 (55.100.DP-C.20.E.25) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08) Medium mechanical machines Wire harnesses - Electrical schematic sheet 21 (55.100.DP-C.20.E.21) Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08) Medium EH machines Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08)

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Electrical systems - FAULT CODES

1030-Throttle Sensor - Out Of Range Short to Ground/ Open Circuit Context: The instrument cluster has detected an problem with the throttle signal to the instrument cluster. Diagnostic Trouble Code 1030 has an error priority of White. White errors are not displayed on the instrument cluster. Engine speed is set to 1500 RPM while Diagnostic Trouble Code 1030 is active. Cause: The instrument cluster has sensed that the throttle signal has failed. The fault is active while the engine is on and the throttle input voltage, X-C23 pin 22 falls below 0.2 V. Possible failure modes: 1. Shorted wire in circuit. 2. Open wire in circuit. 3. Failure of the throttle position sensor. 4. 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 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 throttle position sensor.

RAPH12SSL0300FA

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Electrical systems - FAULT CODES

(1) (2)

Schematic Legend Hand Throttle Position Sensor (4) Foot Throttle Position Sensor (5)

(3)

Instrument Cluster

Connector XCC1A/1B pin 13 Connector XCC2A/2B pin 8 XCC2A/2B pin 13

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4. Measure the throttle signal from the sensor.

RCPH10TLB053FAM

(1) (2)

Throttle Signal Legend Throttle Signal Voltage Throttle movement in degrees of travel. 0 degrees equals low idle. 20 degrees 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.

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RAPH12SSL0301FA

(1) (2)

Throttle Position Sensor Instrument Cluster

Schematic legend Breakout Tee (3)

Connect the breakout tee and measure the voltage between pin A and pin B (or slide Back Probes into pin A and B). Turn the ignition switch ON, engine OFF. Measure the voltage between pin A to 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 5. 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 0.5 V at low idle. Temporarily replace the sensor and retest. Return to step 1 to confirm elimination of fault. 5. Measure the throttle signal from the sensor to the instrument cluster. Turn the ignition switch OFF. Remove the breakout harness and 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 from removed wire, pin 22 to X-C25 pin 20 (chassis ground). Move the throttle from low idle to WOT (wide open 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 0.5 V to 4.2 V. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault.

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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 0.5 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. 6. Measure the voltage at the instrument cluster Turn the ignition switch OFF. Remove the wires X-C23 pin 17 and X-C23 25 from instrument cluster connector. 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 and 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. Mechanical Units F5H engine Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08) EH Units F5H engine Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08) Small mechanical machines ISM engine Wire harnesses - Electrical schematic sheet 25 (55.100.DP-C.20.E.25) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08) Medium mechanical machines ISM engine Wire harnesses - Electrical schematic sheet 21 (55.100.DP-C.20.E.21) Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08)

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1031-Hand Throttle Sensor - Short To Ground/ Open Circuit Context: Diagnostic Trouble Code 1031 has an error priority of White. Engine speed is set to 1500 RPM while Diagnostic Trouble Code 1031 is active. Cause: The instrument cluster has sensed that the throttle signal has failed. The fault is active while the engine is on and the throttle input voltage, X-C23 pin 22 falls below 0.2 V. Possible failure modes: 1. Shorted wire in circuit. 2. Open wire in circuit. 3. Failure of the throttle position sensor. 4. Failure of the instrument cluster. Solution: 1. Verify that the fault code is active. Use the Electronic Service Tool to clear all fault codes. To check for fault code: Start and operate machine. A. The fault 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 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 throttle position sensor.

RAPH12SSL0300FA

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(1) (2)

Schematic Legend Hand Throttle Position Sensor (4) Foot Throttle Position Sensor (5)

(3)

Instrument Cluster

Connector XCC1A/1B pin 13 Connector XCC2A/2B pin 8 XCC2A/2B pin 13

RCPH10TLB053FAM

(1) (2)

Throttle Signal Legend Throttle Signal Voltage Throttle movement in degrees of travel. 0 degrees equals low idle. 20 degrees 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.

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RAPH12SSL0301FA

(1) (2)

Throttle Position Sensor Instrument Cluster

Schematic legend Breakout Tee (3)

Connect the breakout tee and measure the voltage between pin C and pin B (or slide Back Probes into pin C and B). Turn the ignition switch ON, engine OFF. Measure the voltage between pin C to 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 5. 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 0.5 V at low idle. Temporarily replace the sensor and retest. Return to step 1 to confirm elimination of fault. 5. Measure the throttle signal from the sensor to the Instrument Cluster. Turn the ignition switch OFF. Remove the breakout harness and 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 from removed wire, pin 23 to X-C25 pin 20 (chassis ground). Move the throttle from low idle to WOT (wide open 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 0.5 V to 4.2 V. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault.

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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 0.5 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. 6. Measure the voltage at the instrument cluster. Turn the ignition switch OFF. Remove the wires X-C23 pin 17 and X-C23 25 from instrument cluster connector. 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 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. Small mechanical machines Wire harnesses - Electrical schematic sheet 25 (55.100.DP-C.20.E.25) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08) Medium mechanical machines Wire harnesses - Electrical schematic sheet 21 (55.100.DP-C.20.E.21) Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08) Medium EH machines Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08)

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1040-Engine overspeed warning, Engine speed greater than 2750 RPM for 5 seconds 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 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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1044-Fuel level sensor below 2.0 ohm for 5 seconds, shorted low Context: The instrument cluster has detected the fuel sender resistance is below 2 Ω for a period greater than 2 s. Cause: The instrument cluster has detected the fuel sender resistance is below 2 Ω for a period greater than 2 s. Possible failure modes: 1. Wiring or circuits shorted to minus battery or chassis ground. 2. Faulty fuel level sensor. 3. 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 connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance at the fuel level sensor. Tilt the cab and remove the fuel level sender from the tank. Disconnect the harness from the sender. Move the fuel level float from the low to 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 fuel level 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. Measure the resistance between X-14 pin B and 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. A. The resistance measurements from the sensor are within specifications. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. 47711684 06/05/2014

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B. The resistance readings are not within the limits defined in the step. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. Mechanical Units F5H engine Wire harnesses - Electrical schematic sheet 21 (55.100.DP-C.20.E.21) Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) Wire harnesses - Electrical schematic sheet 04 (55.100.DP-C.20.E.04) EH Units F5H engine Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Wire harnesses - Electrical schematic sheet 12 (55.100.DP-C.20.E.12) Wire harnesses - Electrical schematic sheet 04 (55.100.DP-C.20.E.04) Small mechanical machines ISM engine Wire harnesses - Electrical schematic sheet 25 (55.100.DP-C.20.E.25) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Medium mechanical machines ISM engine Wire harnesses - Electrical schematic sheet 21 (55.100.DP-C.20.E.21) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26)

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1045-Fuel Level Sensor Open Circuit Context: The instrument cluster has detected an open circuit in the fuel sender signal. Cause: The instrument cluster has determined that the fuel level sensor resistance has failed high. Possible failure modes: 1. Open wire in circuit. 2. Faulty fuel level sensor. 3. 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 connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance at the fuel level sensor. Disconnect the harness from the sender. Tilt the cab and remove the fuel level sender from the tank. 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. 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.

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Measure the resistance between X-14 pin B and ground (engine block). 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. Mechanical Units F5H engine Wire harnesses - Electrical schematic sheet 21 (55.100.DP-C.20.E.21) Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) Wire harnesses - Electrical schematic sheet 04 (55.100.DP-C.20.E.04) EH Units F5H engine Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Wire harnesses - Electrical schematic sheet 12 (55.100.DP-C.20.E.12) Wire harnesses - Electrical schematic sheet 04 (55.100.DP-C.20.E.04) Small mechanical machines ISM engine Wire harnesses - Electrical schematic sheet 25 (55.100.DP-C.20.E.25) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Medium mechanical machines ISM engine Wire harnesses - Electrical schematic sheet 21 (55.100.DP-C.20.E.21) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26)

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1051-Timeout of CAN message EEC1, 5 seconds without message Context: CAN bus communications between the instrument cluster and the ECU have been lost. The instrument cluster did not receive the EEC1 message from the ECU. This fault code may be displayed with other CAN bus fault code messages. Cause: The instrument cluster has stopped receiving CAN messages from the ECU. CAN bus communications between the instrument cluster and the ECU 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. Go to step 2. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Verify the connections to the ECU, instrument cluster, diagnostic connector, 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. A. The CAN bus 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. Go to step 1 to confirm elimination of fault. 3. Measure the resistance through the CAN Data Link harness. Turn the ignition switch OFF. Measure the resistance between the diagnostic port connector, CAN High pin C and CAN Low pin D. The resistance should be approximately 60 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is between 54 Ω and 66 Ω. Go to step 4. B. The resistance is less than 50 Ω. Go to step 5. C. The resistance is greater than 70 Ω. Go to step 6. 47711684 06/05/2014

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4. Measure harness resistance to chassis ground and positive battery. Turn the ignition switch OFF. Disconnect the instrument cluster connector, X-C23. Disconnect all devices connected to the CAN Data Link. Measure the resistance between X-C23 pin 5 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. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-C23 pin 6 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. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-C23 pin 5 and positive battery, X-C23 pin 7. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-C23 pin 6 and positive battery, XST2 pin 7.The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition. Circuit description Switched Battery Minus Battery CAN High CAN Low

Instrument Cluster connection X-C23 pin 7 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. 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 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. 5. Measure the resistance between the CAN high and CAN low. Turn the ignition switch OFF. Disconnect all modules on the CAN bus. Measure the resistance between CAN high (diagnostic connector X-DIAG pin C) and CAN low (diagnostic connector X-DIAG pin D). 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. Connect each component to the CAN Bus one at a time. The resistance should be greater than 60 Ω. Replace the module that drops the CAN Bus line 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. 6. Measure the resistance through the CAN Data Link 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 the CAN High and CAN Low pins on the ECU harness connector. Connect the jumper wire between the CAN High and CAN Low pins on the ECU harness connector. Measure the resistance across Diagnostic Port connector X-DIAG pin C and pin D. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance across the Telematics connector pins 3 and 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 across the UCM connector (if installed) X-CN2B pin 1 and X-CN2B pin 10. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance across Instrument Cluster connector X-C23 pin 5 and X-C23 pin 6. 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 or more resistance measurement are greater than 20,000 Ω. There is an open circuit in the CAN bus wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 7. Measure the resistance of the CAN circuit in the ECU and the instrument cluster. Turn the ignition switch OFF. Disconnect the ECU and the instrument cluster from the harness. Measure the resistance directly on the ECU CAN bus pin. The resistance should be between 108 Ω and 132 Ω.

RAIL12DOZ0152FA

Measure the resistance directly on the instrument cluster CAN bus pins. Measure the resistance between XST2 pin 4 and pin 3. The resistance should be between 108 Ω and 132 Ω. A. Both resistance measurements are approximately 120 Ω. Return to step 6. B. One or more resistance measurements are greater than 140 Ω. There is an open circuit in the CAN bus within the control. Replace the control module. Return to step 1 to confirm elimination of the fault. Mechanical Units F5H engine Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) Wire harnesses - Electrical schematic sheet 21 (55.100.DP-C.20.E.21) Wire harnesses - Electrical schematic sheet 25 (55.100.DP-C.20.E.25) Wire harnesses - Electrical schematic sheet 27 (55.100.DP-C.20.E.27) EH Units F5H engine Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) Wire harnesses - Electrical schematic sheet 12 (55.100.DP-C.20.E.12) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Wire harnesses - Electrical schematic sheet 31 (55.100.DP-C.20.E.31) Wire harnesses - Electrical schematic sheet 35 (55.100.DP-C.20.E.35) Small mechanical machines ISM engine Wire harnesses - Electrical schematic sheet 31 (55.100.DP-C.20.E.31) 47711684 06/05/2014

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Wire harnesses - Electrical schematic sheet Wire harnesses - Electrical schematic sheet Wire harnesses - Electrical schematic sheet Small EH machines ISM engine Wire harnesses - Electrical schematic sheet Wire harnesses - Electrical schematic sheet Wire harnesses - Electrical schematic sheet Wire harnesses - Electrical schematic sheet Wire harnesses - Electrical schematic sheet Medium mechanical machines ISM engine Wire harnesses - Electrical schematic sheet Wire harnesses - Electrical schematic sheet Wire harnesses - Electrical schematic sheet Wire harnesses - Electrical schematic sheet Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet Wire harnesses - Electrical schematic sheet Wire harnesses - Electrical schematic sheet Wire harnesses - Electrical schematic sheet Wire harnesses - Electrical schematic sheet

25 (55.100.DP-C.20.E.25) 10 (55.100.DP-C.20.E.10) 29 (55.100.DP-C.20.E.29) 33 26 06 31 19

(55.100.DP-C.20.E.33) (55.100.DP-C.20.E.26) (55.100.DP-C.20.E.06) (55.100.DP-C.20.E.31) (55.100.DP-C.20.E.19)

27 21 06 25

(55.100.DP-C.20.E.27) (55.100.DP-C.20.E.21) (55.100.DP-C.20.E.06) (55.100.DP-C.20.E.25)

34 26 06 31 19

(55.100.DP-C.20.E.34) (55.100.DP-C.20.E.26) (55.100.DP-C.20.E.06) (55.100.DP-C.20.E.31) (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

1053-Timeout of CAN message CM1BC 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-Timeout of CAN message EEC1, 5 seconds without message (55.408)

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Electrical systems - FAULT CODES

1054-Timeout of CAN message engine temperature, 5 seconds without message 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-Timeout of CAN message EEC1, 5 seconds without message (55.408)

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Electrical systems - FAULT CODES

1056-Timeout of CAN message DPFC1, 5 seconds without message 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-Timeout of CAN message EEC1, 5 seconds without message (55.408)

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Electrical systems - FAULT CODES

1058-Timeout of CAN message EDC2BC, 5 seconds without message 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-Timeout of CAN message EEC1, 5 seconds without message (55.408)

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Electrical systems - FAULT CODES

1059-Timeout of CAN message DM1, 5 seconds without message 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-Timeout of CAN message EEC1, 5 seconds without message (55.408)

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Electrical systems - FAULT CODES

1201-Hydraulic oil filter switch open circuit Context: 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. White errors are not displayed on the instrument cluster and are not known to the Owner/Operator. They will appear in the EST when the technician checks for active trouble codes. There are no restrictions with Diagnostic Trouble Code 1201. 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. Open circuit in the wiring. 2. Failure of the hydraulic filter restriction switch. 3. 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 code: 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. 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 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 across the switch. Turn the ignition switch OFF. Disconnect the hydraulic oil filter switch connector. Measure the resistance between hydraulic 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 less than 10 Ω. 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 switch. Replace the switch and retest. Return to step 1 to confirm elimination of fault. 4. Measure the resistance through the signal wire. Turn the ignition switch OFF. Leave the hydraulic oil filter switch disconnected. Disconnect instrument cluster connector X-C23. 47711684 06/05/2014

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Electrical systems - FAULT CODES

Fabricate a jumper wire that will connect between the hydraulic oil filter switch pin 1 and chassis ground. Connect the jumper wire between the hydraulic oil filter switch pin 1 and chassis ground. The chassis ground connection must be clean and free of paint, oil and dirt. Measure the resistance between instrument cluster connector X-C23 pin 1 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. Small mechanical machines Wire harnesses - Electrical schematic sheet 25 (55.100.DP-C.20.E.25) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Small EH machines Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Wire harnesses - Electrical schematic sheet 12 (55.100.DP-C.20.E.12) Medium mechanical machines Wire harnesses - Electrical schematic sheet 21 (55.100.DP-C.20.E.21) Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) Medium EH machines Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Wire harnesses - Electrical schematic sheet 12 (55.100.DP-C.20.E.12)

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Electrical systems - FAULT CODES

1205-Hydraulic Enable (EH Machines) - Hydraulic Enable Output, Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

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 active while Ignition is on and Hydraulic Enable Commanded State is Low and Hydraulic Enable Solenoid is energized. Possible failure modes: 1. Faulty wiring or connectors. 2. Faulty Instrument Cluster. Solution: 1. Verify that the fault code is still active. Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence. (1) Use the Electronic Service Tool to clear all fault codes. (2) To check for fault code: Start and operate machine. A. Fault is not recorded again. OK to return the machine to service. B. Fault code is recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect Instrument Cluster connector X-C23 and the UCM connections. All connections should be secure, tight, free of corrosion, abrasion and/or damage. (2) Inspect the harness from the Instrument Cluster to the UCM. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment.

RAPH12SSL0269FA

(1)

Instrument Cluster Connector X-C23 pin 30

Schematic Legend (2)

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UCM Connector X-CN3A pin 23

Electrical systems - FAULT CODES

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Electrical systems - FAULT CODES

1212-Calibration Functions - Ground Drive Calibration Not Complete L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 1212 has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 1212. Cause: UCM has sensed that the Ground Drive Calibration is not complete. Possible failure modes: 1. Calibration not complete 2. Failure of UCM Solution: 1. 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, replace the Ground Drive and reperform calibration. If the code persists, replace 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 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 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 1213 has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 1213. Cause: UCM has sensed that the Loader Valve Calibration is not complete. Possible failure modes: 1. Calibration not complete 2. Failure of UCM Solution: 1. 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. Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Loader valve (55.000) A. If the fault code clears, continue normal operation. B. If the fault code does not clear, replace the Loader Valve and reperform calibration. If the code persists, replace UCM. 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 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

1214-Calibration Functions - Throttle Calibration Not Complete L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 1214 has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 1214. Cause: UCM has sensed that the Throttle Calibration is not complete. Possible failure modes: 1. Calibration not complete 2. Failure of UCM Solution: 1. Use the machine to recreate conditions for error. Use the EST to verify fault code 1214 Calibration Functions Throttle Calibration Not Complete is active. A. If the fault is active, continue with step 2. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 3. 2. Use the EST to perform calibration on the Throttle. Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Throttle (55.000) A. If the fault code clears, continue normal operation. B. If the fault code does not clear, replace the Throttle and reperform calibration. If the code persists, replace UCM. 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 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

1221-Health Monitor Functions - UCM - UCM Temperature / Current Draw Over Limit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 1221 has an error priority of Amber. Limp Home Hydraulics are enabled with Diagnostic Trouble Code 1221. Cause: UCM has sensed high current or high temperature in the UCM. Possible failure modes: 1. Failure of UCM. Solution: 1. Turn off the machine. Restart the machine and recreate conditions for error. Use the EST to verify fault code 1221 Health Monitor Functions - UCM - UCM 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 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

1222-Health Monitor Functions - UCM - UCM Sustained Over Temperature Limit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 1222 has an error priority of Red. Disable Hydraulics is enabled with Diagnostic Trouble Code 1222. Cause: UCM has sensed high temperature in the UCM. Possible failure modes: 1. Failure of UCM. Solution: 1. Turn off the machine. Restart the machine and recreate conditions for error. Use the EST to verify fault code 1222 Health Monitor Functions - UCM - UCM Sustained Over Temperature Limit is active. A. If the fault is active, the UCM has failed. Replace the UCM. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 2. 2. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

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Electrical systems - FAULT CODES

1223-Health Monitor Functions - UCM - UCM Sustained Over Current Limit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 1223 has an error priority of Red. Disable Hydraulics is enabled with Diagnostic Trouble Code 1223. Cause: UCM has sensed high current in the UCM. Possible failure modes: 1. Failure of UCM. Solution: 1. Turn off the machine. Restart the machine and recreate conditions for error. Use the EST to verify fault code 1223 Health Monitor Functions - UCM - UCM Sustained Over Current Limit is active. A. If the fault is active, the UCM has failed. Replace the UCM. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 2. 2. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

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Electrical systems - FAULT CODES

1224-Health Monitor Functions - UCM - Internal Memory or Core Monitoring Fault L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 1224 has an error priority of Red. Disable Hydraulics is enabled with Diagnostic Trouble Code 1224. Cause: UCM has sensed an internal fault in the UCM. Possible failure modes: 1. Failure of UCM. Solution: 1. Turn off the machine. Restart the machine and recreate conditions for error. Use the EST to verify fault code 1224 Health Monitor Functions - UCM - Internal Memory or Core Monitoring Fault is active. A. If the fault is active, the UCM has failed. Replace the UCM. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 2. 2. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

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Electrical systems - FAULT CODES

1225-Health Monitor Functions - UCM - EEPROM Memory Checksum Fault L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 1225 has an error priority of Red. Disable Hydraulics is enabled with Diagnostic Trouble Code 1225. Cause: UCM has sensed a checksum failure in the UCM memory. Possible failure modes: 1. Failure of UCM. Solution: 1. Turn off the machine. Restart the machine and recreate conditions for error. Use the EST to verify fault code 1225 Health Monitor Functions - UCM - EEPROM Memory Checksum Fault is active. A. If the fault persists for three machine restarts, the UCM has failed. Replace the UCM. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 2. 2. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

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Electrical systems - FAULT CODES

1350-Hyd Enable Switch - Implausible State (Hardwire vs CAN) L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 1350 has an error priority of amber. Loader limp home and ground drive limp home operating modes are enabled while Diagnostic Trouble Code 1350 is active. Cause: 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. Shorted wire in circuit. 2. Open wire in circuit. 3. Failure of the instrument cluster. 4. 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 1350 is recorded again. Fault code 9156 may also be active. Go to step 2. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Verify the connections to the UCM and instrument cluster are tight and secure. Verify the harness is free of damage, abrasion, corrosion and incorrect attachment from the UCU to the instrument cluster. 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 signal line to chassis ground. Turn the ignition switch OFF. Disconnect instrument cluster connector X-C23. Disconnect UCM connector X-CN3A. Measure the resistance between X-CN3A pin 23 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 4. 4. Measure the voltage on the signal wire. 47711684 06/05/2014

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Electrical systems - FAULT CODES

Turn the ignition switch ON. Measure the voltage between X-CN3A pin 23 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. Small EH machines Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 12 (55.100.DP-C.20.E.12) Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Medium EH machines Wire harnesses - Electrical schematic sheet 23 (55.100.DP-C.20.E.23) Wire harnesses - Electrical schematic sheet 24 (55.100.DP-C.20.E.24)

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Electrical systems - FAULT CODES

1532-Backup Alarm - Short to Ground L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 1532 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in EST when the technician checks for active trouble codes. Backup Alarm is disabled with Diagnostic Trouble Code 1532. Cause: UCM has sensed improper current from the Backup Alarm. The fault is only when both pumps are in reverse and backup alarm solenoid output current is high. Possible failure modes: 1. Shorted wire in circuit. 2. Faulty backup alarm. 3. UCM has internal failure. Solution: 1. Use the machine to recreate conditions for error. Use the EST to verify fault code 1532 is active. A. If the fault is active, continue with step 2. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 4. 2. Check for a short circuit to ground. Disconnect connector X-BKUP-PWR from the backup alarm. Disconnect UCM connector X-CN3B. Using a multi-meter, check for continuity between X-CN3B pin 18 and chassis ground. A. If there is no continuity, continue with step 3. B. If there is continuity, there is a short to ground condition on wire 895 (White) between connector X-BKUP-PWR pin 1 and UCM connector X-CN3B pin 18. Repair or replace the wire. 3. Check for proper resistance in the Backup Alarm. Disconnect connector X-BKUP-GND from the Backup Alarm. Using a multi-meter to check for resistance between 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 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. Small EH machines Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Medium EH machines Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20)

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Electrical systems - FAULT CODES

1533-Backup Alarm - Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 1533 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in EST when the technician checks for active trouble codes. Backup Alarm is disabled with Diagnostic Trouble Code 1533. Cause: UCM has sensed that the Backup Alarm solenoid output does not agree with the desired Backup Alarm status. The fault is activate when the pumps not in reverse and the backup alarm solenoid output voltage is greater than 8 V. Possible failure modes: 1. Shorted wire in circuit. 2. UCM has internal failure. Solution: 1. Use the machine to recreate conditions for error. Use the EST to verify fault code 1533 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 to high. Disconnect connector X-BKUP-PWR from the Backup Alarm. Disconnect UCM connector X-CN3B. Using a multi-meter, check for voltage between UCM connector X-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 high source on wire 895 (White) between connector X-BKUP-PWR pin 1 and connector X-CN3B pin 18. Repair or replace the wire. 3. Check for proper operation of the UCM. Reconnect UCM connector X-CN3B. Using a multi-meter, check for 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 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. Small EH machines Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Medium EH machines Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20)

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Electrical systems - FAULT CODES

1900-UCM - UCM Ground Fault L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 1900 has an error priority of Red. All hydraulics are disabled while Diagnostic Trouble Code 1900 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. Bad chassis ground connections. 2. Open wire 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. OK to return the machine to service. B. Fault code 1900 is recorded again. Go to step 2. C. If fault code 1900 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 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 connection is 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 X-CN1A. Measure the resistance between X-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. Measure the resistance between X-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. 47711684 06/05/2014

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Electrical systems - FAULT CODES

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 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. EH machines F5H engine Wire harnesses - Electrical schematic sheet 04 (55.100.DP-C.20.E.04) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 04 (55.100.DP-C.20.E.04) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 04 (55.100.DP-C.20.E.04)

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1901-UCM - UCM Supply Voltage High L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 1901 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in EST when the technician checks for active trouble codes. There are no restrictions with Diagnostic Trouble Code 1901. Cause: UCM has sensed that the supply voltage is high. The fault is active while Ignition is On, and the input voltage is greater than 16 V. Possible failure modes: 1. Problem with battery or charging system. 2. Failure of 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 1901 is recorded again. Go to step 2. C. If fault code 1901 is recorded along with other diagnostic codes such 1014 and 3051, 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 connector X-CN1A pin 20 and 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 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 and measure the voltage at the alternator. The voltage should be approximately 14.8 V. A. The voltage is approximately 14.8 V. Go to step 4. B. The voltage is greater than 16 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.

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Measure the voltage between UCM connector X-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. Small EH machines F5H engine Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03)

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Electrical systems - FAULT CODES

1902-UCM - UCM Supply Voltage Low L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 1902 has an error priority of White. There are no restrictions with Diagnostic Trouble Code 1902. Cause: UCM has sensed that a 12 V UCM input is low. The fault becomes active when UCM input voltage, X-CN1A pin 20 is less than 11.5 V but greater than 9 Vfor a period greater than 30 s. Possible failure modes: 1. Faulty alternator output. 2. Shorted wire in the charging circuit. 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 code: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1902 is recorded again. Go to step 2. C. If fault code 1902 is recorded along with other diagnostic codes such 1015 and 3052, 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 connector X-CN1A pin 20 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 and measure the voltage at the alternator. The voltage should be approximately 14.8 V. A. The voltage is approximately 14.8 V. Go to step 4. B. The voltage is less than 9 V. Replace the alternator. Return to step 1 to confirm elimination of fault. 4. Measure the voltage at the UCM. Turn the ignition switch ON. Measure the voltage between UCM connector X-CN1A pin 20 and chassis ground. The voltage should be between 11 V and 14.8 V. 47711684 06/05/2014

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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 9 V. Replace the alternator. Return to step 1 to confirm elimination of fault. Small EH machines F5H engine Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03)

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Electrical systems - FAULT CODES

1903-UCM - UCM Supply Voltage Below Operational Limit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 1903 has an error priority of Red. All Hydraulics are disabled while Diagnostic Trouble Code 1903 is active. Cause: UCM has sensed that a 12 V UCM input is low. The fault becomes active when UCM input voltage, X-CN1A pin 20 is less than 11.5 V but greater than 9 V for a period greater than 30 s. Possible failure modes: 1. Alternator output. 2. Shorted wire in circuit. 3. Failure of 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 1903 is recorded again. Go to step 2. C. If fault code 1903 is recorded along with other diagnostic codes such 1015 and 3052, 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 connector X-CN1A pin 20 and the alternator are tight and secure. Verify the chassis grounds 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 and measure the voltage at the alternator. The voltage should be approximately 14.8 V. A. The voltage is approximately 14.8 V. Go to step 4. B. The voltage is less than 9 V. Replace the alternator. Return to step 1 to confirm elimination of fault. 4. Measure the voltage at the UCM. Turn the ignition switch ON. Measure the voltage between UCM connector X-CN1A pin 20 and chassis ground. The voltage should be between 11 V and 14.8 V. 47711684 06/05/2014

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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. Small EH machines F5H engine Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03)

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Electrical systems - FAULT CODES

1904-UCM - Rail 12VB: 5V Regulators Supply Input Power Off L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: UCM has sensed that a 12 V UCM input has failed low. Diagnostic Trouble Code 1904 has an error priority of Red. All Hydraulics are disabled while Diagnostic Trouble Code 1904 is active. Cause: UCM has sensed that a 12 V UCM input has failed low. The fault is active while the ignition is ON, crank input pin is low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V. Possible failure modes: 1. Open wire in circuit. 2. Shorted wire in circuit. 3. 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 1904 is recorded again. Go to step 2. C. Fault code 1904 is recorded along with other diagnostic codes such as 1907 to 1917 and/or Right or Left Swatch Plate Sensor fault codes. 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 X-CN1A pin 26 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. Test the UCM connection Turn the ignition switch OFF. Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN1A pin 26. Connect the jumper from the positive battery post to UCM connector X-CN1A pin 26. Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be active. A. The fault code is not longer active. There is a problem in the wiring from between Splice SP-119 and the UCM connector. Repair as required. Return to step 1 to confirm elimination of the fault. B. The fault code is still active. There is a problem with UCM. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 47711684 06/05/2014

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Small EH machines F5H engine Wire harnesses - Electrical schematic Wire harnesses - Electrical schematic Wire harnesses - Electrical schematic Wire harnesses - Electrical schematic Wire harnesses - Electrical schematic Small EH machines ISM engine Wire harnesses - Electrical schematic Wire harnesses - Electrical schematic Wire harnesses - Electrical schematic Wire harnesses - Electrical schematic Wire harnesses - Electrical schematic Medium EH machines ISM engine Wire harnesses - Electrical schematic Wire harnesses - Electrical schematic Wire harnesses - Electrical schematic Wire harnesses - Electrical schematic Wire harnesses - Electrical schematic

sheet sheet sheet sheet sheet

01 02 03 19 20

(55.100.DP-C.20.E.01) (55.100.DP-C.20.E.02) (55.100.DP-C.20.E.03) (55.100.DP-C.20.E.19) (55.100.DP-C.20.E.20)

sheet sheet sheet sheet sheet

19 20 01 02 03

(55.100.DP-C.20.E.19) (55.100.DP-C.20.E.20) (55.100.DP-C.20.E.01) (55.100.DP-C.20.E.02) (55.100.DP-C.20.E.03)

sheet sheet sheet sheet sheet

19 20 01 02 03

(55.100.DP-C.20.E.19) (55.100.DP-C.20.E.20) (55.100.DP-C.20.E.01) (55.100.DP-C.20.E.02) (55.100.DP-C.20.E.03)

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Electrical systems - FAULT CODES

1905-UCM - 5VREF1 Sensor Supply Voltage Out of Range L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: UCM has sensed that the sensor supply voltage X-CN1A pin 8 is out of range. Diagnostic Trouble Code 1905 has an error priority of Red. All hydraulics are disabled while Diagnostic Trouble Code 1905 is active. Cause: UCM has sensed that the sensor supply voltage X-CN1A pin 8 is out of range. The fault is active while the ignition switch is ON and the voltage at pin 8 is less than 4.8 V or greater than 5.2 V. Possible failure modes: 1. Faulty wiring. 2. Faulty sensor. 3. 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 1905 is active and recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, EHF pressure transducer, right hand control handle, throttle position sensor, chassis loader interface and Universal Joystick Module. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the EHF pressure transducer, right hand control handle, throttle position sensor, chassis loader interface and 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 and measure the voltage between UCM connector X-CN1A pin 8 and chassis ground. A. The voltage is less than 4.8 V. Go to step 4. B. The voltage is greater than 5.2 V. Go to step 6. C. The voltage is greater than 4.8 V but less than 5.2 V. There does not seem to be a problem at this time. Reprogram the UCM with the latest software. If the fault code persists, temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 4. Check for a short to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector, X-CN1A. 47711684 06/05/2014

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Disconnect the EHF pressure transducer, right hand control handle, throttle position sensor, chassis loader interface and Universal Joystick Module. Use a digital voltmeter to measure the resistance between X-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 X-CN1A pin 8 and chassis ground. Reconnect the components one at a time (EHF pressure transducer, right hand control handle, throttle position sensor, chassis loader interface and 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 a short to battery Turn the ignition switch OFF. Disconnect the UCM connector, X-CN1A. Disconnect the EHF pressure transducer, right hand control handle, throttle position sensor, chassis loader interface and Universal Joystick Module. Turn the ignition switch ON and measure the voltage between X-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 7. 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. 7. Reconnect the components to the harness while monitoring the voltage Use a digital voltmeter to measure the voltage between X-CN1A pin 8 and chassis ground. Reconnect the components one at a time (EHF pressure transducer, right hand control handle, throttle position sensor, chassis loader interface and Universal Joystick Module), while monitoring the volatge 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. Small EH machines F5H engine Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) 47711684 06/05/2014

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Wire harnesses - Electrical schematic Wire harnesses - Electrical schematic Wire harnesses - Electrical schematic Medium EH machines ISM engine Wire harnesses - Electrical schematic Wire harnesses - Electrical schematic Wire harnesses - Electrical schematic Wire harnesses - Electrical schematic Wire harnesses - Electrical schematic

sheet 01 (55.100.DP-C.20.E.01) sheet 02 (55.100.DP-C.20.E.02) sheet 03 (55.100.DP-C.20.E.03) sheet sheet sheet sheet sheet

19 20 01 02 03

(55.100.DP-C.20.E.19) (55.100.DP-C.20.E.20) (55.100.DP-C.20.E.01) (55.100.DP-C.20.E.02) (55.100.DP-C.20.E.03)

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Electrical systems - FAULT CODES

1906-UCM - 5VREF3 Sensor Supply Voltage Out of Range L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 1906 has an error priority of Red. All Hydraulics are disabled while Diagnostic Trouble Code 1906 is active. Cause: UCM has sensed that the sensor supply voltage X-CN1A pin 9 is out of range. The fault is active while the ignition switch is ON and voltage at pin 9 is less than 4.8 V or greater than 5.2 V. Possible failure modes: 1. Faulty wiring. 2. Faulty sensor. 3. 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 1906 is active and recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, right hand control handle and Universal Joystick Module. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the right hand control handle and 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 and measure the voltage between UCM connector X-CN1A pin 9 and chassis ground. A. The voltage is less than 4.8 V. Go to step 4. B. The voltage is greater than 5.2 V. Go to step 6. C. The voltage is greater than 4.8 V but less than 5.2 V. There does not seem to be a problem at this time. Reprogram the UCM with the latest software. If the fault code persists, temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 4. Check for a short to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector, X-CN1A. Disconnect the right hand control handle and Universal Joystick Module.

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Use a digital voltmeter to measure the resistance between X-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 one at a time while monitoring the resistance. Use a digital voltmeter to measure the resistance between X-CN1A pin 9 and chassis ground. Reconnect the components one at a time (right hand control handle and 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. 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 a short to battery. Turn the ignition switch OFF. Disconnect the UCM connector, X-CN1A. Disconnect the right hand control handle and Universal Joystick Module. Turn the ignition switch ON and measure the voltage between X-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 7. 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. 7. Reconnect the components to the harness while monitoring the voltage. Use a digital voltmeter to measure the voltage between X-CN1A pin 9 and chassis ground. Reconnect the components one at a time (right hand control handle and 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. Small EH machines F5H engine Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Medium EH machines ISM engine 47711684 06/05/2014

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Wire Wire Wire Wire Wire

harnesses harnesses harnesses harnesses harnesses

Electrical Electrical Electrical Electrical Electrical

schematic schematic schematic schematic schematic

sheet sheet sheet sheet sheet

19 20 01 02 03

(55.100.DP-C.20.E.19) (55.100.DP-C.20.E.20) (55.100.DP-C.20.E.01) (55.100.DP-C.20.E.02) (55.100.DP-C.20.E.03)

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Electrical systems - FAULT CODES

1907-UCM - Rail 12VF1: Aux Retract Input Power Off L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 1907 has an error priority of Amber. Disable Aux operating mode is enabled with Diagnostic Trouble Code 1907. Cause: UCM has sensed that a 12 V UCM input has failed low. The fault is active while Ignition is On, crank pin is low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V. Possible failure modes: 1. Blown fuse. 2. Open wire in circuit. 3. Shorted wire in circuit. 4. Failure of UCM. Solution: 1. 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 1907 is recorded again. Go to step 2. C. Fault code 1907 is recorded along with other diagnostic codes such as 1904, 1908 to 1917 and/or Right or Left Swatch Plate Sensor fault codes. 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 X-CN1B pin 26 and X-CN1B pin 27 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 from the UCM Prop Aux Fuse F-018 terminal B2 to chassis ground. The voltage should be approximately 12 V. A. The voltage is approximately 12 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.

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Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN1B pin 26 and X-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 displayed. 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 from the UCM Prop Aux Fuse F-018 terminal B1 to chassis ground. The voltage should be approximately 12 V. A. The voltage is approximately 12 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 from the UCM Power Relay to the fuse. Check Splice 119 and Splice 118 and associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. Small EH machines F5H engine Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03)

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1908-UCM - Rail 12VF2: Bucket Extend Input Power Off L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: UCM has sensed that a 12 V UCM input has failed low. Diagnostic Trouble Code 1908 has an error priority of Red. Disable Bucket operating mode is enabled while Diagnostic Trouble Code 1908 is active. Cause: UCM has sensed that a 12 V UCM input has failed low. The fault is active while the ignition is ON, crank pin is low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V. Possible failure modes: 1. Open wire in circuit. 2. Shorted wire in circuit. 3. Failure of 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 1908 is recorded again. Go to step 2. C. Fault code 1908 is recorded along with fault code 1913. Check Fuse F-019 and the wiring to splice SP-111. Repair as required. Return to step 1 to confirm elimination of the fault. D. Fault code 1908 is recorded along with other diagnostic codes such as 1904, 1907, 1909 to 1917 and/or Right or Left Swatch Plate Sensor fault codes. 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 X-CN4A pin 1 and X-CN4A pin 8 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. Test the UCM connection. Turn the ignition switch OFF. Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN4A pin 1 and X-CN4A pin 8. Connect the jumper from the positive battery post to UCM connector X-CN4A pin 1 and X-CN4A pin 8. Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be displayed.

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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. Small EH machines F5H engine Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03)

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Electrical systems - FAULT CODES

1909-UCM - Rail 12VF3: Boom Raise/Lower Input Power Off L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: UCM has sensed that a 12 V UCM input has failed low. Diagnostic Trouble Code 1909 has an error priority of Red. Boom operation is disabled while Diagnostic Trouble Code 1909 is active. Cause: UCM has sensed that a 12 V UCM input has failed low. The fault is only activated when the ignition is ON, crank pin is low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V. Possible failure modes: 1. Blown fuse. 2. Open wire in circuit. 3. Shorted wire in circuit. 4. Failure of 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 1909 is recorded again. Go to step 2. C. Fault code 1909 is recorded along with other diagnostic codes such as 1904, 1907, 1908, 1910 to 1917 and/or Right or Left Swatch Plate Sensor fault codes. 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 X-CN2B pin 9 and X-CN2B pin 17 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 from the UCM Boom Fuse F-022 terminal B6 to chassis ground. The voltage should be approximately 12 V. A. The voltage is approximately 12 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.

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Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN2B pin 9 and X-CN2B pin 17. Connect the jumper from the positive battery post to UCM connector X-CN2B pin 9 and X-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 displayed. 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 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 from the UCM Boom Fuse F-022 terminal B5 to chassis ground. The voltage should be approximately 12 V. A. The voltage is approximately 12 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 from the UCM Power Relay to the fuse. Check Splice 119 and Splice 118 and associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. Small EH machines F5H engine Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03)

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1910-UCM - Rail 12VH: Ldr Plt Interlk & Port Lock Input Power Off L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: UCM has sensed that a 12 V UCM input has failed low. Diagnostic Trouble Code 1910 has an error priority of Red. Loader Hydraulics are disabled while Diagnostic Trouble Code 1910 is active. Cause: UCM has sensed that a 12 V UCM input has failed low. The fault is active while the ignition is ON, crank pin is low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V. Possible failure modes: 1. Blown fuse. 2. Open wire in circuit. 3. Shorted wire in circuit. 4. Failure of UCM. Solution: 1. 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. Fault code is not recorded again. OK to return the machine to service. B. Fault code 1910 is recorded again. Go to step 2. C. Fault code 1910 is recorded along with other diagnostic codes such as 1904, 1907 to 1909, 1911 to 1917 and/or Right or Left Swatch Plate Sensor fault codes. 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 X-CN2A pin 7 and X-CN2A pin 13 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 from the UCM Interlocks Fuse F-025 terminal C4 to chassis ground. The voltage should be approximately 12 V. A. The voltage is approximately 12 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.

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Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN2A pin 7 and X-CN2A pin 13. Connect the jumper from the positive battery post to UCM connector X-CN2A pin 7 and X-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 displayed. 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 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 from the UCM Prop Aux Fuse F-025 terminal C3 to chassis ground. The voltage should be approximately 12 V. A. The voltage is approximately 12 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 from the UCM Power Relay to the fuse. Check Splice 119 and Splice 118 and associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. Small EH machines F5H engine Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03)

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1911-UCM - Rail 12VH1: Left & Right Pump Reverse Input Power Off L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: UCM has sensed that a 12 V UCM input has failed low. Diagnostic Trouble Code 1911 has an error priority of red. Reverse Ground Drive is disabled while Diagnostic Trouble Code 1911 is active. Cause: UCM has sensed that a 12 V UCM input has failed low. The fault is active while the ignition is ON, crank pin is low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V. Possible failure modes: 1. Open wire in circuit. 2. Shorted wire in circuit. 3. 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 1911 is recorded again. Go to step 2. C. Fault code 1911 is recorded along with Swash Plate Sensor Faults such as 4734 and 4744. Check Fuse F-017 and the wiring to splice SP-152. Repair as required. Return to step 1 to confirm elimination of the fault. D. Fault code 1911 is recorded along with other diagnostic codes such as 1904, 1907 to 1910, 1912 to 1917 and/or Right or Left Swatch Plate Sensor fault codes. 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 X-CN2A pin 2 and X-CN2A pin 3 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. Test the UCM connection. Turn the ignition switch OFF. Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN2A pin 2 and X-CN2A pin 3. Connect the jumper from the positive battery post to UCM connector X-CN2A pin 2 and X-CN2A pin 3. Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be displayed.

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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. Small EH machines F5H engine Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03)

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1912-UCM - Rail 12VM: Left & Right Brake Lights & Aux Extend Input Power Off L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: UCM has sensed that a 12 V UCM input has failed low. Diagnostic Trouble Code 1912 has an error priority of Amber. Aux operating mode is disabled while Diagnostic Trouble Code 1912 is active. Cause: UCM has sensed that a 12 V UCM input has failed low. The fault is active while the ignition is ON, crank pin is low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V. Possible failure modes: 1. Blown fuse. 2. Open wire in circuit. 3. Shorted wire in circuit. 4. Failure of UCM. Solution: 1. 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 1912 is recorded again. Go to step 2. C. Fault code 1912 is recorded along with other diagnostic codes such as 1904, 1907 to 1911, 1913 to 1917 and/or Right or Left Swatch Plate Sensor fault codes. 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 X-CN1B pin 31 and X-CN1B pin 32 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 from the UCM Brake Lamps Fuse F-015 terminal A2 to chassis ground. The voltage should be approximately 12 V. A. The voltage is approximately 12 V. Go to step 4. B. The voltage is less than 9 V. Go to step 5. 4. Test the UCM connection.

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Turn the ignition switch OFF. Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN1B pin 31 and X-CN1B pin 32. Connect the jumper from the positive battery post to UCM connector X-CN1B pin 31 and X-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 displayed. A. The fault code is not longer active. There is a problem in the wiring to the UCM. Check Splice SP-113 and 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 from the UCM Brake Lamps Fuse F-015 terminal A1 to chassis ground. The voltage should be approximately 12 V. A. The voltage is approximately 12 V. Replace the fuse and retest. 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 from the UCM Power Relay to the fuse. Check Splice 119 and associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. Small EH machines F5H engine Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03)

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1913-UCM - Rail 12VS1: Bucket Curl Input Power Off L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: UCM has sensed that a 12 V UCM input has failed low. Diagnostic Trouble Code 1913 has an error priority of Red. Bucket operating mode is disabled while Diagnostic Trouble Code 1913 is active. Cause: UCM has sensed that a 12 V UCM input has failed low. The fault is active while the ignition is On, crank pin is low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V. Possible failure modes: 1. Open wire in circuit. 2. Shorted wire in circuit. 3. Failure of 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 1913 is recorded again. Go to step 2. C. Fault code 1913 is recorded along with fault code 1908. Check Fuse F-019 and the wiring to splice SP-111. Repair as required. Return to step 1 to confirm elimination of the fault. D. Fault code 1913 is recorded along with other diagnostic codes such as 1904, 1907 to 1912, 1914 to 1917 and/or Right or Left Swatch Plate Sensor fault codes. 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 X-CN3B pin 8 and X-CN3B pin 9 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. Test the UCM connection. Turn the ignition switch OFF. Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN3B pin 8 and X-CN3B pin 9. Connect the jumper from the positive battery post to UCM connector X-CN3B pin 8 and X-CN3B pin 9. Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be displayed.

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1914-UCM - Rail 12VS2: Backup Alarm Input Power Off L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: UCM has sensed that a 12 V UCM input has failed low. Diagnostic Trouble Code 1914 has an error priority of Amber. There are no restrictions while Diagnostic Trouble Code 1914 is active. Cause: UCM has sensed that a 12 V UCM input has failed low. The fault is active while the ignition is ON, crank pin is low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V. Possible failure modes: 1. Blown fuse. 2. Open wire in circuit. 3. Shorted wire in circuit. 4. Failure of UCM. Solution: 1. 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. Fault code is not recorded again. OK to return the machine to service. B. Fault code 1914 is recorded again. Go to step 2. C. Fault code 1914 is recorded along with other diagnostic codes such as 1904, 1907 to 1913, 1915 to 1917 and/or Right or Left Swatch Plate Sensor fault codes. 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 X-CN3B pin 3 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 from the UCM Backup Alarm Fuse F-007 terminal B2 to chassis ground. The voltage should be approximately 12 V. A. The voltage is approximately 12 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.

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Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN3B pin 3. Connect the jumper from the positive battery post to UCM connector X-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 displayed. A. The fault code is not longer active. There is a problem in the wiring from 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 from the UCM Backup Alarm Fuse F-007 terminal B1 to chassis ground. The voltage should be approximately 12 V. A. The voltage is approximately 12 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 from the UCM Power Relay to the fuse. Check Splice 119 and Splice 117. Repair as required. Return to step 1 to confirm elimination of the fault. Small EH machines F5H engine Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03)

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Electrical systems - FAULT CODES

1915-UCM - Rail 12VT1: Two Speed Input Power Off L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: UCM has sensed that a 12 V UCM input has failed low. Diagnostic Trouble Code 1915 has an error priority of Amber. There are no restrictions while Diagnostic Trouble Code 1915 is active. Cause: UCM has sensed that a 12 V UCM input has failed low. The fault is active while the ignition is ON, crank pin is low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V. Possible failure modes: 1. Blown fuse. 2. Open wire in circuit. 3. Shorted wire in circuit. 4. Failure of UCM. Solution: 1. 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. Fault code is not recorded again. OK to return the machine to service. B. Fault code 1915 is recorded again. Go to step 2. C. Fault code 1915 is recorded along with other diagnostic codes such as 1904, 1907 to 1914, 1916 and 1917 and/or Right or Left Swatch Plate Sensor fault codes. 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 X-CN3A pin 7 and X-CN3A pin 13 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 from the UCM 2SPD Fuse F-027 terminal E4 to chassis ground. The voltage should be approximately 12 V. A. The voltage is approximately 12 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.

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Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN3A pin 7 and X-CN3A pin 13. Connect the jumper from the positive battery post to UCM connector X-CN3A pin 7 and X-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 displayed. A. The fault code is not longer active. There is a problem in the wiring from between Splice SP-115 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 from the UCM 2SPD Fuse F-027 terminal E3 to chassis ground. The voltage should be approximately 12 V. A. The voltage is approximately 12 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 from the UCM Power Relay to the fuse. Check Splice 119 and associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. Small EH machines F5H engine Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03)

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Electrical systems - FAULT CODES

1916-UCM - Rail 12VU1: Right & Left Pumps Forward Input Power Off L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: UCM has sensed that a 12 V UCM input has failed low. Diagnostic Trouble Code 1916 has an error priority of Red. Forward Ground Drive is disabled while Diagnostic Trouble Code 1916 is active. Cause: UCM has sensed that a 12 V UCM input has failed low. The fault is active while Ignition is On, crank pin is low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V. Possible failure modes: 1. Blown fuse. 2. Open wire in circuit. 3. Shorted wire in circuit. 4. Failure of UCM. Solution: 1. 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 1916 is recorded again. Go to step 2. C. Fault code 1916 is recorded along with other diagnostic codes such as 1904, 1907 to 1915, 1917 and/or Right or Left Swatch Plate Sensor fault codes. 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 X-CN3A pin 21 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 from the UCM Pump FWD Fuse F-021 terminal B4 to chassis ground. The voltage should be approximately 12 V. A. The voltage is approximately 12 V. Go to step 4. B. The voltage is less than 9 V. Go to step 5. 4. Test the UCM connection.

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Electrical systems - FAULT CODES

Turn the ignition switch OFF. Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN3A pin 21. Connect the jumper from the positive battery post to UCM connector X-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 displayed. A. The fault code is not longer active. There is a problem in the wiring from 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 from the UCM Pump FWD Fuse F-021 terminal B3 to chassis ground. The voltage should be approximately 12 V. A. The voltage is approximately 12 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 from the UCM Power Relay to the fuse. Check Splice 119 and Splice 117. Repair as required. Return to step 1 to confirm elimination of the fault. Small EH machines F5H engine Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03)

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Electrical systems - FAULT CODES

1917-UCM - Rail 12VU2: Park Brake Solenoid Input Power Off L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: UCM has sensed that a 12 V UCM input has failed low. Diagnostic Trouble Code 1917 has an error priority of Red. Ground Drive is disabled while Diagnostic Trouble Code 1917 is active. Cause: UCM has sensed that a 12 V UCM input has failed low. The fault is active while the ignition is ON, crank pin is low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V. Possible failure modes: 1. Blown fuse. 2. Open wire in circuit. 3. Shorted wire in circuit. 4. Failure of UCM. Solution: 1. 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 1917 is recorded again. Go to step 2. C. If fault code 1917 is recorded along with other diagnostic codes such as 1904, 1907 to 1916 and/or Right or Left Swatch Plate Sensor fault codes. 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 X-CN3A pin 2 and X-CN3A pin 3 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 from the UCM GRND DRV Interlocks Fuse F-016 terminal A4 to chassis ground. The voltage should be approximately 12 V. A. The voltage is approximately 12 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.

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Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN3A pin 2 and X-CN3A pin 3. Connect the jumper from the positive battery post to UCM connector X-CN3A pin 2 and X-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 displayed. A. The fault code is not longer active. There is a problem in the wiring between Fuse F-017 and the UCM connector. Check Splice SP-114 and 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 from the UCM GRND DRV Interlocks Fuse F-016 terminal A3 to chassis ground. The voltage should be approximately 12 V. A. The voltage is approximately 12 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 from the UCM Power Relay to the fuse. Check Splice 119 and Splice 118 and associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. Small EH machines F5H engine Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03)

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Electrical systems - FAULT CODES

3390-Engine Air Filter Restriction Context: The instrument cluster detects a signal to ground on 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. Faulty air filter restriction 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 code: 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 connectors as required. Return to step 1 to confirm elimination of fault. 4. Test the air filter restriction circuit. Disconnect the signal wire from air filter restriction switch. Turn the ignition switch ON, engine OFF. Access the fault code screen on the Electronic Service Tool. The air filter restriction fault code should no longer be active. A. The fault code is no longer active. Go to Step 4. B. Fault code 3390 is still active. Go to step 5. 5. Check air filter restriction switch.

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Remove the air filter restriction switch from the air filter housing. Measure the resistance across the switch. The resistance should be greater than 20,000 Ω. A. The resistance is greater than 20,000 Ω. Inspect the wiring around the sensor. Go to Step 5. B. The resistance is less than 20,000 Ω. Temporarily replace the air filter restriction switch and retest. Return to step 1 to confirm elimination of fault. 6. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect instrument cluster connector X-C23. Measure the resistance between X-C23 pin 11 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 20,000 Ω. There is a short to chassis ground in the signal wire. Repair or replace the wire as required. Return to step 1 to confirm elimination of fault. Small mechanical machines Wire harnesses - Electrical schematic sheet 25 (55.100.DP-C.20.E.25) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Small EH machines Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Wire harnesses - Electrical schematic sheet 12 (55.100.DP-C.20.E.12) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03) Medium mechanical machines Wire harnesses - Electrical schematic sheet 21 (55.100.DP-C.20.E.21) Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) Medium EH machines Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Wire harnesses - Electrical schematic sheet 12 (55.100.DP-C.20.E.12) Wire harnesses - Electrical schematic sheet 03 (55.100.DP-C.20.E.03)

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Electrical systems - FAULT CODES

4043-Hydraulic Oil Temperature Sender Short To Ground Context: The hydraulic oil temperature signal is shorted to ground. Cause: The hydraulic oil temperature signal, X-C23 pin 16 has a short circuit. 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. Faulty sensor. 3. Faulty instrument cluster Solution: 1. Verify that the fault code is still active (1) Start and operate machine. (2)Use the Electronic Service Tool to view active fault codes. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. A. Fault 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. (1) Inspect Instrument Cluster connector X-C23 and the Hydraulic Oil Temperature Sensor connections. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) 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.

RAPH12SSL0141FA

(1)

Instrument Cluster connector X-C23 pin 16

Schematic Legend (2)

Hydraulic oil temperature sensor

A. The connectors are secure and 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 temperature of the signal wire to chassis ground. 47711684 06/05/2014

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(1) Turn the key switch OFF. (2) Disconnect the Instrument Cluster connector X-C23 and the hydraulic oil temperature sensor connector. (3) Measure the resistance from Hydraulic Oil Temperature Sensor signal wire X-C23 pin 16 to chassis ground. The resistance should be greater than 20,000 Ω . Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Go to Step 4. B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return to Step 1 to confirm elimination of the fault. 4. Measure the resistance of the Temperature Sensor (1) Measure the resistance of the temperature sensor to chassis ground. 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 greater than 30 Ω. Temporarily replace the Instrument Cluster and retest. Go to Step 1. B. The resistance measurements are not within range. The measured resistance is less than 30 Ω. Temporarily replace the temperature sensor and retest. Go to Step 1 to confirm elimination of fault. Mechanical Units F5H engine Wire harnesses - Electrical schematic sheet 21 (55.100.DP-C.20.E.21) Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) EH Units F5H engine Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Wire harnesses - Electrical schematic sheet 12 (55.100.DP-C.20.E.12) Small mechanical machines ISM engine Wire harnesses - Electrical schematic sheet 25 (55.100.DP-C.20.E.25) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Wire harnesses - Electrical schematic sheet 12 (55.100.DP-C.20.E.12) Medium mechanical machines ISM engine Wire harnesses - Electrical schematic sheet 21 (55.100.DP-C.20.E.21) Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Wire harnesses - Electrical schematic sheet 12 (55.100.DP-C.20.E.12)

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Electrical systems - FAULT CODES

4044-Hydraulic Oil Temperature Sender Open Circuit Context: The instrument cluster detects an open circuit in the hydraulic oil temperature signal. Cause: The hydraulic oil temperature signal, X-C23 pin 16 has an open circuit. The oil temperature sensor resistance is greater than 30,000 Ω. Possible failure modes: 1. Faulty wiring or connections from the hydraulic oil temperature sensor to the instrument cluster. 2. Faulty hydraulic oil temperature sensor. 3. Faulty instrument cluster. Solution: 1. Verify that the fault code is still active (1) Start and operate machine. (2)Use the Electronic Service Tool to view active fault codes. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. A. Fault 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. (1) Inspect Instrument Cluster connector X-C23 and the hydraulic oil temperature sensor connections. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) 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.

RAPH12SSL0141FA

(1)

Instrument Cluster connector X-C23 pin 16

Schematic Legend (2)

Hydraulic oil temperature sensor

A. The connectors are secure and 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. 47711684 06/05/2014

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(1) Turn the key switch OFF. Disconnect the Instrument cluster connector X-C23 and the Hydraulic Oil Temperature Sensor connector. (2) Measure the resistance from 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. (3) Measure the resistance from 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 resistance of the temperature signal wire to battery. (1) Turn the key switch ON. (2) 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. (1) 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. Go to Step 1. B. The resistance measurements were not within range. The measured resistance is greater than 10,000 Ω. Temporarily replace the temperature sensor and retest. Go to Step 1 to confirm elimination of fault. Mechanical Units F5H engine Wire harnesses - Electrical schematic sheet 21 (55.100.DP-C.20.E.21) Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) EH Units F5H engine Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Wire harnesses - Electrical schematic sheet 12 (55.100.DP-C.20.E.12) Small mechanical machines ISM engine Wire harnesses - Electrical schematic sheet 25 (55.100.DP-C.20.E.25) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 26 (55.100.DP-C.20.E.26) Wire harnesses - Electrical schematic sheet 12 (55.100.DP-C.20.E.12) Medium mechanical machines ISM engine 47711684 06/05/2014

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Wire harnesses - Electrical schematic Wire harnesses - Electrical schematic Medium EH machines ISM engine Wire harnesses - Electrical schematic Wire harnesses - Electrical schematic

sheet 21 (55.100.DP-C.20.E.21) sheet 10 (55.100.DP-C.20.E.10) sheet 26 (55.100.DP-C.20.E.26) sheet 12 (55.100.DP-C.20.E.12)

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4055-Park Brake Valve (On/Off) - Solenoid Supply Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: The UCM has sensed an open circuit in the park brake solenoid circuit. Diagnostic Trouble Code 4055 has an error priority of Red. Ground drive is disabled while Diagnostic Trouble Code 4055 is active. Cause: The UCM has sensed an open circuit in the park brake solenoid circuit. The fault is active when UCM pin voltage, X-CN3A pin 4 is less than 1 V or greater than 8 V. Possible failure modes: 1. Open wire in the circuit. 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 code: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4055 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 connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid wire. Turn the ignition switch OFF. Disconnect UCM connector X-CN3A. Measure the resistance between X-CN3A pin 4 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 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 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. 47711684 06/05/2014

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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 the solenoid ground wire, 960, BK 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 between connector X-CN3A and connector X-BRK. 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. Small EH machines Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Medium EH machines Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09)

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4056-Park Brake Valve (On/Off) - Solenoid Supply Short to Ground L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: There is a problem in the park brake solenoid circuit. Diagnostic Trouble Code 4056 has an error priority of Red. Ground drive is disabled while Diagnostic Trouble Code 4056 is active. Cause: The UCM has sent a signal to the park brake solenoid to energize, but no voltage is detected. The fault is active when the hydraulics are enabled, the park brake is disabled, and the current for the park brake solenoid is greater than 3 A. Possible failure modes: 1. A 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 code: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4056 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 connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid wire. Turn the ignition switch OFF. Disconnect UCM connector X-CN3A. Disconnect the park brake solenoid connector X-BRK. Measure the resistance between X-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. 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. 47711684 06/05/2014

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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. Small EH machines Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Medium EH machines Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09)

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4057-Park Brake Valve (On/Off) - Solenoid Supply Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: The UCM has sent a signal to the park brake valve solenoid to de-energize, but voltage is still detected on the output pin. Diagnostic Trouble Code 4057 has an error priority of Red. Ground drive is disabled while Diagnostic Trouble Code 4057 is active. Cause: The UCM has sent a signal to the park brake valve solenoid to de-energize, but voltage is still detected on the output pin. The fault is active while the hydraulics are disabled or the park brake is enabled and the voltage on the park brake solenoid pin, X-CN3A 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 code: Start and operate the machine. A. The fault is not recorded again. OK to return the machine to service. B. Fault code 4057 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 connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the solenoid wire. Turn the ignition switch OFF. Disconnect UCM connector X-CN3A. Disconnect the park brake solenoid connector X-BRK. Turn the ignition switch ON. Measure the voltage between X-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. 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. Small EH machines 47711684 06/05/2014

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Wire harnesses - Electrical Wire harnesses - Electrical Medium EH machines Wire harnesses - Electrical Wire harnesses - Electrical

schematic sheet 20 (55.100.DP-C.20.E.20) schematic sheet 09 (55.100.DP-C.20.E.09) schematic sheet 20 (55.100.DP-C.20.E.20) schematic sheet 09 (55.100.DP-C.20.E.09)

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4061-Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: The UCM has sensed improper Right Drive Pump Forward Solenoid current. Diagnostic Trouble Code 4061 has an error priority of Red. Forward ground drive is disabled while Diagnostic Trouble Code 4061 is active. Cause: The UCM has sensed improper Right Drive Pump Forward Solenoid current, X-CN3B pin 32. The fault is active while the hydraulics are enabled and solenoid resistance is greater than normal. Possible failure modes: 1. Open wire in circuit. 2. Right Drive Pump Forward solenoid has failed in the open position. 3. 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 4061 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 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 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 Right Drive Pump Forward solenoid connector X-17 pin 1 and X-17 pin 2. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3B and X-CN2B. Use the jumper wire to short X-17 pin 1 to X-17 pin 2. Measure the resistance between X-CN3B pin 32 and X-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.

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B. The resistance is greater than 10 Ω. There is an open circuit in the solenoid signal or 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-17 pin 1 and X-17 pin 2. Reconnect UCM connectors X-CN3B and X-CN2B. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4061 should no longer be active. Fault code 4062 should become active. A. Fault code 4062 is active and fault code 4061 is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4061 is still active. Fault code 4062 did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. EH machines F5H engine Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09)

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4062-Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: The UCM has sent a signal to the Right Forward Ground Drive Solenoid to energize, but no voltage detected. Diagnostic Trouble Code 4062 has an error priority of Red. Forward ground drive is disabled while Diagnostic Trouble Code 4062 is active. Cause: The UCM has sent a signal to the Right Forward Ground Drive Solenoid to energize, but no voltage detected. The fault is active while the hydraulics are enabled and Aux Override is disabled, the park brake is off and the solenoid output pin, X-CN3B pin 32 current is high. Possible failure modes: 1. Shorted wire in circuit. 2. Right Drive Pump Forward Solenoid has failed. 3. 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 4062 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 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 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 X-CN3B, X-CN2B and the Right Drive Pump Forward solenoid connector X-17. Measure the resistance between X-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 X-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. A. Both resistance measurements are greater than 20,000 Ω. Go to step 4. B. One or both resistance measurements is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return step 1 to confirm elimination of the fault. 47711684 06/05/2014

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4. Test the UCM. Reconnect UCM connectors X-CN3B and X-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 should no longer be active. Fault code 4061 should become active. A. Fault code 4061 is active and fault code 4062 is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4062 is still active. Fault code 4061 did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. EH machines F5H engine Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09)

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4071-Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: The UCM has sensed improper Left Drive Pump Forward Solenoid current. Diagnostic Trouble Code 4071 has an error priority of Red. Forward ground drive is disabled while Diagnostic Trouble Code 4071 is active. Cause: The UCM has sensed improper Left Drive Pump Forward Solenoid current, X-CN3B pin 33. The fault is active while the hydraulics are enabled and solenoid resistance is greater than normal. Possible failure modes: 1. An open wire in the circuit. 2. Left Drive Pump Forward solenoid has failed in the open position. 3. 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 4071 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 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 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 Left Drive Pump Forward solenoid connector X-13 pin 1 and X-13 pin 2. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3B and X-CN2B. Use the jumper wire to short X-13 pin 1 to X-13 pin 2. Measure the resistance between X-CN3B pin 33 and X-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.

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B. The resistance is greater than 10 Ω. There is an open circuit in the solenoid signal or 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-13 pin 1 and X-13 pin 2. Reconnect UCM connector X-CN3B and X-CN2B. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4071 should no longer be active. Fault code 4072 should become active. A. Fault code 4072 is active and fault code 4071 is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4071 is still active. Fault code 4072 did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. EH machines F5H engine Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09)

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4072-Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: The UCM has sent a signal to the Left Drive Pump Forward Solenoid to energize, but there is no voltage detected. Diagnostic Trouble Code 4072 has an error priority of Red. Forward ground drive is disabled while Diagnostic Trouble Code 4072 is active. Cause: The UCM has sent a signal to the Left Drive Pump Forward Solenoid to energize, but there is no voltage detected. The fault is activate while the hydraulics are enabled and Aux Override is disabled and Parking Brake is off and solenoid output pin, X-CN3B pin 33 current is high. Possible failure modes: 1. Shorted wire in the circuit. 2. The Left Drive Pump Forward 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4072 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 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 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 X-CN3B, X-CN2B and the Left Drive Pump Forward solenoid connector X-13. Measure the resistance between X-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 X-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. A. Both resistance measurements are greater than 20,000 Ω. Go to step 4. B. One or both resistance measurements is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return step 1 to confirm elimination of the fault. 47711684 06/05/2014

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4. Test the UCM. Reconnect UCM connectors X-CN3B and X-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 should no longer be active. Fault code 4071 should become active. A. Fault code 4071 is active and fault code 4072 is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4072 is still active. Fault code 4071 did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. EH machines F5H engine Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09)

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4081-Forward Pump Control Valves (Directional) - Common Solenoid Return Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 4081 has an error priority of Red. Forward Ground Drive is disabled while Diagnostic Trouble Code 4081 is active. Cause: UCM has sensed higher than normal voltage on the Forward Ground Drive Valve Solenoids ground line. The fault is active while Hydraulics are disabled and solenoid voltage feedback is greater than 5 V. Possible failure modes: 1. Shorted wire in circuit. 2. UCM has internal failure. Solution: 1. 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 4081 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 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 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-17 and X-13. Disconnect UCM connector X-CN2B and X-CN3B. Turn the ignition switch ON. Measure the voltage from X-17 pin 1 to chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage from X-17 pin 2 to chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage from X-13 pin 1 to chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage from X-13 pin 2 to 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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A. All voltage measurement are less than 0.5 V. Go to step 4. B. One or more voltage measurements is greater than 0.5 V. There is an short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connectors X-CN2B and X-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 should no longer be active. Fault code 4081 should become active. A. Fault code 4083 is active and fault code 4081 is no longer active. Temporarily replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4081 is still active. Fault code 4083 did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. EH machines F5H engine Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09)

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4082-Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: The UCM has sensed that the solenoid return voltage is low. Diagnostic Trouble Code 4082 has an error priority of Red. Forward ground drive is disabled while Diagnostic Trouble Code 4082 is active. Cause: The UCM has sensed that the solenoid return voltage is low. The fault is active while the hydraulics are disabled and solenoid return voltage feedback is low. Possible failure modes: 1. Shorted wire in circuit. 2. Failure of 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 the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4082 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 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 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 connector X-17 and X-13. Disconnect UCM connector X-CN2B and X-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. 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. 47711684 06/05/2014

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B. One or more resistance measurements is less than 20,000 Ω. There is an short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connectors X-CN2B and X-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 should no longer be active. Fault code 4083 should become active. A. Fault code 4083 is active and fault code 4082 is no longer active. Temporarily replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4082 is still active. Fault code 4083 did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. EH machines F5H engine Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09)

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4083-Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: The UCM has sensed improper Forward Pump Control Valve solenoid current. Diagnostic Trouble Code 4083 has an error priority of Red. Forward ground drive operating mode is disabled while Diagnostic Trouble Code 4083 is active. Cause: The UCM has sensed improper Forward Pump Control Valve solenoid current, X-CN2B pin 25. The fault is active when the hydraulics are enabled and solenoid return current is incorrect. Possible failure modes: 1. Open wire in solenoid ground 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4083 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 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 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 Right Drive Pump Reverse solenoid connector X-18 pin 1 and X-18 pin 2. Turn the ignition switch OFF. Disconnect UCM connectors X-CN2A and X-CN1A. Disconnect connectors X-18 and X-16. Use the jumper wire to short X-18 pin 1 to X-18 pin 2. Measure the resistance between X-CN2A pin 8 and X-CN1A pin 19. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Use the jumper wire to short X-16 pin 1 to X-16 pin 2.

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Measure the resistance between X-CN2A pin 14 and X-CN1A pin 19. 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 is greater than 10 Ω. There is an open circuit in the solenoid signal or 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. Turn the ignition switch OFF. Reconnect UCM connectors X-CN2B and X-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 4081 should no longer be active. Fault code 4083 should become active. A. Fault code 4083 is active and fault code 4081 is no longer active. Temporarily replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4081 is still active. Fault code 4083 did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. EH machines F5H engine Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09)

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4309-Park Brake Button - Park Brake Button Timeout (30 sec) L218 L220

WE WE

Context: Diagnostic Trouble Code 4309 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. There are no restrictions with Diagnostic Trouble Code 4309. Cause: UCM has sensed that the signal has failed. (The fault is only activated when Ignition is On and Park Brake button output is high for more than 30 s.) Possible failure modes: 1. Failure of Park Brake switch. 2. Failure of UCM. 3. Failure of Instrument Cluster. Solution: 1. Use the machine to recreate conditions for error. Use the EST to verify 4309 - Park Brake Button - Park Brake Button Timeout (30 sec) is active. A. If the fault is active, continue with step 2. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 3. 2. Check for proper resistance in the PARK BRAKE SWITCH. Disconnect connector X-406 from the PARK BRAKE SWITCH. Using a multi-meter, check for resistance between PARK BRAKE SWITCH pins A and B. A. If resistance is infinite, the PARK BRAKE SWITCH is not closed. Continue with step 3. B. If resistance is 0 Ω, the PARK BRAKE SWITCH has shorted internally. Replace the PARK BRAKE SWITCH. 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 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 continue operation. Wire harnesses - Electrical schematic sheet 26 Wire harnesses - Electrical schematic sheet 02 Wire harnesses - Electrical schematic sheet 03 Wire harnesses - Electrical schematic sheet 07

readings are indicated, erase the Diagnostic Trouble Code and (55.100.DP-C.20.E.26) (55.100.DP-C.20.E.02) (55.100.DP-C.20.E.03) (55.100.DP-C.20.E.07)

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4309-Park Brake Button - Park Brake Button Timeout (30 sec) L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 4309 has an error priority of White. White errors are not displayed on the instrument cluster and are not known to the Owner/Operator. They will appear in EST when the technician checks for active trouble codes. Cause: The UCM has sensed that the signal has failed. The fault is active when the voltage on the park brake input, X-CN2B pin 22 is greater than 10 V for more than 30 s. Possible failure modes: 1. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4309 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 voltage on the signal wire. Turn the ignition switch OFF. Disconnect UCM connector X-CN2B. Disconnect right joystick harness X-406. Turn the ignition switch ON. Measure the voltage between X-406 pin B to chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit 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.

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Leave connector X-406 disconnected. Verify that the parking brake switch is in the OFF position. Measure the resistance between park brake switch pin A and pin B. The resistance should be greater than 20,000 Ω. A. The resistance is greater than 20,000 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 20,000 Ω. The switch has an internal short circuit. Replace the switch and retest. Return to step 1 to confirm elimination of fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Case models Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland models Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Case models Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland models Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17)

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4361-Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: The UCM has sensed improper Right Drive Pump Reverse Solenoid current. Diagnostic Trouble Code 4361 has an error priority of Red. Reverse ground drive is disabled while Diagnostic Trouble Code 4361 is active. Cause: The UCM has sensed improper Right Drive Pump Reverse Solenoid current, X-CN2A pin 8. The fault is active while the hydraulics are enabled and solenoid resistance is greater than normal. Possible failure modes: 1. An open wire in circuit. 2. The Right Drive Pump Reverse solenoid has failed in the open position. 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 4361 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 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 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 Right Drive Pump Reverse solenoid connector X-18 pin 1 and X-18 pin 2. Turn the key switch OFF. Disconnect UCM connectors X-CN2A and X-CN1A. Use the jumper wire to short X-18 pin 1 to X-18 pin 2. Measure the resistance between X-CN2A pin 8 and X-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.

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B. The resistance is greater than 10 Ω. There is an open circuit in the solenoid signal or 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 connector X-CN2A and X-CN1A. Turn the key switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4361 should no longer be active. Fault code 4362 should become active. A. Fault code 4362 is active and fault code 4361 is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4361 is still active. Fault code 4362 did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. EH machines F5H engine Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09)

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4362-Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: The UCM has sent a signal to the Right Reverse Ground Drive Solenoid to energize, but no voltage detected. Diagnostic Trouble Code 4362 has an error priority of Red. Reverse ground drive is disabled while Diagnostic Trouble Code 4362 is active. Cause: The UCM has sent a signal to the Right Reverse Ground Drive Solenoid to energize, but there is no voltage detected. The fault is active when hydraulics are enabled and Aux Override is disabled and Park Brake is off and solenoid output pin, X-CN2A pin 8 current is high. Possible failure modes: 1. Shorted wire in circuit. 2. The Right Drive Pump Reverse 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4362 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 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 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 X-CN2A, X-CN1A and Right Drive Pump Reverse solenoid connector X-18. Measure the resistance between X-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 X-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. A. Both resistance measurements are greater than 20,000 Ω. Go to step 4. B. One or both resistance measurements is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return step 1 to confirm elimination of the fault. 47711684 06/05/2014

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4. Test the UCM. Reconnect UCM connectors X-CN2A and X-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 should no longer be active. Fault code 4361 should become active. A. Fault code 4361 is active and fault code 4362 is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4362 is still active. Fault code 4361 did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. EH machines F5H engine Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09)

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4371-Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: The UCM has sensed improper Left Drive Pump Reverse Solenoid current. Diagnostic Trouble Code 4371 has an error priority of Red. Reverse ground drive is disabled while Diagnostic Trouble Code 4371 is active. Cause: the UCM has sensed improper Left Drive Pump Reverse Solenoid current, X-CN2A pin 14. The fault is active while the hydraulics are enabled and solenoid resistance is greater than normal. Possible failure modes: 1. Open wire in circuit. 2. The Left Drive Pump Reverse solenoid has failed in the open position. 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 4371 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 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 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 Left Drive Pump Reverse solenoid connector X-16 pin 1 and X-16 pin 2. Turn the ignition switch OFF. Disconnect UCM connectors X-CN2A and X-CN1A. Use the jumper wire to short X-16 pin 1 to X-16 pin 2. Measure the resistance between X-CN2A pin 14 and X-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.

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B. The resistance is greater than 10 Ω. There is an open circuit in the solenoid signal or 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-16 pin 1 and X-16 pin 2. Reconnect UCM connector X-CN2A and X-CN1A. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4371 should no longer be active. Fault code 4372 should become active. A. Fault code 4372 is active and fault code 4371 is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4371 is still active. Fault code 4372 did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. EH machines F5H engine Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09)

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4372-Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: The UCM has sent a signal to the Left Drive Pump Reverse Solenoid to energize, but no voltage detected. Diagnostic Trouble Code 4372 has an error priority of Red. Reverse Ground Drive is disabled while Diagnostic Trouble Code 4372 is active. Cause: The UCM has sent a signal to the Left Drive Pump Reverse Solenoid to energize, but no voltage detected. The fault is active when the hydraulics are enabled and Aux Override is disabled and Parking Brake is off and solenoid output pin, X-CN2A pin 14 current is high. Possible failure modes: 1. Shorted wire in circuit. 2. The Left Drive Pump Reverse 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4372 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 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 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 X-CN2A, X-CN1A and the Left Drive Pump Reverse solenoid connector X-16. Measure the resistance between X-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 X-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. A. Both resistance measurements are greater than 20,000 Ω. Go to step 4. B. One or both resistance measurements is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return step 1 to confirm elimination of the fault. 47711684 06/05/2014

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4. Test the UCM. Reconnect UCM connectors X-CN2A and X-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 should no longer be active. Fault code 4371 should become active. A. Fault code 4371 is active and fault code 4372 is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4372 is still active. Fault code 4371 did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. EH machines F5H engine Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09)

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4381-Reverse Pump Control Valves (Directional) - Common Solenoid Return Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: The UCM has sensed higher than normal voltage on the Reverse Ground Drive Valve Solenoids ground line. Diagnostic Trouble Code 4381 has an error priority of Red. Reverse ground drive is disabled while Diagnostic Trouble Code 4381 is active. Cause: The UCM has sensed higher than normal voltage on the Reverse Ground Drive Valve Solenoids ground line. The fault is active while hydraulics are disabled and solenoid voltage feedback is greater than 5 V. Possible failure modes: 1. Shorted wire in circuit. 2. UCM has internal failure. Solution: 1. 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 4081 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 and the Left Drive Pump Reverse 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 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 X-CN2A and X-CN1A. Turn the ignition switch ON. Measure the voltage from X-18 pin 1 to chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage from X-18 pin 2 to chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage from X-16 pin 1 to chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage from X-16 pin 2 to chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. 47711684 06/05/2014

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A. All voltage measurement are less than 0.5 V. Go to step 4. B. One or more voltage measurements is greater than 0.5 V. There is an short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connectors X-CN2A and X-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 should no longer be active. Fault code 4383 should become active. A. Fault code 4383 is active and fault code 4382 is no longer active. Temporarily replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4382 is still active. Fault code 4383 did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. EH machines F5H engine Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09)

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4382-Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: The UCM has sensed that the solenoid return voltage is low. Diagnostic Trouble Code 4382 has an error priority of Red. Reverse ground drive is disabled while Diagnostic Trouble Code 4382 is active. Cause: The UCM has sensed that the solenoid return voltage is low. The fault is active when the hydraulics are disabled and solenoid return voltage feedback is low. Possible failure modes: 1. Shorted wire in circuit. 2. Failure of 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 the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4382 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage.

RAPH12SSL0385FA

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(1)

(2)

(3) (4) (5)

Schematic legend (6)

Pump Right Reverse UCM Connector X-CN2A pin 8 Pump Left Reverse UCM Connector X-CN2A pin 14 M-018 Right Drive Pump Reverse M-016 Left Drive Pump Reverse Drive Reverse Return UCM Connector X-CN1A pin 19

(7)

(8) (9) (10)

Pump Right Forward UCM Connector X-CN3B pin 32 Pump Left Forward UCM Connector X-CN3B pin 33 M-017 Right Drive Pump Forward M-013 Left Drive Pump Forward Drive Forward Return UCM Connector X-CN2B pin 25

(1) Inspect the UCM, Right Drive Pump Reverse and Left Drive Pump Reverse connections. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the UCM to the Right Drive Pump Reverse solenoid and 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 resistance of the solenoid wires to chassis ground. Turn the ignition switch OFF. Disconnect solenoid connector X-18 and X-16. Disconnect UCM connector X-CN2A and X-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. 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 is less than 20,000 Ω. There is an short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connectors X-CN2A and X-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 should no longer be active. Fault code 4383 should become active. A. Fault code 4383 is active and fault code 4382 is no longer active. Temporarily replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4382 is still active. Fault code 4383 did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. EH machines F5H engine Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) 47711684 06/05/2014

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Wire harnesses - Electrical schematic Wire harnesses - Electrical schematic Small EH machines ISM engine Wire harnesses - Electrical schematic Wire harnesses - Electrical schematic Medium EH machines ISM engine Wire harnesses - Electrical schematic Wire harnesses - Electrical schematic

sheet 19 (55.100.DP-C.20.E.19) sheet 20 (55.100.DP-C.20.E.20) sheet 19 (55.100.DP-C.20.E.19) sheet 09 (55.100.DP-C.20.E.09) sheet 19 (55.100.DP-C.20.E.19) sheet 09 (55.100.DP-C.20.E.09)

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4383-Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: The UCM has sensed improper Forward Pump Control Valve solenoid current. Diagnostic Trouble Code 4383 has an error priority of Red. Reverse ground drive operating mode is disabled while Diagnostic Trouble Code 4383 is active. Cause: The UCM has sensed improper Forward Pump Control Valve solenoid current, X-CN1A pin 19. The fault is active when the hydraulics are enabled and solenoid return current is incorrect. Possible failure modes: 1. Open wire in solenoid ground circuit. 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 4383 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 and the Left Drive Pump Reverse 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 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 resistance through the harness. Fabricate a jumper wire that will connect between the Right Drive Pump Forward solenoid connector X-17 pin 1 and X-17 pin 2. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3B and X-CN2B. Disconnect connectors X-17 and X-13. Use the jumper wire to short X-17 pin 1 to X-17 pin 2. Measure the resistance between X-CN3B pin 32 and X-CN2B pin 25. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Use the jumper wire to short X-13 pin 1 to X-13 pin 2.

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Measure the resistance between X-CN3B pin 33 and X-CN2B pin 25. 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 is greater than 10 Ω. There is an open circuit in the solenoid signal or 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. Turn the ignition switch OFF. Reconnect UCM connector X-CN3B and X-CN2B. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4383 should no longer be active. Fault code 4381 should become active. A. Fault code 4381 is active and fault code 4383 is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4383 is still active. Fault code 4381 did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. EH machines F5H engine Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09)

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Electrical systems - FAULT CODES

4401-Park Brake (Mechanical Machines) - Park Brake Solenoid - Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

Context: 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. Open wire in circuit. 2. The brake valve solenoid has failed. 3. The instrument cluster has an internal failure. Solution: 1. Verify that the fault code is active. (1) Use the Electronic Service Tool to clear all fault codes. Prior to clearing fault codes, write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) To check for active fault codes: Start and operate machine. A. The fault 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.

RAPH12SSL0400FA

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(1) (2)

Schematic legend (3)

Instrument cluster Connector X-C23 Park brake switch signal to the instrument (4) cluster.

Cab to interface harness Connector X-CC2A/2B pin 3 Park brake solenoid Connector X-BRK

(1) Inspect the instrument cluster and the park brake solenoid connections. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) 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 connectors as required. Return to Step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid wire. (1) Turn the key switch OFF. (2) Disconnect instrument cluster connector X-C23 . (3) 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. Go to Step 4. 4. Measure the resistance through the solenoid. (1) Disconnect the brake valve solenoid connector X-BRK. (2) Measure the resistance across the solenoid terminals. The resistance should be less than 100 Ω. A. The resistance is less than 100 Ω. Go to Step 5. 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. (1) Leave connector X-BRK disconnected. (2) Measure the resistance between the solenoid ground wire, 960, BK 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 100 Ω. There is an open circuit between connector X-C23 and connector X-BRK . Repair or replace the harness as required. 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 ground wire. Repair or replace the harness as required. Return to Step 1 to confirm elimination of the fault. F5H engine Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Small mechanical machines ISM engine Wire harnesses - Electrical schematic sheet 25 (55.100.DP-C.20.E.25) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines ISM engine Wire harnesses - Electrical schematic sheet 15 (55.100.DP-C.20.E.15) 47711684 06/05/2014

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Case machines ISM engine Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines ISM engine Wire harnesses - Electrical schematic sheet 15 (55.100.DP-C.20.E.15) New Holland machines ISM engine Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) Medium mechanical machines ISM engine Wire harnesses - Electrical schematic sheet 21 (55.100.DP-C.20.E.21) Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) Case machines ISM engine Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Case machines ISM engine Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) New Holland machines ISM engine Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) New Holland machines ISM engine Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13)

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Electrical systems - FAULT CODES

4402-Park Brake (Mechanical Machines) - Park Brake Solenoid Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

Context: Diagnostic Trouble Code 4402 has an error priority of Red. 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 off, the brake commanded state, X-C23 pin 21 is low. Possible failure modes: 1. Signal wire is has a short circuit to another voltage source. 2. Instrument Cluster has an internal failure. Solution: 1. Verify that the fault code is active. (1) Use the Electronic Service Tool to clear all fault codes. Prior to clearing fault codes, write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) To check for active fault codes: Start and operate machine. A. The fault 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.

RAPH12SSL0400FA

(1) (2)

Schematic legend Instrument cluster (3) Connector X-C23 Park brake switch signal to the instrument (4) cluster. 47711684 06/05/2014

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Cab to interface harness Connector X-CC2A/2B pin 3 Park brake solenoid Connector X-BRK

Electrical systems - FAULT CODES

(1) Inspect the instrument cluster and the park brake solenoid connections. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) 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 connectors as required. Return to Step 1 to confirm elimination of fault. 3. Measure the voltage through the solenoid wire. (1) Turn the ignition switch OFF. (2) Disconnect instrument cluster connector X-C23. (3) Disconnect the park brake solenoid connector X-BRK . (4) Turn the ignition switch ON. (5) 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. F5H engine Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Small mechanical machines ISM engine Wire harnesses - Electrical schematic sheet 25 (55.100.DP-C.20.E.25) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines ISM engine Wire harnesses - Electrical schematic sheet 15 (55.100.DP-C.20.E.15) Case machines ISM engine Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines ISM engine Wire harnesses - Electrical schematic sheet 15 (55.100.DP-C.20.E.15) New Holland machines ISM engine Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) Medium mechanical machines ISM engine Wire harnesses - Electrical schematic sheet 21 (55.100.DP-C.20.E.21) Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) Case machines ISM engine Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Case machines ISM engine Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) New Holland machines ISM engine Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) New Holland machines ISM engine Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13)

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Electrical systems - FAULT CODES

4431-Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: UCM has sensed disagreement between the park brake pressure switch and the park brake solenoid. Diagnostic Trouble Code 4431 has an error priority of amber. There are no restrictions while Diagnostic Trouble Code 4431 is active. Cause: UCM has sensed disagreement between the park brake pressure switch and the park brake solenoid. The fault is active while engine is running and the park brake pressure switch input X-CN2B pin 13 is ON and the solenoid current output X-CN3A pin 4 is less than 1 A or The park brake pressure switch input X-CN2B pin 13 is OFF and the solenoid current output X-CN3A pin 4 is greater than 1 A. Possible failure modes: 1. Low charge pressure. 2. Open or shorted wire in the circuit. 3. Failure of the park brake solenoid. 4. Failure of the park brake pressure switch. 5. 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 the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4431 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 is still active. Go to step 3. B. Charge pressure is not correct. Repair the cause of 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. 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. Use EST to test the system. 47711684 06/05/2014

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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 will be come active after 30 minutes. Go to troubleshooting procedure 4309. B. The park brake switch status is OFF. The solenoid status is ON. Fault code 4056 is active. Go to troubleshooting procedure 4056. C. The park brake switch status is OFF and the solenoid status is OFF. Fault code 4431 is not active. Go to step 5 to confirm elimination of fault. 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 is active. Go to step 6. B. The park brake switch status is ON and the solenoid status is ON. Fault code 4431 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 and install a jumper wire that will connect between X-BRKPRS pin 1 and pin 2. 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. A. The park brake status is ON. Fault code 4431 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 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 pin 2. 47711684 06/05/2014

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Disconnect UCM connector X-CN2B. Measure the resistance between X-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 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. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09)

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Electrical systems - FAULT CODES

4731-Right Swash Plate Sensor - Pin A Short to Ground/ Open Circuit Right Hand Pump Angle #1 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: The UCM has sensed that the swash plate angle sensor signal has failed. Diagnostic Trouble Code 4731 has an error priority of Amber. Limp home ground drive operating mode is enabled while Diagnostic Trouble Code 4731 is active. Cause: The UCM has sensed that the swash plate angle sensor signal has failed low. The fault is active while the engine is on and the Right Swash Plate Angle Sensor voltage, X-CN2B pin 32 is less than 0.2 V. Possible failure modes: 1. A short circuit to chassis ground. 2. An open circuit in the sensor signal wire. 3. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4731 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. 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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B. The voltage measurement is less than 10 V. There is a problem in the voltage supply or sensor ground wire to the sensor. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN2B. Disconnect Right Hand Swash Plate Sensor connector X-93. Measure the resistance from connector X-CN2B pin 32 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 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. Fabricate a jumper wire that will connect between the UCM connector X-CN2B and chassis ground. Turn the ignition switch OFF. Disconnect connectors X-CN2B and X-93. Use the jumper wire to connect X-CN2B pin 32 to 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 UCM connector X-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 4731 should no longer be active. Fault code 4744 is active. A. Fault code 4731 is no longer active. Fault code 4744 is active. Replace the Swash Plate Angle sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4731 is still active. Fault code 4744 did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) 47711684 06/05/2014

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4732-Right Swash Plate Sensor - Pin A Short to Power Right Hand Pump Angle #1 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Context: he UCM has sensed a higher than normal voltage from the right hand swash plate sensor. Diagnostic Trouble Code 4732 has an error priority of Amber. Limp home ground drive operating mode is enabled while Diagnostic Trouble Code 4732 is active. Cause: The UCM has sensed a higher than normal voltage from the right hand swash plate sensor. The fault is active while the engine is on and the swash plate angle sensor voltage, X-CN2B pin 32 is greater than 4.8 V. Possible failure modes: 1. The signal wire has a short circuit to another voltage source. 2. 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 code: Start and operate the machine. A. The fault is not recorded again. OK to return the machine to service. B. Fault code 4732 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. Measure the voltage on the sensor signal wire. Turn the ignition switch OFF. Disconnect the right hand swash plate sensor connector X-93. Disconnect UCM connector X-CN2B. 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 connectors as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM.

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Turn the ignition switch OFF. Reconnect UCM connector X-CN2B. Disconnect swash plate sensor connectors X-93 and X-94. Connect the left hand swash plate sensor harness on to the right hand swash plate sensor. Connect the right hand swash plate sensor harness on to the left hand swash plate sensor. Turn the ignition switch ON. Monitor the active diagnostic screen. Fault code 4732 should no longer be active. Fault code 4745 is active. A. Fault code 4732 is no longer active. Fault code 4745 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 is still active. Fault code 4745 did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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4734-Right Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit Right Hand Pump Angle #2 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Context: The UCM has sensed that the swash plate angle sensor signal has failed. Diagnostic Trouble Code 4734 has an error priority of Amber. Limp home ground drive operating mode is enabled while Diagnostic Trouble Code 4734 is active. Cause: The UCM has sensed that the swash plate angle sensor signal has failed low. The fault is active while the engine is on and the Right Swash Plate Angle Sensor voltage, X-CN2B pin 33 is less than 0.2 V. Possible failure modes: 1. A short circuit to chassis ground. 2. An open circuit in the sensor signal wire. 3. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4734 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. Measure the supply voltage to 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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B. The voltage measurement is less than 10 V. There is a problem in the voltage supply or sensor ground wire to the sensor. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN2B. Disconnect Right Hand Swash Plate Sensor connector X-93. Measure the resistance from connector X-CN2B pin 33 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 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. Fabricate a jumper wire with alligator clips that can reach between the UCM connector X-CN2B and chassis ground. Turn the ignition switch OFF. Disconnect connectors X-CN2B and X-93. Use the jumper wire to connect X-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. The resistance measurement is less than 10 Ω. Go to step 6. B. The resistance measurement is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 6. Test the UCM. Turn the ignition switch OFF. Remove the jumper wire. Reconnect UCM connector X-CN2B. 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 should no longer be active. Fault code 4741 is active. A. Fault code 4734 is no longer active. Fault code 4741 is active. Replace the Swash Plate Angle sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4734 is still active. Fault code 4741 did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) 47711684 06/05/2014

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Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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4735-Right Swash Plate Angle Sensor - Pin B Short to Power Right Hand Pump Angle #2 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Context: Diagnostic Trouble Code 4735 has an error priority of Amber. Limp Home Ground Drive operating mode is enabled while Diagnostic Trouble Code 4735 is active. Cause: The UCM has sensed a higher than normal voltage from the right hand swash plate sensor. The fault is active while the engine is on and the swash plate angle sensor voltage, X-CN2B pin 33 is greater than 4.8 V. Possible failure modes: 1. The signal wire has a short circuit to another voltage source. 2. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4735 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. Measure the voltage on the sensor signal wire. Turn the ignition switch OFF. Disconnect the right hand swash plate sensor connector X-93. Disconnect UCM connector X-CN2B. 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 connectors as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. Turn the ignition switch OFF. 47711684 06/05/2014

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Reconnect UCM connector X-CN2B. Disconnect swash plate sensor connectors X-93 and X-94. Connect the left hand swash plate sensor harness on to the right hand swash plate sensor. Connect the right hand swash plate sensor harness on to the left hand swash plate sensor. Turn the ignition switch ON. Monitor the active diagnostic screen. Fault code 4735 should no longer be active. Fault code 4742 is active. A. Fault code 4735 is no longer active. Fault code 4742 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 is still active. Fault code 4742 did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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4737-Right Swash Plate Angle Sensor - In Range Fault Right Hand Pump Angle #1 and Right Hand Pump Angle #2 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Context: The UCM has sensed that the right swash plate angle sensor has failed. Diagnostic Trouble Code 4737 has an error priority of Amber. Limp home ground drive operating mode is enabled while Diagnostic Trouble Code 4737 is active. Cause: The UCM has sensed that the right swash plate angle sensor has failed. The fault is active while of the swash plate angle sensor inputs, X-CN2B pin 32 and X-CN2B pin 33 are less than 4.8 V or greater than 5.2 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4737 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. 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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B. The voltage measurement is less than 10 V. There is a problem in the voltage supply or sensor ground wire to the sensor. Check splice SP-136. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN2B. Disconnect Right Hand Swash Plate Sensor connector X-93. Measure the resistance from connector X-CN2B pin 32 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 from connector X-CN2B pin 33 to 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 connectors as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Fabricate a jumper wire with alligator clips that can reach between the UCM connector X-CN2B and chassis ground. Turn the ignition switch OFF. Disconnect connectors X-CN2B and X-93. Use the jumper wire to connect X-CN2B pin 32 to 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 X-CN2B pin 32. Use the jumper wire to connect X-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 X-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 4737 should no longer be active. Fault code 4747 is active. A. Fault code 4737 is no longer active. Fault code 4747 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 4737 is still active. Fault code 4747 did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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4741-Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit Left Hand Angle #1 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Context: The UCM has sensed that the swash plate angle sensor signal has failed low. Diagnostic Trouble Code 4741 has an error priority of Amber. Limp home ground drive operating mode is enabled while Diagnostic Trouble Code 4741 is active. Cause: The UCM has sensed that the swash plate angle sensor signal has failed low. The fault is active while the engine is on and the Left Swash Plate Angle Sensor voltage, X-CN3A pin 9 is less than 0.2 V. Possible failure modes: 1. A short circuit to chassis ground. 2. An open circuit in the sensor signal wire. 3. 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 code: Start and operate the machine. A. The fault is not recorded again. OK to return the machine to service. B. Fault code 4741 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. 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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B. The voltage measurement is less than 10 V. There is a problem in the voltage supply or sensor ground wire to the sensor. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN3A. Disconnect the Left Hand Swash Plate Sensor connector X-94. Measure the resistance from connector X-CN3A 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 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. Fabricate a jumper wire that will connect between the UCM connector X-CN3A and chassis ground. Turn the ignition switch OFF. Disconnect X-CN3A and X-94. Use the jumper wire to connect X-CN3A pin 9 to 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 X-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 should no longer be active. Fault code 4734 is active. A. Fault code 4741 is no longer active. Fault code 4734 is active. Replace the Swash Plate Angle sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4741 is still active. Fault code 4734 did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) 47711684 06/05/2014

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4742-Left Swash Plate Angle Sensor - Pin A Short to Power Left Hand Angle #1 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Context: The UCM has sensed a higher than normal voltage from the left hand swash plate sensor. Diagnostic Trouble Code 4742 has an error priority of Amber. Limp home ground drive operating mode is enabled while Diagnostic Trouble Code 4742 is active. Cause: The UCM has sensed a higher than normal voltage from the left hand swash plate sensor. The fault is active while the engine is on and the swash plate angle sensor voltage, X-CN3A pin 9 is greater than 4.8 V. Possible failure modes: 1. The signal wire has a short circuit to another voltage source. 2. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4742 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. Measure the voltage on the sensor signal wire. Turn the ignition switch OFF. Disconnect the left hand swash plate sensor connector X-94. Disconnect UCM connector X-CN3A. 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 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 connectors as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM.

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Turn the ignition switch OFF. Reconnect UCM connector X-CN3A. Disconnect swash plate sensor connectors X-93 and X-94. Connect the left hand swash plate sensor harness on to the right hand swash plate sensor. Connect the right hand swash plate sensor harness on to the left hand swash plate sensor. Turn the ignition switch ON. Monitor the active diagnostic screen. Fault code 4742 should no longer be active. Fault code 4735 is active. A. Fault code 4742 is no longer active. Fault code 4735 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 is still active. Fault code 4735 did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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4744-Left Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit Left Hand Pump Angle #2 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Context: The UCM has sensed that the swash plate angle sensor signal has failed low. Diagnostic Trouble Code 4744 has an error priority of Amber. Limp home ground drive operating mode is enabled while Diagnostic Trouble Code 4734 is active. Cause: The UCM has sensed that the swash plate angle sensor signal has failed low. The fault is active while the engine is on and the Left Swash Plate Angle Sensor voltage, X-CN3A pin 10 is less than 0.2 V. Possible failure modes: 1. A short circuit to chassis ground. 2. An open circuit in the sensor signal wire. 3. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4744 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. Measure the supply voltage to 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-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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B. The voltage measurement is less than 10 V. There is a problem in the voltage supply or sensor ground wire to the sensor. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN3A. Disconnect Left Hand Swash Plate Sensor connector X-94. Measure the resistance from connector X-CN3A pin 10 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 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. Fabricate a jumper wire with alligator clips that can reach between the UCM connector X-CN3A and chassis ground. Turn the ignition switch OFF. Disconnect connectors X-CN3A and X-94. Use the jumper wire to connect X-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 X-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 should no longer be active. Fault code 4731 is active. A. Fault code 4744 is no longer active. Fault code 4731 is active. Replace the Swash Plate Angle sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4744 is still active. Fault code 4731 did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) 47711684 06/05/2014

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Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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4745-Left Swash Plate Angle Sensor - Pin B Short to Power Left Hand Pump Angle #2 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Context: The UCM has sensed a higher than normal voltage from the left hand swash plate sensor. Diagnostic Trouble Code 4745 has an error priority of Amber. Limp home ground drive operating mode is enabled while Diagnostic Trouble Code 4745 is active. Cause: The UCM has sensed a higher than normal voltage from the left hand swash plate sensor. The fault is active while the engine is on and the swash plate angle sensor voltage, X-CN3A pin 10 is greater than 4.8 V. Possible failure modes: 1. The signal wire has a short circuit to another voltage source. 2. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4745 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. Measure the voltage on the sensor signal wire. Turn the ignition switch OFF. Disconnect the right hand swash plate sensor connector X-94. Disconnect UCM connector X-CN3A. 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 connectors as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM.

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Turn the ignition switch OFF. Reconnect UCM connector X-CN3A. Disconnect swash plate sensor connectors X-93 and X-94. Connect the left hand swash plate sensor harness on to the right hand swash plate sensor. Connect the right hand swash plate sensor harness on to the left hand swash plate sensor. Turn the ignition switch ON. Monitor the active diagnostic screen. Fault code 4745 should no longer be active. Fault code 4732 is active. A. Fault code 4745 is no longer active. Fault code 4732 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 is still active. Fault code 4732 did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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4747-Left Swash Plate Angle Sensor - In Range Fault Left Hand Pump Angle #1 and Left Hand Pump Angle #2 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Context: The UCM has sensed that the left swash plate angle sensor has failed. Diagnostic Trouble Code 4747 has an error priority of Amber. Limp home ground drive operating mode is enabled while Diagnostic Trouble Code 4747 is active. Cause: The UCM has sensed that the left swash plate angle sensor has failed. The fault is active while of the swash plate angle sensor inputs, X-CN3A pin 9 and X-CN3A pin 10 are less than 4.8 V or greater than 5.2 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4747 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. 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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B. The voltage measurement is less than 10 V. There is a problem in the voltage supply or sensor ground wire to the sensor. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN3A. Disconnect left hand swash plate sensor connector X-94. Measure the resistance from connector X-CN3A pin 9 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 from connector X-CN3A pin 10 to 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 connectors 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 the UCM connector X-CN3A and chassis ground. Turn the ignition switch OFF. Disconnect connectors X-CN3A and X-94. Use the jumper wire to connect X-CN3A pin 9 to 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 X-CN3A pin 9. Use the jumper wire to connect X-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. Both resistance measurements are less than 10 Ω. Go to step 6. B. One or both resistance measurements are greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 6. Test the UCM. Turn the ignition switch OFF. Remove the jumper wire. Reconnect UCM connector X-CN3A. 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 4747 should no longer be active. Fault code 4737 is active. A. Fault code 4747 is no longer active. Fault code 4737 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 4747 is still active. Fault code 4737 did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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4752-Left Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle Left Hand Pump Angle #1 and Left Hand Pump Angle #2 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Context: The UCM has sensed that the swash plate sensor signal does not agree with the direction of vehicle travel. Diagnostic Trouble Code 4752 has an error priority of Red. Forward and reverse functions are disabled while Diagnostic Trouble Code 4752 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4752 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. 4. Verify that the swash plate sensors are connected properly. 47711684 06/05/2014

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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. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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4754-Right Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle Right Hand Pump Angle #1 and Right Hand Pump Angle #2 L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Context: The UCM has sensed that the swash plate sensor signal does not agree with the direction of vehicle travel. Diagnostic Trouble Code 4754 has an error priority of Red. Forward and reverse functions are disabled while Diagnostic Trouble Code 4754 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 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4754 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. 4. Verify that the swash plate sensors are connected properly. 47711684 06/05/2014

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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. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Wire harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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4781-Solenoid Valve - Solenoid Supply Open Circuit Two Speed Solenoid L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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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 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST when the technician checks for active trouble codes. Two Speed operating mode is disabled while Diagnostic Trouble Code 4781 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 when the Engine is on and solenoid output X-CN3A pin 25 is greater than 8 V or less than 1 V. Possible failure modes: 1. Open wire in circuit. 2. Two Speed solenoid has failed. 3. 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 4781 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 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 Two Speed solenoid connector X-2SPD pin A and X-2SPD pin B. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3A. Use the jumper wire to short X-2SPD pin A to X-SPD pin B. Measure the resistance between X-CN3A pin 25 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to step 4. 47711684 06/05/2014

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B. The resistance is greater than 10 Ω. There is an open circuit in the solenoid signal or 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 X-CN3A. Turn the ignition switch ON. Activate the two speed feature while monitoring the fault code screen. Fault code 4781 should no longer be active. Fault code 4782 should become active. A. Fault code 4782 is active and fault code 4781 is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4781 is still active. Fault code 4782 did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Medium EH machines Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Case models Wire harnesses - Electrical schematic sheet 16 (55.100.DP-C.20.E.16) New Holland models Wire harnesses - Electrical schematic sheet 16 (55.100.DP-C.20.E.16)

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4782-Solenoid Valve - Solenoid Supply Short to Ground Two Speed Solenoid L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: The UCM has sent a signal to the Two Speed solenoid to energize, but no voltage detected. Diagnostic Trouble Code 4782 has an error priority of White. Two Speed operating mode is disabled while Diagnostic Trouble Code 4782 is active. Cause: The UCM has sent a signal to the Two Speed solenoid to energize, but no voltage detected. The fault is active when Two Speed is on and solenoid output, X-CN3A pin 25 current is high. Possible failure modes: 1. Shorted wire in circuit. 2. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4782 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 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 solenoid connector X-2SPD. Disconnect UCM connector X-CN3A. 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. 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.

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Reconnect UCM connector X-CN3A. Leave connector X-2SPD disconnected. Turn the ignition switch ON. Activate the Two Speed function while monitoring the fault code screen. Fault code 4872 should no longer be active. Fault code 4781 should become active. A. Fault code 4781 is active and fault code 4782 is no longer active. Temporarily replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4782 is still active. Fault code 4781 did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Medium EH machines Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Case models Wire harnesses - Electrical schematic sheet 16 (55.100.DP-C.20.E.16) New Holland models Wire harnesses - Electrical schematic sheet 16 (55.100.DP-C.20.E.16)

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4783-Solenoid Valve - Solenoid Supply Short to Power Two Speed Solenoid L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: The UCM has sensed higher than normal voltage on the Two Speed Solenoid. Diagnostic Trouble Code 4783 has an error priority of Amber. Ground Drive Limp Home operating mode is enabled while Diagnostic Trouble Code 4783 is active. Cause: The UCM has sensed higher than normal voltage on the Two Speed Solenoid. The fault is active when the Two Speed function is off and the Two Speed Solenoid output voltage, X-CN3A pin 25 is greater than 8 V. Possible failure modes: 1. Shorted wire in circuit. 2. Failure of the Two Speed 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4783 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 solenoid connector X-2SPD. Disconnect UCM connector X-CN3A. 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. 4. Test the UCM.

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Turn the ignition switch OFF. Reconnect UCM connector X-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 should no longer be active. Fault code 4781 should become active. A. Fault code 4781 is active. Fault code 4783 is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4783 is still active. Fault code 4781 did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Medium EH machines Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Case models Wire harnesses - Electrical schematic sheet 16 (55.100.DP-C.20.E.16) New Holland models Wire harnesses - Electrical schematic sheet 16 (55.100.DP-C.20.E.16)

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4951-Hydraulic Enable (Mechanical Machines) - Hydraulic Interlock Solenoid, Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

Context: Diagnostic Trouble Code 4951 has an error priority of Red. The vehicle is disabled with Diagnostic Trouble Code 4951. Cause: Instrument Cluster has sensed a short to another voltage source in the Hydraulic Interlock circuit. The fault is active when Ignition is On and Hydraulic Enable Commanded state is low and Hydraulic Enable solenoid is energized. Possible failure modes: 1. Faulty wiring or connectors. 2. Faulty Instrument Cluster. Solution: 1. Verify that the fault code is still active. Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence. (1) Use the Electronic Service Tool to clear all fault codes. (2) To check for fault code: Start and operate machine. A. Fault is not recorded again. OK to return the machine to service. B. Fault code is recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect Instrument Cluster connector X-C23 and the Hydraulic Interlock Solenoid connections. All connections should be secure, tight, free of corrosion, abrasion and/or damage. (2) 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.

RAPH12SSL0267FA

(1) (2)

Schematic Legend Port Lock Connector (3) X-PORT_LK PIN 1 Vehicle Working Condition to Telematics (4) Wire 308, YE

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Instrument Cluster Connector X-C23 pin 30 Chassis Ground X-CNH_GND_RR

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4952-Hydraulic Enable (Mechanical Machines) - Hydraulic Interlock Solenoid Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

NOTE: A machine with Loader Lock on will trigger trouble code 4952. This is normal. Context: Diagnostic Trouble Code 4952 has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 4952. Cause: Instrument Cluster has sensed an open circuit condition in the Hydraulic Interlock circuit. The fault is active while Ignition is On and Hydraulic Enable commanded state is high and Hydraulic Enable solenoid is not energized. Possible failure modes: 1. Faulty wiring or connectors. 2. The Hydraulic Interlock Solenoid wiring has an open circuit. 3. Open circuit in the Hydraulic Interlock Solenoid. 4. Faulty Instrument Cluster. Solution: 1. Verify that the fault code is still active. Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence. (1) Use the Electronic Service Tool to clear all fault codes. (2) To check for fault code: Start and operate machine. A. Fault is not recorded again. OK to return the machine to service. B. Fault code is recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect Instrument Cluster connector X-C23 and the Hydraulic Interlock Solenoid connections. All connections should be secure, tight, free of corrosion, abrasion and/or damage. (2) 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.

RAPH12SSL0267FA

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(1) (2)

Schematic Legend (3)

Port Lock Connector X-PORT_LK PIN 1 Vehicle Working Condition to Telematics (4) Wire 308, YE

Instrument Cluster Connector X-C23 pin 30 Chassis Ground X-CNH_GND_RR

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 wire. (1) Turn the key switch OFF. (2) Disconnect Instrument Cluster connector X-C23. (3) 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. Go 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. 4. Measure the resistance of the Hydraulic Interlock Solenoid. (1) Turn the key switch OFF. (2) Disconnect connector X-PORT_LK from the Hydraulic Interlock Solenoid. (3) Measure the resistance across 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 wire. (1) Disconnect X-C23 and the Hydraulic Interlock Solenoid connector, X-PORT_LK . (2) Fabricate a 15 cm (6 in) jumper wire with pins on each end. Insert the jumper in connector X-PORT_LK pin 1 and X-PORT_LK pin 2. (3) 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. Go 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. Mechanical Units F5H engine Wire harnesses - Electrical schematic sheet 21 (55.100.DP-C.20.E.21) Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) Small mechanical machines ISM engine Wire harnesses - Electrical schematic sheet 25 (55.100.DP-C.20.E.25) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 12 (55.100.DP-C.20.E.12) Medium mechanical machines ISM engine Wire harnesses - Electrical schematic sheet 21 (55.100.DP-C.20.E.21) Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) Wire harnesses - Electrical schematic sheet 09 (55.100.DP-C.20.E.09) 47711684 06/05/2014

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5051-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5051 has an error priority of Red. Loader hydraulics are disabled while Diagnostic Trouble Code 5051 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, X-CN2A pin 4 is less 1 V or greater than 8 V. Possible failure modes: 1. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5051 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 connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connector X-CN2A. Measure the resistance between X-CN2A pin 4 and chassis ground. The resistance should be less than 100 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is less than 100 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance measurement is 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 loader interlock solenoid terminals, pin 1 and pin 2. The resistance should be less than 20 Ω.

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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 connector X-CN2A disconnected. Fabricate a jumper wire that will connect between X-PLTLK pin 1 and pin 2. Connect the jumper wire between X-PLTLK pin 1 and pin 2. Measure the resistance between X-CN2A 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. 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. EH machines F5H engine Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10)

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5052-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Ground L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5052 has an error priority of Red. Loader hydraulics are disabled while Diagnostic Trouble Code 5052 is active. Cause: The UCM has sent a signal to the Loader Pilot Interlock solenoid to energize, but there is no voltage detected. The fault is active while hydraulics are enabled and the loader pilot interlock solenoid output, X-CN2A pin 4 is greater than 3 A. Possible failure modes: 1. Short circuit in the solenoid wiring. 2. The loader pilot interlock 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5052 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 connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connector X-CN2A. Disconnect solenoid connector X-PLTLK. Measure the resistance between X-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. 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.

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Measure the resistance across the loader interlock solenoid terminals, pin 1 and pin 2. The resistance should be greater than 5 Ω. A. The resistance is greater than 5 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. EH machines F5H engine Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10)

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5053-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5053 has an error priority of Red. Loader hydraulics are disabled while Diagnostic Trouble Code 5053 is active. Cause: The UCM has sent a signal to the Loader Pilot Interlock solenoid to energize, but there is no voltage detected. The fault is active while hydraulics are enabled and the loader pilot interlock solenoid output, X-CN2A pin 4 is greater than 3 A. Possible failure modes: 1. Short circuit in the solenoid wiring. 2. The loader pilot interlock 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5053 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 connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connector X-CN2A. Disconnect solenoid connector X-PLTLK. Measure the resistance between X-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. 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.

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5061-Port Lock Valve (On/Off) - Solenoid Supply Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5061 has an error priority of Red. Loader hydraulics are disabled while Diagnostic Trouble Code 5061 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, X-CN2A pin 5 is less 1 V or greater than 8 V. Possible failure modes: 1. An open circuit in the solenoid wiring. 2. The loader lock 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5061 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 connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connector X-CN2A. Measure the resistance between X-CN2A pin 5 and chassis ground. The resistance should be less than 100 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is less than 100 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance measurement is 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 loader lock 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. 47711684 06/05/2014

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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 connector X-CN2A disconnected. Fabricate a jumper wire that will connect between X-PORT_LK pin 1 and pin 2. Connect the jumper wire between X-PORT_LK pin 1 and pin 2. Measure the resistance between X-CN2A pin 5 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 wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. EH machines F5H engine Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10)

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5062-Port Lock Valve (On/Off) - Solenoid Supply Short to Ground L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5062 has an error priority of Red. Loader hydraulics are disabled while Diagnostic Trouble Code 5062 is active. Cause: The UCM has sent a signal to the Loader Port Lock solenoid to energize, but there is no voltage detected. The fault is active while hydraulics are enabled and the loader port lock solenoid output, X-CN2A pin 5 is greater than 3 A. Possible failure modes: 1. Short circuit in the solenoid wiring. 2. The loader port lock 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5062 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. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connector X-CN2A. Disconnect solenoid connector X-PORT_LK. Measure the resistance between X-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. 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 5 Ω. 47711684 06/05/2014

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A. The resistance is greater than 5 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. EH machines F5H engine Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10)

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5063-Port Lock Valve (On/Off) - Solenoid Supply Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5063 has an error priority of Red. Loader hydraulics are disabled while Diagnostic Trouble Code 5063 is active. Cause: The UCM has sent a signal to the loader port lock solenoid to de-energize, but the UCM detects a voltage on the output. The fault is active when the hydraulics are disabled and the loader port lock solenoid output, X-CN2A pin 5 is greater than 8 V. Possible failure modes: 1. Signal wire is shorted 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5063 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. Measure the voltage on the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connector X-CN2A. Disconnect solenoid connector X-PORT_LK. Turn the ignition switch ON. Measure the voltage between X-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. A. The voltage is less than 0.5 V. Temporarily replace the UCM and retest. Return to step 1. B. The voltage is 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. EH machines F5H engine Wire harnesses - Electrical schematic sheet 10 (55.100.DP-C.20.E.10) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) 47711684 06/05/2014

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Small EH machines ISM engine Wire harnesses - Electrical schematic Wire harnesses - Electrical schematic Medium EH machines ISM engine Wire harnesses - Electrical schematic Wire harnesses - Electrical schematic

sheet 19 (55.100.DP-C.20.E.19) sheet 10 (55.100.DP-C.20.E.10) sheet 19 (55.100.DP-C.20.E.19) sheet 10 (55.100.DP-C.20.E.10)

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5121-Right Joystick F-B Axis - Pin A Short to Power/ Short to Ground/ Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5121 has an error priority of Amber. Limp home ground drive operating mode is enabled while Diagnostic Trouble Code 5121 is active. Cause: While in the H-Pattern, the UCM has sensed that the Right Joystick F-B signal has failed. The fault is active while the voltage on X-CN4A pin 17 is less than 0.2 V or the voltage 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. Short circuit in the signal wire. 2. Open circuit in the signal wire. 3. Failure of the Right Hand 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 5121 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 voltage on the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-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. 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. 47711684 06/05/2014

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4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-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 of the signal wire. Use a jumper wire with alligator clips on both ends to short connector X-CN4A pin 17 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 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.

RAPH12SSL0351FA

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(1) (2)

Connector X-UJMR Joystick X-Y Position Sensor

Schematic legend (3) (4)

DVM set to measure voltage. Right Joystick F-B X-CN4A pin 17 Fault code 5121 or 5124

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 Right Joystick connector X-UJMR. Fabricate a breakout tee to measure the voltage output of the sensor.

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. 47711684 06/05/2014

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Measure the voltage between pins 3 and 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 in a smooth fashion 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 was not 2.5 V in the neutral position or the voltage change was erratic. Temporarily replace the Joystick and retest. Return to step 1 to confirm elimination of fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17)

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5122-Right Joystick F-B Axis - Pin B Short to Power/ Short to Ground/ Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5122 has an error priority of Amber. Limp home ground drive operating mode is enabled while Diagnostic Trouble Code 5122 is active. Cause: While in the H-Pattern, the UCM has sensed that the Right Joystick F-B signal has failed. The fault is active while the voltage on X-CN1B pin 13 is less than 0.2 V or the voltage 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. Short circuit in signal wire. 2. Open circuit in signal wire. 3. Failure of the Right Hand 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 5122 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 voltage on the signal wire to chassis ground, short circuit. Turn the ignition switch OFF. Disconnect the UCM connector X-CN1B. Disconnect the Right Joystick connector X-UJMR. Turn the ignition switch ON. Measure the voltage of X-UJMR pin 9 to chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 47711684 06/05/2014

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4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-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. Use a jumper wire with alligator clips on both ends to short connector X-CN1B pin 13 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 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.

RAPH12SSL0353FA

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(1) (2)

Connector X-UJMR Joystick X-Y Position Sensor

Schematic legend (3) (4)

DVM set to measure voltage. Right Joystick F-B X-CN1B pin 13 Fault code 5122 or 5124

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. 47711684 06/05/2014

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5124-Right Joystick F-B Axis - In Range Fault L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5124 has an error priority of Amber. Limp Home Ground Drive operating mode is enabled with Diagnostic Trouble Code 5124. Cause: The UCM has sensed that the Right Joystick F-B signal has failed. The fault is active while the voltage on X-CN4A pin 17 and X-CN1B pin 13 is less than 0.2 V or the voltage 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 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 Hand Control Module. 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 5124 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 voltage of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connectors X-CN4A and X-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. 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.

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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 fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN4A and X-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 of the signal wire. Use a jumper wire with alligator clips on both ends to short connector X-CN4A pin 17 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 3 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect one end of the jumper wire to connector X-CN1B pin 13 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-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 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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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 X-CN4A pin 17 Fault code 5121 or 5124 Right Joystick F-B X-CN1B pin 13 Fault code 5122 or 5124

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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 pins 3 and 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 pins 9 and 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 Joysticks, 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. 47711684 06/05/2014

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B. On one or both Joysticks, the voltage was not 2.5 V in the neutral position or the voltage change was erratic. Temporarily replace the Joystick and retest. Return to step 1 to confirm elimination of fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17)

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5131-Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Ground/ Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5131 has an error priority of Amber. Limp home implement operating mode is enabled while Diagnostic Trouble Code 5131 is active. Cause: The UCM has sensed that the Right Joystick R-L signal has failed low. The fault is active while the engine is ON and the voltage on X-CN4A pin 24 is less than 0.2 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. Short circuit in the signal wire. 2. Open circuit in the signal wire. 3. Failure of the Right Hand Control Handle. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5131 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 resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN4A. Disconnect the Right Joystick connector X-UJMR. Measure the resistance of X-UJMR pin 2 to chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Go to step 4. B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire. 47711684 06/05/2014

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Use a jumper wire with alligator clips on both ends to short connector X-CN4A pin 24 to chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance of 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. 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)

DVM set to measure voltage. Right Joystick R-L X-CN4A pin 24 Fault code 5131, 5132 or 5137

A. The voltage is approximately 5 V. Go to step 6. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is an open circuit in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the Right Joystick connector X-UJMR. Fabricate a breakout tee to measure the voltage output of the sensor. 47711684 06/05/2014

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RAPH12SSL0373GA

(1)

Schematic legend Dealer supplied breakout harness (2)

DVM set to measure voltage.

Turn the ignition switch ON. Connect the breakout harness between the two mating connectors on X-UJMR. Measure the voltage between pins 2 and 4 on the break out harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the R-L position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. The voltage is approximately 2.5 V in the neutral position and the voltage changes in a smooth fashion 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 was not 2.5 V in the neutral position or the voltage change was erratic. Temporarily replace the Joystick and retest. Return to step 1 to confirm elimination of fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines 47711684 06/05/2014

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Wire harnesses - Electrical Medium EH machines Wire harnesses - Electrical Wire harnesses - Electrical Wire harnesses - Electrical Wire harnesses - Electrical Case machines Wire harnesses - Electrical New Holland machines Wire harnesses - Electrical

schematic sheet 17 (55.100.DP-C.20.E.17) schematic schematic schematic schematic

sheet sheet sheet sheet

19 20 13 14

(55.100.DP-C.20.E.19) (55.100.DP-C.20.E.20) (55.100.DP-C.20.E.13) (55.100.DP-C.20.E.14)

schematic sheet 17 (55.100.DP-C.20.E.17) schematic sheet 17 (55.100.DP-C.20.E.17)

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5132-Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5132 has an error priority of Amber. Limp Home Implement operating mode is enabled with Diagnostic Trouble Code 5132. Cause: The UCM has sensed that the Right Joystick R-L signal has failed. The fault is active when the voltage on X-CN4A pin 24 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. Signal wire short circuit to another voltage source. 2. Failure of the Right Joystick. 3. The UCM has and 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 5132 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 voltage on the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN4A. Disconnect the Right Joystick connector X-UJMR. Turn the ignition switch ON. Measure the voltage of X-UJMR pin 2 to chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit 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.

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Turn the ignition switch OFF. Use a jumper wire with alligator clips on both ends to short connector X-CN4A pin 24 to chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance of 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. 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 X-CN4A pin 24 Fault code 5131, 5132 or 5137

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RAPH12SSL0373GA

(1)

Schematic legend Dealer supplied breakout harness (2)

DVM set to measure voltage.

Turn the ignition switch ON. Connect the breakout harness between the two mating connectors on X-UJMR. Measure the voltage between pins 2 and 4 on the break out harness. The voltage should be approximately 2.5 V while the joystick is in the neutral position. Continue measuring the voltage while slowly moving the throttle in the R-L position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. The voltage is approximately 2.5 V in the neutral position and the voltage changes in a smooth fashion 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 was not 2.5 V in the neutral position or the voltage change was erratic. Temporarily replace the Joystick and retest. Return to step 1 to confirm elimination of fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines 47711684 06/05/2014

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schematic sheet 17 (55.100.DP-C.20.E.17) schematic schematic schematic schematic

sheet sheet sheet sheet

19 20 13 14

(55.100.DP-C.20.E.19) (55.100.DP-C.20.E.20) (55.100.DP-C.20.E.13) (55.100.DP-C.20.E.14)

schematic sheet 17 (55.100.DP-C.20.E.17) schematic sheet 17 (55.100.DP-C.20.E.17)

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5134-Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Ground/ Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5134 has an error priority of Amber. Limp home implement operating mode is enabled with Diagnostic Trouble Code 5134. Cause: The UCM has sensed that the Right Joystick R-L signal has failed low. The fault is active while engine is ON and voltage on X-CN3A pin 11 is less than 0.2 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. Short circuit in the signal wire. 2. Open circuit in the signal wire. 3. Failure of the Right Hand Control Handle. 4. 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 5134 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and 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 resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN3A. Disconnect the Right Joystick connector X-UJMR. Measure the resistance of X-UJMR 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 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 of the signal wire. 47711684 06/05/2014

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Use a jumper wire with alligator clips on both ends to short connector X-CN3A pin 11 to chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil and paint. Measure the resistance of connector X-UJMR 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 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)

DVM set to measure voltage. Right Joystick R-L X-CN3A pin 11 Fault code 5134, 5135 or 5137

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RAPH12SSL0374GA

(1)

Schematic legend Dealer supplied breakout harness (2)

DVM set to measure voltage.

Turn the ignition switch ON. Connect the breakout harness between the two mating connectors on X-UJMR. Measure the voltage between pins 8 and 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. The voltage is approximately 2.5 V in the neutral position and the voltage changes in a smooth fashion 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 was not 2.5 V in the neutral position or the voltage change was erratic. Temporarily replace the Joystick and retest. Return to step 1 to confirm elimination of fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines 47711684 06/05/2014

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schematic sheet 17 (55.100.DP-C.20.E.17) schematic schematic schematic schematic

sheet sheet sheet sheet

19 20 13 14

(55.100.DP-C.20.E.19) (55.100.DP-C.20.E.20) (55.100.DP-C.20.E.13) (55.100.DP-C.20.E.14)

schematic sheet 17 (55.100.DP-C.20.E.17) schematic sheet 17 (55.100.DP-C.20.E.17)

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5135-Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5135 has an error priority of Amber. Limp Home Implement operating mode is enabled with Diagnostic Trouble Code 5135. Cause: UCM has sensed that the Right Joystick R-L signal has failed. The fault is active when the voltage on X-CN3A pin 11 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. Signal wire has a short circuit to another voltage source. 2. Failure of the Right Joystick. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5135 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 voltage on the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN3A. Disconnect the Right Joystick connector X-UJMR. Turn the ignition switch ON. Measure the voltage of X-UJMR pin 8 to chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit 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.

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Turn the ignition switch OFF. Use a jumper wire with alligator clips on both ends to short connector X-CN3A pin 11 to chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance of connector X-UJMR 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 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 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)

DVM set to measure voltage. Right Joystick R-L X-CN3A pin 11 Fault code 5134, 5135 or 5137

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RAPH12SSL0374GA

(1)

Schematic legend Dealer supplied breakout harness (2)

DVM set to measure voltage.

Turn the ignition switch ON. Connect the breakout harness between the two mating connectors on X-UJMR. Measure the voltage between pins 8 and 10 on the break out harness. The voltage should be approximately 2.5 V while the joystick is in the neutral position. Continue measuring the voltage while slowly moving the throttle in the R-L position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. The voltage is approximately 2.5 V in the neutral position and the voltage changes in a smooth fashion 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 was not 2.5 V in the neutral position or the voltage change was erratic. Temporarily replace the Joystick and retest. Return to step 1 to confirm elimination of fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines 47711684 06/05/2014

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schematic sheet 17 (55.100.DP-C.20.E.17) schematic schematic schematic schematic

sheet sheet sheet sheet

19 20 13 14

(55.100.DP-C.20.E.19) (55.100.DP-C.20.E.20) (55.100.DP-C.20.E.13) (55.100.DP-C.20.E.14)

schematic sheet 17 (55.100.DP-C.20.E.17) schematic sheet 17 (55.100.DP-C.20.E.17)

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5137-Right Joystick R-L Axis (ISO/H Pattern) - In Range Fault L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5137 has an error priority of Red. The bucket is disabled while Diagnostic Trouble Code 5137 is active. Cause: The UCM has sensed that the Right Joystick R-L signal has failed. The fault is active while the engine is ON and the voltage on X-CN4A pin 24 and X-CN3A pin 11 is less than 0.2 V or greater than 4.8 V. Normal operating voltage of the sensor output is 0.5 V to 4.5 V. Output of the sensor in the neutral position is approximately 2.5 V. Possible failure modes: 1. Open circuit in the signal wire. 2. Short circuit in the signal wire. 3. Failure of the Right Hand Control Module. 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 5137 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 voltage of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN4A and X-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. 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.

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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 fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN4A and X-CN3A. Disconnect the Right Joystick connector X-UJMR. Measure the resistance of X-UJMR 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-UJMR 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. Use a jumper wire with alligator clips on both ends to short connector X-CN4A pin 24 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 2 to chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect the jumper wire between connector X-CN3A 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 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. 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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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 X-CN4A pin 24 Fault code 5131, 5132 or 5137 Right Joystick R-L X-CN3A pin 11 Fault code 5134, 5135 or 5137

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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 pins 2 and 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 pins 8 and 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 Joysticks, 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. On one or both Joysticks, the voltage was not 2.5 V in the neutral position or the voltage change was erratic. Temporarily replace the Joystick and retest. Return to step 1 to confirm elimination of fault. 47711684 06/05/2014

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Small EH machines Wire harnesses - Electrical Wire harnesses - Electrical Wire harnesses - Electrical Wire harnesses - Electrical Case machines Wire harnesses - Electrical New Holland machines Wire harnesses - Electrical Medium EH machines Wire harnesses - Electrical Wire harnesses - Electrical Wire harnesses - Electrical Wire harnesses - Electrical Case machines Wire harnesses - Electrical New Holland machines Wire harnesses - Electrical

schematic schematic schematic schematic

sheet sheet sheet sheet

19 20 13 14

(55.100.DP-C.20.E.19) (55.100.DP-C.20.E.20) (55.100.DP-C.20.E.13) (55.100.DP-C.20.E.14)

schematic sheet 17 (55.100.DP-C.20.E.17) schematic sheet 17 (55.100.DP-C.20.E.17) schematic schematic schematic schematic

sheet sheet sheet sheet

19 20 13 14

(55.100.DP-C.20.E.19) (55.100.DP-C.20.E.20) (55.100.DP-C.20.E.13) (55.100.DP-C.20.E.14)

schematic sheet 17 (55.100.DP-C.20.E.17) schematic sheet 17 (55.100.DP-C.20.E.17)

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5141-Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5141 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST when the technician checks for active trouble codes. The auxiliary hydraulics are disabled while Diagnostic Trouble Code 5141 is active. Cause: The UCM has sensed that the auxiliary thumbwheel signal has failed low. The fault is active when the ignition is ON and the aux thumbwheel axis input voltage, X-CN2B pin 28 is less than 0.2 V. Possible failure modes: 1. Shorted wire in the circuit. 2. Open wire in the circuit. 3. Failure of the right hand 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 5141 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right hand joystick connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the right hand 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 hand 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. 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. 47711684 06/05/2014

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Turn the ignition switch OFF. Disconnect UCM connector X-CN2B. Disconnect connector X-403. Measure the resistance between X-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 X-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 X-CN2B. Remove pin 2 and pin 1 from connector X-403. Use a jumper wire with alligator clips to short X-403 pin 2 to X-403 pin 1. Reconnect X-403 on to the joystick. Turn the ignition switch ON. Use EST to access the fault code screen. Fault code 5141 should no longer be active. Fault code 5142 is now active. A. Fault code 5141 is no longer active. Fault code 5142 is now active. Replace the aux thumbwheel and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5141 is active. Fault code 5142 did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines 47711684 06/05/2014

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Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17)

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5142-Aux Thumbwheel Axis - Pin A Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5142 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST when the technician checks for active trouble codes. The auxiliary hydraulics are disabled while Diagnostic Trouble Code 5142 is active. Cause: The UCM has sensed that the auxiliary thumbwheel signal has failed high. The fault is active when the ignition is ON and the aux thumbwheel axis input voltage, X-CN2B pin 28 is greater than 4.8 V. Possible failure modes: 1. Shorted wire in the circuit. 2. The right hand control handle has an internal failure. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5142 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right hand joystick connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the right hand 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 of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN2B. Disconnect connector X-403. Turn the ignition switch ON. Measure the voltage between X-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.

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4. Test the UCM. Reconnect UCM connector X-CN2B. Remove pin 2 and pin 3 from connector X-403. Use a jumper wire with alligator clips to short 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 should no longer be active. Fault code 5141 is now active. A. Fault code 5142 is no longer active. Fault code 5141 is now active. Replace the aux thumbwheel and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5142 is active. Fault code 5141 did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17)

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5144-Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5144 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST when the technician checks for active trouble codes. The auxiliary hydraulics are disabled while Diagnostic Trouble Code 5144 is active. Cause: The UCM has sensed that the auxiliary thumbwheel signal has failed low. The fault is active when the ignition is ON and the aux thumbwheel axis input voltage, X-CN4B pin 21 is less than 0.2 V. Possible failure modes: 1. Shorted wire in the circuit. 2. Open wire in the circuit. 3. Failure of the right hand 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 5144 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right hand joystick connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the right hand 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 hand 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. 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. 47711684 06/05/2014

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Turn the ignition switch OFF. Disconnect UCM connector X-CN4B. Disconnect connector X-403. Measure the resistance between X-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 X-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 X-CN1B. Remove pin 10 and pin 11 from connector X-403. Use a jumper wire with alligator clips to short X-403 pin 10 to X-403 pin 11. Reconnect X-403 on to the joystick. Turn the ignition switch ON. Use EST to access the fault code screen. Fault code 5144 should no longer be active. Fault code 5145 is now active. A. Fault code 5144 is no longer active. Fault code 5145 is now active. Replace the aux thumbwheel and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5144 is active. Fault code 5145 did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines 47711684 06/05/2014

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Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17)

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5145-Aux Thumbwheel Axis - Pin B Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5145 has an error priority of White. White errors are not displayed on the instrument cluster and are not known to the Owner/Operator. They will appear in the EST when the technician checks for active trouble codes. The auxiliary hydraulics are disabled while Diagnostic Trouble Code 5145 is active. Cause: The UCM has sensed that the auxiliary thumbwheel signal has failed high. The fault is active when the ignition is ON and the aux thumbwheel axis input voltage, X-CN4B pin 21 is greater than 4.8 V. Possible failure modes: 1. Shorted wire in the circuit. 2. The right hand control handle has an internal failure. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5145 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right hand joystick connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the right hand 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 of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN4B. Disconnect connector X-403. Turn the ignition switch ON. Measure the voltage between X-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.

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4. Test the UCM. Reconnect UCM connector X-CN4B. Remove pin 11 and pin 12 from connector X-403. Use a jumper wire with alligator clips to short 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 should no longer be active. Fault code 5144 is now active. A. Fault code 5145 is no longer active. Fault code 5144 is now active. Replace the aux thumbwheel and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5145 is active. Fault code 5144 did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17)

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5147-Aux Thumbwheel Axis - In Range Fault L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5147 has an error priority of White. White errors are not displayed on the instrument cluster and are not known to the Owner/Operator. They will appear in the EST when the technician checks for active trouble codes. The auxiliary hydraulics are disabled while Diagnostic Trouble Code 5147 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, XCN2B pin 28 and X-CN4B pin 21 is greater than 5.2 V or less than 4.8 V. Possible failure modes: 1. Faulty wiring or connectors. 2. Failure of the Aux Thumbwheel 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5147 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right hand joystick connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the right hand 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 is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and 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 hand 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. 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. 47711684 06/05/2014

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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 to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN2B. Disconnect UCM connector X-CN4B. Disconnect connector X-403. Turn the ignition switch ON. Measure the voltage between X-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 X-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 X-CN2B and X-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 X-CN2B pin 28 and X-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 wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 6. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN2B. Disconnect UCM connector X-CN4B. Disconnect connector X-403. Measure the resistance between X-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 X-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. 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. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) 47711684 06/05/2014

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Wire harnesses - Electrical Wire harnesses - Electrical Wire harnesses - Electrical Case machines Wire harnesses - Electrical New Holland machines Wire harnesses - Electrical Medium EH machines Wire harnesses - Electrical Wire harnesses - Electrical Wire harnesses - Electrical Wire harnesses - Electrical Case machines Wire harnesses - Electrical New Holland machines Wire harnesses - Electrical

schematic sheet 20 (55.100.DP-C.20.E.20) schematic sheet 13 (55.100.DP-C.20.E.13) schematic sheet 14 (55.100.DP-C.20.E.14) schematic sheet 17 (55.100.DP-C.20.E.17) schematic sheet 17 (55.100.DP-C.20.E.17) schematic schematic schematic schematic

sheet sheet sheet sheet

19 20 13 14

(55.100.DP-C.20.E.19) (55.100.DP-C.20.E.20) (55.100.DP-C.20.E.13) (55.100.DP-C.20.E.14)

schematic sheet 17 (55.100.DP-C.20.E.17) schematic sheet 17 (55.100.DP-C.20.E.17)

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5201-Left Joystick L-R Axis - Pin A Short to Power/ Short to Ground/ Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5201 has an error priority of Amber. Limp home ground drive operating mode is enabled while Diagnostic Trouble Code 5201 is active. Cause: The UCM has sensed that the Left Joystick L-R signal has failed. The fault is active while Engine is On and voltage on X-CN4A pin 25 is less than 0.2 V or greater than 4.8 V. Normal operating voltage of the sensor output is 0.5 V to 4.5 V. Output of the sensor in the neutral position is approximately 2.5 V. Possible failure modes: 1. Open circuit in signal wire. 2. Short circuit in signal wire. 3. Failure of the Left Hand Control Module. 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 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 of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN4A. 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. 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. 47711684 06/05/2014

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4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-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 of the signal wire. Use a jumper wire with alligator clips on both ends to short connector X-CN4A pin 25 to 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. 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 Left Joystick connector X-UJML. Reconnect the UCM connector(s). 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

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(1) (2)

Connector X-UJML Joystick X-Y Position Sensor

Schematic legend (3) (4)

DVM set to measure voltage. Left Joystick L-R X-CN4A pin 25 Fault code 5201 or 5204

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 tee to measure the voltage output of the sensor.

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. 47711684 06/05/2014

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Turn the ignition switch ON. Measure the voltage between pins 2 and 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. 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 was not 2.5 V in the neutral position or the voltage change was erratic. Temporarily replace the Joystick and retest. Return to step 1 to confirm elimination of fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17)

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5202-Left Joystick L-R Axis - Pin B Short to Power/ Short to Ground/ Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5202 has an error priority of Amber. Limp Home Ground Drive operating mode is enabled while Diagnostic Trouble Code 5202 is active. Cause: The UCM has sensed that the Left Joystick L-R signal has failed. The fault is active while the voltage on X-CN2B pin 14 is less than 0.2 V or greater than 4.8 V. Normal operating voltage of the sensor output is 0.5 V to 4.5 V. Output of the sensor in the neutral position is approximately 2.5 V. Possible failure modes: 1. Open circuit in signal wire. 2. Short circuit in signal wire. 3. Failure of the Left Hand Control Module. 4. 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 5202 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 of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN2B. Disconnect the Left Joystick connector X-UJML. Turn the ignition switch ON. 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. 47711684 06/05/2014

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4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN2B. Disconnect the Left Joystick connector X-UJML. 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. Use a jumper wire with alligator clips on both ends to short connector X-CN2B pin 14 to 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. Disconnect the Left Joystick connector X-UJML. Reconnect the UCM connector(s). 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

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(1) (2)

Connector X-UJML Joystick X-Y Position Sensor

Schematic legend (3) (4)

DVM set to measure voltage. Left Joystick L-R X-CN2B pin 14 Fault code 5202 or 5204

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 tee to measure the voltage output of the sensor.

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. 47711684 06/05/2014

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Turn the ignition switch ON. Measure the voltage between pins 8 and 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 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 was not 2.5 V in the neutral position or the voltage change was erratic. Temporarily replace the Joystick and retest. Return to step 1 to confirm elimination of fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17)

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5204-Left Joystick L-R Axis - In Range Fault L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5204 has an error priority of Amber. Limp home ground drive operating mode is enabled while Diagnostic Trouble Code 5204 is active. Cause: The UCM has sensed that the Left Joystick L-R signal has failed. The fault is active while the voltage on X-CN4A pin 25 and X-CN2B pin 14 is less than 0.2 V or greater than 4.8 V. Normal operating voltage of the sensor output is 0.5 V to 4.5 V. Output of the sensor in the neutral position is approximately 2.5 V. Possible failure modes: 1. Open circuit in the signal wire. 2. Short circuit in the signal wire. 3. Failure of the Left Hand Control Module. 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 5204 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 of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN4A and X-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. 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.

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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 fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN4A and X-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. Use a jumper wire with alligator clips on both ends to short connector X-CN4A pin 25 to 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 X-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. Disconnect the Left Joystick connector X-UJML. Reconnect the UCM connector(s). 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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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 X-CN4A pin 25 Fault code 5201 or 5204 Left Joystick L-R X-CN2B pin 14 Fault code 5202 or 5204

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 tee to measure the voltage output of the sensor.

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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 pins 2 and 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 pins 8 and 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 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 Joysticks, 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. 47711684 06/05/2014

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5211-Left Joystick F-B Axis - Pin A Short to Ground/ Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5211 has an error priority of Amber. Limp home ground drive operating mode is enabled while Diagnostic Trouble Code 5211 is active. Cause: The UCM has sensed that the Left Joystick F-B 5 V signal has failed low. The fault is active while the engine is ON and the voltage on X-CN4A pin 18 is less than 0.2 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. 2. An open circuit in the signal wire. 3. Failure of the Left Hand 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 5211 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 resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN4A. 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. 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 of the signal wire.

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Use a jumper wire with alligator clips on both ends to short connector X-CN4A pin 18 to chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance of connector X-UJML pin 3 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 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 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 X-CN4A pin 18 Fault code 5211, 5212 or 5217

A. The voltage is approximately 5 V. Go to step 6. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is an open circuit in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the Left Joystick connector X-UJML. Fabricate a breakout tee to measure the voltage output of the sensor. 47711684 06/05/2014

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RAPH12SSL0342GA

(1)

Schematic legend Dealer supplied breakout harness (2)

DVM set to measure voltage.

Turn the ignition switch ON. Connect the breakout harness between the two mating connectors on X-UJML. Measure the voltage between pins 4 and 3 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 in a smooth fashion 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 was not 2.5 V in the neutral position or the voltage change was erratic. Temporarily replace the Joystick and retest. Return to step 1 to confirm elimination of fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines 47711684 06/05/2014

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schematic sheet 17 (55.100.DP-C.20.E.17) schematic schematic schematic schematic

sheet sheet sheet sheet

19 20 13 14

(55.100.DP-C.20.E.19) (55.100.DP-C.20.E.20) (55.100.DP-C.20.E.13) (55.100.DP-C.20.E.14)

schematic sheet 17 (55.100.DP-C.20.E.17) schematic sheet 17 (55.100.DP-C.20.E.17)

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5212-Left Joystick F-B Axis - Pin A Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5212 has an error priority of Amber. Limp home ground drive operating mode is enabled while Diagnostic Trouble Code 5212 is active. Cause: UCM has sensed that the 5 V signal has failed high. The fault is active while Ignition is On and Voltage 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. Open circuit in signal wire. 2. Short circuit in signal wire to another voltage source. 3. Left Hand Control Module. 4. 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 5212 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the Left Joystick connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the Left Joystick. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN4A. Disconnect the Left Joystick connector X-UJML. Turn the ignition switch ON. Measure the voltage of X-UJML pin 3 to chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit 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. 47711684 06/05/2014

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Turn the ignition switch OFF. Use a jumper wire with alligator clips on both ends to short connector X-CN4A pin 18 to chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance of connector X-UJML pin 3 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 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 Left Joystick connector X-UJML. Reconnect the UCM connector(s). 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 X-CN4A pin 18 Fault code 5211, 5212 or 5217

A. The voltage is approximately 5 V. Go to step 6. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is an open circuit in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the Left Joystick connector X-UJML. Fabricate a breakout tee to measure the voltage output of the sensor. 47711684 06/05/2014

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RAPH12SSL0342GA

(1)

Schematic legend Dealer supplied breakout harness (2)

DVM set to measure voltage.

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schematic sheet 17 (55.100.DP-C.20.E.17) schematic schematic schematic schematic

sheet sheet sheet sheet

19 20 13 14

(55.100.DP-C.20.E.19) (55.100.DP-C.20.E.20) (55.100.DP-C.20.E.13) (55.100.DP-C.20.E.14)

schematic sheet 17 (55.100.DP-C.20.E.17) schematic sheet 17 (55.100.DP-C.20.E.17)

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5214-Left Joystick F-B Axis - Pin B Short to Ground/ Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5214 has an error priority of Amber. Limp home ground drive operating mode is enabled while Diagnostic Trouble Code 5211 is active. Cause: The UCM has sensed that the Left Joystick F-B 5 V signal has failed low. The fault is active while the engine is ON and the voltage on X-CN2B pin 31 is less than 0.2 V. Normal operating voltage of the sensor output is 0.5 V to 4.5 V. Output of the sensor in the neutral position is approximately 2.5 V. Possible failure modes: 1. Short circuit in the signal wire. 2. Open circuit in the signal wire. 3. Failure of Left Hand Control Handle. 4. 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 5214 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 resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN2B. Disconnect the Left Joystick connector X-UJML. 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 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 of the signal wire.

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Use a jumper wire with alligator clips on both ends to short connector X-CN2B pin 31 to chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance of connector X-UJML pin 9 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 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 Left Joystick connector X-UJML. Reconnect the UCM connector(s). 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 X-CN2B pin 31 Fault code 5214, 5215 or 5217

A. The voltage is approximately 5 V. Go to step 6. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is an open circuit in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the Left Joystick connector X-UJML. Fabricate a breakout tee to measure the voltage output of the sensor. 47711684 06/05/2014

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RAPH12SSL0347GA

(1)

Schematic legend Dealer supplied breakout harness (2)

DVM set to measure voltage.

Turn the ignition switch ON. Connect the breakout harness between the two mating connectors on X-UJML. Measure the voltage between pins 9 and 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 in a smooth fashion 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 was not 2.5 V in the neutral position or the voltage change was erratic. Temporarily replace the Joystick and retest. Return to step 1 to confirm elimination of fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines 47711684 06/05/2014

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schematic sheet 17 (55.100.DP-C.20.E.17) schematic schematic schematic schematic

sheet sheet sheet sheet

19 20 13 14

(55.100.DP-C.20.E.19) (55.100.DP-C.20.E.20) (55.100.DP-C.20.E.13) (55.100.DP-C.20.E.14)

schematic sheet 17 (55.100.DP-C.20.E.17) schematic sheet 17 (55.100.DP-C.20.E.17)

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5215-Left Joystick F-B Axis - Pin B Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5215 has an error priority of Amber. Limp home ground drive operating mode is enabled with Diagnostic Trouble Code 5215. Cause: The UCM has sensed that the signal has failed high. The fault is active when the ignition is ON and the voltage is greater than 4.8 V. Possible failure modes: 1. Shorted wire in the circuit. 2. Failure of the Left Hand Control Module. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5215 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the Left Joystick connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the Left Joystick. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN2B. Disconnect the Left Joystick connector X-UJML. Turn the ignition switch ON. Measure the voltage of X-UJML pin 9 to chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit 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. Use a jumper wire with alligator clips on both ends to short connector X-CN2B pin 31 to chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. 47711684 06/05/2014

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Measure the resistance of connector X-UJML pin 9 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 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 Left Joystick connector X-UJML. Reconnect the UCM connector(s). 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 X-CN2B pin 31 Fault code 5214, 5215 or 5217

A. The voltage is approximately 5 V. Go to step 6. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is an open circuit in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the Left Joystick connector X-UJML. Fabricate a breakout tee to measure the voltage output of the sensor.

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RAPH12SSL0347GA

(1)

Schematic legend Dealer supplied breakout harness (2)

DVM set to measure voltage.

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schematic sheet 17 (55.100.DP-C.20.E.17) schematic schematic schematic schematic

sheet sheet sheet sheet

19 20 13 14

(55.100.DP-C.20.E.19) (55.100.DP-C.20.E.20) (55.100.DP-C.20.E.13) (55.100.DP-C.20.E.14)

schematic sheet 17 (55.100.DP-C.20.E.17) schematic sheet 17 (55.100.DP-C.20.E.17)

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5217-Left Joystick F-B Axis - In Range Fault L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5217 has an error priority of Amber. Limp home ground drive operating mode is enabled while Diagnostic Trouble Code 5217 is active. Cause: The UCM has sensed that the Left Joystick F-B signal has failed. The fault is active while the engine is ON and voltage on X-CN4A pin 18 and X-CN2B pin 31 is less than 0.2 V or greater than 4.8 V. Normal operating voltage of the sensor output is 0.5 V to 4.5 V. Output of the sensor in the neutral position is approximately 2.5 V. Possible failure modes: 1. Open circuit in the signal wire. 2. A short circuit to another voltage source. 3. Failure of the Left Hand Control Module. 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 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage.

RAPH12SSL0335FA

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(1)

(2)

(3) (4)

Left Joystick F-B X-CN4A pin 18 Fault code 5211, 5212 or 5217 Left Joystick F-B X-CN2B pin 31 Fault code 5214, 5215 or 5217 Connector X-UJML Joystick X-Y Position Sensor

Schematic legend (5)

Joystick X-Y Position Sensor

(6)

Sensor supply voltage from UCM

(7)

Sensor supply ground from UCM

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 of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connectors X-CN4A and X-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. 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 X-CN4A and X-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. Use a jumper wire with alligator clips on both ends to short connector X-CN4A pin 18 to 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 to chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.

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Connect one end of the jumper wire to connector X-CN2B pin 31 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-UJML pin 9 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. Disconnect the Left Joystick connector X-UJML. Reconnect the UCM connector(s). 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.

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 X-CN4A pin 18 Fault code 5211, 5212 or 5217 Left Joystick F-B X-CN2B pin 31 Fault code 5214, 5215 or 5217

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7. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the Left Joystick connector X-UJML. Fabricate a breakout tee to measure the voltage output of the sensor.

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 pins 3 and 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 pins 9 and 10 on the break out harness. The voltage should be approximately 2.5 V while the joystick in the neutral position.

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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 Joysticks, 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. On one or both Joysticks, the voltage was not 2.5 V in the neutral position or the voltage change was erratic. Temporarily replace the Joystick and retest. Return to step 1 to confirm elimination of fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 14 (55.100.DP-C.20.E.14) Case machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17)

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5221-Loader Arm Valve (Directional) - Solenoid Raise A Supply Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5221 has an error priority of Red. The loader arm functions are disabled while Diagnostic Trouble Code 5221 is active. Cause: The UCM has sensed an open circuit in the loader solenoid circuit, X-CN3B pin 6. The fault is active when the hydraulics are enabled and the calculated solenoid resistance has increased over 70 %. Possible failure modes: 1. Open wire or connection 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5221 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 through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3B and X-CN2B. Measure the resistance between X-CN3B pin 6 and X-CN2B pin 7. The resistance should be less than 100 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is less than 100 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance measurement is 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.

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A. The resistance is less than 20 Ω. Go to step 5. B. The resistance is greater than 20 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the circuit. Leave UCM connectors X-CN3B and X-CN2B disconnected. Fabricate a jumper wire that will connect between X-28 pin 1 and X-28 pin 2. Connect the jumper wire between X-28 pin 1 and X-28 pin 2. Measure the resistance between X-CN3B pin 6 and X-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. Check splice SP-108. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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5222-Loader Arm Valve (Directional) - Solenoid Raise A Supply Short to Ground L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5222 has an error priority of Red. The loader arm functions are disabled while Diagnostic Trouble Code 5222 is active. Cause: The UCM has sensed that the loader extend solenoid current is too high. The fault is active when hydraulics are enabled and solenoid output current, X-CN3B pin 6 is greater than 3 A. Possible failure modes: 1. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5222 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. 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 should no longer be active. Fault code 5221 is now active. A. Fault code 5222 is no longer active. Fault code 5221 is now active. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5222 is active. Fault code 5221 did not become active. Go to step 4. 4. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. 47711684 06/05/2014

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Disconnect UCM connectors X-CN3B and X-CN2B. Measure the resistance between X-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 X-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. 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. F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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5231-Loader Arm Valve (Directional) - Solenoid Lower B Supply Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5231 has an error priority of Red. The loader arm functions are disabled while Diagnostic Trouble Code 5231 is active. Cause: The UCM has sensed an open circuit in the loader solenoid circuit, X-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. Open wire or connection 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5231 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 through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3A and X-CN2B. Measure the resistance between X-CN3A pin 22 and X-CN2B pin 7. The resistance should be less than 100 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is less than 100 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance measurement is 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 retract solenoid terminals, pin 1 and pin 2. The resistance should be less than 20 Ω.

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A. The resistance is less than 20 Ω. Go to step 5. B. The resistance is greater than 20 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the circuit. Leave UCM connectors X-CN3A and X-CN2B 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 X-CN3A pin 22 and X-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. F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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5232-Loader Arm Valve (Directional) - Solenoid Lower B Supply Short to Ground L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5232 has an error priority of Red. The loader arm functions are disabled while Diagnostic Trouble Code 5232 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. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5232 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. 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 should no longer be active. Fault code 5231 is now active. A. Fault code 5232 is no longer active. Fault code 5231 is now active. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5232 is active. Fault code 5231 did not become active. Go to step 4. 4. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. 47711684 06/05/2014

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Disconnect UCM connectors X-CN3A and X-CN2B. Measure the resistance between X-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 X-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. 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. F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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5241-Boom Valve (Directional) - Common Solenoid (C) Return Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Fault code 5241 has an error priority of White. White errors are not displayed on the instrument cluster and are not known to the Owner/Operator. They will appear in the EST when the technician checks for active trouble codes. Loader arm functions are disabled while Diagnostic Trouble Code 5241 is active. Cause: The UCM has sensed higher than normal voltage on the loader solenoid lines, X-CN3A pin 22 or X-CN3B pin 6. The fault is active when hydraulics are disabled and the solenoid voltage feedback is greater than 5 V. Possible failure modes: 1. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5241 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader solenoids. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the signal wires. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3A, X-CN2B, and X-CN3B. Turn the ignition switch ON. Measure the voltage between X-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 X-CN2B pin 7 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. Measure the voltage between X-CN3B pin 6 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. 47711684 06/05/2014

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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. F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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5242-Loader Arm Valve (Directional) - Loader Arm Solenoids Short to Ground L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Fault code 5242 has an error priority of White. Loader arm functions are disabled while Diagnostic Trouble Code 5242 is active. Cause: The UCM has sensed that the solenoid voltages are too low. The fault is active when the hydraulics are disabled and solenoid voltages on pin X-CN3A pin 22 and X-CN3B pin 6 are less than 2 V. Possible failure modes: 1. Shorted wire in the circuit. 2. 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 the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5242 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. Test the UCM. Turn the ignition switch OFF. Disconnect solenoid connectors X-27 and X-28. Turn the ignition switch ON. Use the electronic service tool to access the fault code screen. Fault code 5242 should no longer be active. Fault code 5243 is now active. A. Fault code 5242 is no longer active. Fault code 5243 is now active. Replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5242 is active. Fault code 5243 did not become active. Go to step 4. 4. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF.

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Disconnect UCM connectors X-CN3A, X-CN2B, and both solenoid connectors, X-27 and X-28. Measure the resistance between X-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 X-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 X-CN3A pin 22 and X-CN2B pin 7. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Leave UCM connectors X-CN3A and X-CN2B disconnected. Disconnect UCM connector X-CN3B. Measure the resistance between X-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 X-CN3B pin 6 and X-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. 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. F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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5243-Boom Valve (Directional) - Common Solenoid (C) Return Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5243 has an error priority of White. The loader arm functions are disabled while Diagnostic Trouble Code 5243 is active. Cause: The UCM has sensed an open circuit in the loader solenoid return circuit, X-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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5243 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 through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3A, X-CN2B and X-CN3B. Measure the resistance between X-CN3A pin 22 and X-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 X-CN3B pin 6 and X-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. 4. Measure the solenoid resistance.

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Measure the resistance across the extend solenoid terminals, pin 1 and pin 2. The resistance should be less than 20 Ω. Measure the resistance across the retract solenoid terminals, pin 1 and pin 2. The resistance should be less than 20 Ω. A. The resistance is less than 20 Ω. Go to step 5. B. The resistance is greater than 20 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the circuit. Leave UCM connectors X-CN3A, X-CN2B and X-CN3B disconnected. Fabricate a jumper wire that will connect between X-27 pin 1 and pin 2. Connect the jumper wire between X-27 pin 1 and pin 2. Measure the resistance between X-CN3A pin 22 and X-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 and connect it between X-28 pin 1 and pin 2. Measure the resistance between X-CN3B pin 6 and X-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. F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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5251-Loader Bucket Valve (Directional) - Solenoid Rollback (A) Supply Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5251 has an error priority of Red. The bucket functions are disabled while Diagnostic Trouble Code 5251 is active. Cause: The UCM has sensed an open circuit in the bucket solenoid circuit, X-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. Open wire or connection 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5251 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 resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3B and X-CN1A. Measure the resistance between X-CN3B pin 17 and X-CN1A pin 13. The resistance should be less than 100 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is less than 100 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance measurement is 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 retract solenoid terminals, pin 1 and pin 2. The resistance should be less than 20 Ω.

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A. The resistance is less than 20 Ω. Go to step 5. B. The resistance is greater than 20 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the circuit. Leave UCM connectors X-CN3B and X-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 X-CN3B pin 17 and X-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. F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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5252-Loader Bucket Valve (Directional) - Solenoid Rollback (A) Supply Short to Ground L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5252 has an error priority of Red. The loader arm functions are disabled while Diagnostic Trouble Code 5252 is active. Cause: The UCM has sensed that the bucket retract solenoid current is too high. The fault is active when hydraulics are enabled and solenoid output current, X-CN3B pin 17 is greater than 3 A. Possible failure modes: 1. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5252 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 should no longer be active. Fault code 5251 is now active. A. Fault code 5252 is no longer active. Fault code 5251 is now active. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5252 is active. Fault code 5251 did not become active. Go to step 4. 4. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. 47711684 06/05/2014

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Leave solenoid connector X-25 disconnected. Disconnect UCM connectors X-CN3B and X-CN1A. Measure the resistance between X-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 X-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 X-CN3B pin 17 and X-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. F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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5261-Bucket Valve (Directional) - Solenoid Dump (B) Supply Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5261 has an error priority of Red. The bucket functions are disabled while Diagnostic Trouble Code 5261 is active. Cause: The UCM has sensed an open circuit in the bucket solenoid circuit, X-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 wire or connection 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5261 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 resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connectors X-CN4A and X-CN1A. Measure the resistance between X-CN4A pin 19 and X-CN1A pin 13. The resistance should be less than 100 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is less than 100 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance measurement is 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.

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A. The resistance is less than 20 Ω. Go to step 5. B. The resistance is greater than 20 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the circuit. Leave UCM connectors X-CN4A and X-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 X-CN4A pin 19 and X-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. F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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5262-Bucket Valve (Directional) - Solenoid Dump (B) Supply Short to Ground L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5262 has an error priority of Red. The loader arm functions are disabled while Diagnostic Trouble Code 5262 is active. Cause: The UCM has sensed that the bucket extend solenoid current is too high. The fault is active when hydraulics are enabled and solenoid output current, X-CN4A pin 19 is greater than 3 A. Possible failure modes: 1. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5262 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-26. Turn the ignition switch ON, activate the hydraulics. Use the electronic service tool and access the fault code screen. Fault code 5262 should no longer be active. Fault code 5261 is now active. A. Fault code 5262 is no longer active. Fault code 5261 is now active. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5262 is active. Fault code 5261 did not become active. Go to step 4. 4. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. 47711684 06/05/2014

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Leave solenoid connector X-26 disconnected. Disconnect UCM connectors X-CN4A and X-CN1A. Measure the resistance between X-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 X-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 X-CN4A pin 19 and X-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. F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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5271-Bucket Valve (Directional) - Common Solenoid (C) Return Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Fault code 5271 has an error priority of White. Bucket functions are disabled while Diagnostic Trouble Code 5271 is active. Cause: The UCM has sensed higher than normal voltage on the bucket solenoid lines, X-CN3B pin 17 or X-CN4A pin 19. The fault is active when hydraulics are disabled and the solenoid voltage feedback is greater than 5 V. Possible failure modes: 1. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5271 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the bucket solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the bucket solenoids. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the signal wires. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3B, X-CN1A, and X-CN4A. Turn the ignition switch ON. Measure the voltage between X-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 X-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 X-CN4A pin 19 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. A. All measured voltages are less than 0.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault.

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5272-Loader Bucket Valve (Directional) - Loader Bucket Solenoids Short to Ground L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Fault code 5272 has an error priority of White. Bucket functions are disabled while Diagnostic Trouble Code 5272 is active. Cause: The UCM has sensed that the solenoid voltages are too low. The fault is active when the hydraulics are disabled and solenoid voltages on pin X-CN3B pin 17 and X-CN4A pin 19 are less than 2 V. Possible failure modes: 1. Shorted wire in the circuit. 2. 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 the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5272 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 connectors X-25 and X-26. Turn the ignition switch ON. Use the electronic service tool to access the fault code screen. Fault code 5272 should no longer be active. Fault code 5273 is now active. A. Fault code 5272 is no longer active. Fault code 5273 is now active. Replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5272 is active. Fault code 5273 did not become active. Go to step 4. 4. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF.

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Disconnect UCM connectors X-CN3B, X-CN1A, and both solenoid connectors, X-25 and X-26. Measure the resistance between X-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 X-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 X-CN3B pin 17 and X-CN1A pin 13. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Leave UCM connectors X-CN3B and X-CN1A disconnected. Disconnect UCM connector X-CN4A. Measure the resistance between X-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 X-CN4A pin 19 and X-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. 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. F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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5273-Bucket Valve (Directional) - Common Solenoid (C) Return Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5273 has an error priority of White. The bucket functions are disabled while Diagnostic Trouble Code 5273 is active. Cause: The UCM has sensed an open circuit in the loader solenoid return circuit, X-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 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5273 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 resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3B, X-CN1A and X-CN4A. Measure the resistance between X-CN3B pin 17 and X-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 X-CN4A pin 19 and X-CN1AB pin 13. The resistance should be less than 100 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 100 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. One or both resistance are greater than 100 Ω. There is an open circuit in the wiring. Go to step 4. 4. Measure the solenoid resistance.

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Measure the resistance across the extend solenoid terminals, pin 1 and pin 2. The resistance should be less than 20 Ω. Measure the resistance across the retract solenoid terminals, pin 1 and pin 2. The resistance should be less than 20 Ω. A. The resistance is less than 20 Ω. Go to step 5. B. The resistance is greater than 20 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the circuit. Leave UCM connectors X-CN3B, X-CN1A and X-CN4A disconnected. Fabricate a jumper wire that will connect between X-25 pin 1 and pin 2. Connect the jumper wire between X-25 pin 1 and pin 2. Measure the resistance between X-CN3B pin 17 and X-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 and connect it between X-26 pin 1 and pin 2. Measure the resistance between X-CN4A pin 19 and X-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. F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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Electrical systems - FAULT CODES

5281-Aux Valve (Directional) - Solenoid Forward (A) Supply Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5281 has an error priority of White. Auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5281 is active. Cause: The UCM has sensed an open circuit in the proportional aux extend solenoid circuit, X-CN1B pin 33 and X-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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5281 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 connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connector X-CN1A. Disconnect UCM connector X-CN1B. Measure the resistance between X-CN1B pin 33 and X-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. Measure the resistance across the solenoid terminals pin 1 and pin 2. The resistance should be less than 100 Ω. 47711684 06/05/2014

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A. The resistance is less than 100 Ω. Go to step 5. B. The resistance is greater than 100 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the circuit. Leave UCM connectors X-CN1A and X-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 X-CN1B pin 33 and X-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. F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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Electrical systems - FAULT CODES

5282-Aux Valve (Directional) - Solenoid Forward (A) Supply Short to Ground L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5282 has an error priority of White. Auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5282 is active. Cause: The UCM has sensed that the Proportional Aux Valve Extend solenoid current is too high. The fault is active when hydraulics are enabled and solenoid output current, X-CN1B pin 33 is greater than 3 A. Possible failure modes: 1. Short circuit in the solenoid wiring. 2. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5282 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 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 should no longer be active. Fault code 5281 is now active. A. Fault code 5282 is no longer active. Fault code 5281 is now active. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5282 is active. Fault code 5281 did not become active. Go to step 4. 4. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. 47711684 06/05/2014

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Disconnect UCM connector X-CN1A. Disconnect UCM connector X-CN1B. Measure the resistance between X-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 X-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 X-CN1B pin 33 and X-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. F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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Electrical systems - FAULT CODES

5291-Aux Valve (Directional) - Solenoid Reverse (B) Supply Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5291 has an error priority of White. Auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5291 is active. Cause: The UCM has sensed an open circuit in the proportional aux retract solenoid circuit, X-CN1A pin 24 and X-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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5291 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 connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connector X-CN1A. Measure the resistance between X-CN1A pin 24 and X-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. 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. 47711684 06/05/2014

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B. The resistance is greater than 100 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the circuit. Leave UCM connector X-CN1A 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 pin 2. Measure the resistance between X-CN1A pin 24 and X-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. F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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Electrical systems - FAULT CODES

5292-Aux Valve (Directional) - Solenoid Reverse (B) Supply Short to Ground L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5292 has an error priority of White. Auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5292 is active. Cause: The UCM has sensed that the Proportional Aux Valve Retract solenoid current is too high. The fault is active when hydraulics are enabled and solenoid output current, X-CN1A pin 24 is greater than 3 A. Possible failure modes: 1. Short circuit in the solenoid wiring. 2. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5292 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 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 should no longer be active. Fault code 5291 is now active. A. Fault code 5292 is no longer active. Fault code 5291 is now active. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5292 is active. Fault code 5291 did not become active. Go to step 4. 4. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. 47711684 06/05/2014

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Disconnect UCM connector X-CN1A and solenoid connector X-29. Measure the resistance between X-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 X-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 X-CN1A pin 24 and X-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. F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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Electrical systems - FAULT CODES

5309-Float Button - Float Button Timeout (30 sec) L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5309 has an error priority of White. Loader Float is disabled with Diagnostic Trouble Code 5309. Cause: UCM has sensed that the Float Switch signal input, X-CN2B pin 27 has been high for more than 30 seconds. Possible failure modes: 1. Short circuit to another voltage source. 2. Failure of the Float 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5309 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and Float Switch connections on the Right Hand 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 Hand 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 resistance through the Float Switch. Turn the ignition switch OFF. Disconnect connector X-403 from the Right Hand 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 Float Switch and retest. Return to step 1 to confirm elimination of the fault. 4. Measure the voltage on the signal wire. Turn the ignition switch OFF. 47711684 06/05/2014

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Disconnect UCM connector X-CN2B. Reconnect Right Hand Joystick connector X-403. Turn the ignition switch ON. Measure the voltage between X-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. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Case machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Case machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17) New Holland machines Wire harnesses - Electrical schematic sheet 17 (55.100.DP-C.20.E.17)

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Electrical systems - FAULT CODES

5371-EHF Pump Control PRV's (Directional) - Forward Solenoid (A) Supply Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5371 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST when the technician checks for active trouble codes. EHF Function is disabled while Diagnostic Trouble Code 5371 is active. Cause: UCM has sensed an open circuit condition for the EHF Extend solenoid, X-CN3A pin 19. The fault is active when EHF setting is activated, Hydraulics are enabled, and solenoid current is below normal. Possible failure modes: 1. Open wire in circuit. 2. Failure of EHF Extend solenoid. 3. Faulty UCM. Solution: 1. Verify that the fault code is still active (1) Use the Electronic Service Tool to clear all fault codes. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) To check for Active fault codes: Start and operate machine. A. The fault is not recorded again. OK to return the machine to service. B. Fault code 5371 is recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage.

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(1)

(2)

(3)

Schematic legend (4)

EHF Extend UCM Connector X-CN3A pin 19 EHF Return UCM Connector X-CN2B pin 8 EHF Retract UCM Connector X-CN3A pin 6

(5)

EHF Extend Connector X-19 EHF Retract Connector X-40

(1) Inspect the UCM and EHF Extend solenoid connections. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the UCM to the EHF Extend 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 resistance through the harness. (1) Fabricate a jumper wire that will connect between the EHF Extend solenoid connector X-19 pin 1 and X-19 pin 2. (2) Turn the key switch OFF. (3) Disconnect UCM connectors X-CN3A and X-CN2B. (4) Use the jumper wire to short X-19 pin 1 to X-19 pin 2. (5) Measure the resistance between X-CN3A pin 19 and X-CN2B pin 8. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to Step 4. B. The resistance is greater than 10 Ω. There is an open circuit in the solenoid signal or solenoid ground line. Check splice SP-193. Repair or replace the harness as required. Return to Step 1 to confirm elimination of the fault. 4. Test UCM (1) Leave the jumper wire installed between X-19 pin 1 and X-19 pin 2 (2) Reconnect UCM connectors X-CN3A and X-CN2B. (3) Turn the key switch ON. (4) Activate the hydraulics while monitoring the fault code screen. Fault code 5371 should no longer be active. Fault code 5372 should become active. A. Fault code 5372 is active and fault code 5371 is no longer active. Temporarily replace the solenoid and retest. Return to Step 1 to confirm elimination of the fault. B. Fault code 5371 is still active. Fault code 5372 did not become active. Temporarily replace the UCM and retest. Return to Step 1 to confirm elimination of the fault. Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 32 (55.100.DP-C.20.E.32) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

5372-EHF Pump Control PRV's (Directional) - Forward Solenoid (A) Supply Short to Ground L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5372 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in EST when the technician checks for active trouble codes. EHF Functions are disabled while Diagnostic Trouble Code 5372 is active. Cause: UCM has sensed a short circuit condition for the EHF Extend solenoid, XCN3A pin 19. The fault is active when EHF setting is activated, Hydraulics are enabled, and solenoid current is greater than 3 A. Possible failure modes: 1. Shorted wire in circuit. 2. Failure of EHF Extend solenoid. Solution: 1. Verify that the fault code is still active (1) Use the Electronic Service Tool to clear all fault codes. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) To check for Active fault codes: Start and operate machine. A. The fault is not recorded again. OK to return the machine to service. B. Fault code 5372 is recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage.

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(1)

(2)

(3)

EHF Extend UCM Connector X-CN3A pin 19 EHF Return UCM Connector X-CN2B pin 8 EHF Retract UCM Connector X-CN3A pin 6

Schematic legend (4)

(5)

EHF Extend Connector X-19 EHF Retract Connector X-40

(1) Inspect the UCM, EHF Extend solenoid and EHF Retract solenoid connections. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the UCM to the EHF Extend and Retract 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 wires to chassis ground (1) Turn the key switch OFF. (2) Disconnect solenoid connector X-19. Disconnect UCM connector X-CN3A and X-CN2B. (3) 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. (4) 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. 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. Repair or replace the harness as required. Return to Step 1 to confirm elimination of fault. 4. Test the UCM (1) Turn the key switch OFF. (2) Reconnect UCM connectors X-CN3A and X-CN2B. Leave connector X-19 disconnected. (3) Turn the key switch ON. (4) Activate EHF hydraulics while monitoring the fault code screen. Fault code 5372 should no longer be active. Fault code 5371 should become active. A. Fault code 5371 is active and fault code 5372 is no longer active. Temporarily replace both solenoids and retest. Return to Step 1 to confirm elimination of the fault. B. Fault code 5372 is still active. Fault code 5371 did not become active. Temporarily replace the UCM and retest. Return to Step 1 to confirm elimination of the fault. Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 32 (55.100.DP-C.20.E.32) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

5381-EHF Pump Control PRV's (Directional) - Reverse Solenoid (B) Supply Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5381 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST when the technician checks for active trouble codes. EHF Function is disabled while Diagnostic Trouble Code 5381 is active. Cause: UCM has sensed an open circuit condition for the EHF Retract solenoid, X-CN3A pin 6. The fault is active when EHF setting is activated, Hydraulics are enabled, and solenoid current is below normal. Possible failure modes: 1. Open wire in circuit. 2. Failure of EHF Retract solenoid. 3. Faulty UCM. Solution: 1. Verify that the fault code is still active (1) Use the Electronic Service Tool to clear all fault codes. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) To check for Active fault codes: Start and operate machine. A. The fault is not recorded again. OK to return the machine to service. B. Fault code 5381 is recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage.

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(1)

(2)

(3)

Schematic legend (4)

EHF Extend UCM Connector X-CN3A pin 19 EHF Return UCM Connector X-CN2B pin 8 EHF Retract UCM Connector X-CN3A pin 6

(5)

EHF Extend Connector X-19 EHF Retract Connector X-40

(1) Inspect the UCM and EHF Retract solenoid connections. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the UCM to the EHF Retract 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 resistance through the harness. (1) Fabricate a jumper wire that will connect between the EHF Retract solenoid connector X-40 pin 1 and X-40 pin 2. (2) Turn the key switch OFF. (3) Disconnect UCM connectors X-CN3A and X-CN2B. (4) Use the jumper wire to short X-40 pin 1 to X-40 pin 2. (5) Measure the resistance between X-CN3A pin 6 and X-CN2B pin 8. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Go to Step 4. B. The resistance is greater than 10 Ω. There is an open circuit in the solenoid signal or solenoid ground line. Check splice SP-193. Repair or replace the harness as required. Return to Step 1 to confirm elimination of the fault. 4. Test UCM (1) Leave the jumper wire installed between X-40 pin 1 and X-40 pin 2 (2) Reconnect UCM connectors X-CN3A and X-CN2B. (3) Turn the key switch ON. (4) Activate the hydraulics while monitoring the fault code screen. Fault code 5381 should no longer be active. Fault code 5382 should become active. A. Fault code 5382 is active and fault code 5381 is no longer active. Temporarily replace the solenoid and retest. Return to Step 1 to confirm elimination of the fault. B. Fault code 5381 is still active. Fault code 5382 did not become active. Temporarily replace the UCM and retest. Return to Step 1 to confirm elimination of the fault. Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 32 (55.100.DP-C.20.E.32) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19)

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5382-EHF Pump Control PRV's (Directional) - Reverse Solenoid (B) Supply Short to Ground L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5382 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in EST when the technician checks for active trouble codes. EHF Functions are disabled while Diagnostic Trouble Code 5382 is active. Cause: UCM has sensed a short circuit condition for the EHF Retract solenoid, XCN3A pin 6. The fault is active when EHF setting is activated, Hydraulics are enabled, and solenoid current is greater than 3 A. Possible failure modes: 1. Shorted wire in circuit. 2. Failure of EHF Retract solenoid. Solution: 1. Verify that the fault code is still active (1) Use the Electronic Service Tool to clear all fault codes. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) To check for Active fault codes: Start and operate machine. A. The fault is not recorded again. OK to return the machine to service. B. Fault code 5382 is recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage.

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(1)

(2)

(3)

EHF Extend UCM Connector X-CN3A pin 19 EHF Return UCM Connector X-CN2B pin 8 EHF Retract UCM Connector X-CN3A pin 6

Schematic legend (4)

(5)

EHF Extend Connector X-19 EHF Retract Connector X-40

(1) Inspect the UCM, EHF Extend solenoid and EHF Retract solenoid connections. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the UCM to the EHF Extend and Retract 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 wires to chassis ground (1) Turn the key switch OFF. (2) Disconnect solenoid connector X-40. Disconnect UCM connector X-CN3A and X-CN2B. (3) 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. (4) 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. 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. Repair or replace the harness as required. Return to Step 1 to confirm elimination of fault. 4. Test the UCM (1) Turn the key switch OFF. (2) Reconnect UCM connectors X-CN3A and X-CN2B. Leave connector X-40 disconnected. (3) Turn the key switch ON. (4) Activate EHF hydraulics while monitoring the fault code screen. Fault code 5382 should no longer be active. Fault code 5381 should become active. A. Fault code 5381 is active and fault code 5382 is no longer active. Temporarily replace both solenoids and retest. Return to Step 1 to confirm elimination of the fault. B. Fault code 5382 is still active. Fault code 5381 did not become active. Temporarily replace the UCM and retest. Return to Step 1 to confirm elimination of the fault. Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 32 (55.100.DP-C.20.E.32) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19)

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5391-EHF Pump Control PRV's (Directional) - Solenoids Return Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5391 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST when the technician checks for active trouble codes. EHF Functions are disabled while Diagnostic Trouble Code 5391 is active. Cause: UCM has sensed an open circuit condition in the EHF Extend solenoid common line X-CN2B pin 8. The fault is active while EHF setting is activated, Hydraulics are enabled and extend solenoid and retract solenoid current is correct. Possible failure modes: 1. Open wire in circuit. 2. Failure of EHF Extend and Retract solenoids. 3. Faulty UCM. Solution: 1. Verify that the fault code is still active (1) Use the Electronic Service Tool to clear all fault codes. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) To check for Active fault codes: Start and operate machine. A. The fault is not recorded again. OK to return the machine to service. B. Fault code 5391 is recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage.

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(1)

(2)

(3)

Schematic legend (4)

EHF Extend UCM Connector X-CN3A pin 19 EHF Return UCM Connector X-CN2B pin 8 EHF Retract UCM Connector X-CN3A pin 6

(5)

EHF Extend Connector X-19 EHF Retract Connector X-40

(1) Inspect the UCM, EHF Extend solenoid and EHF Retract solenoid connections. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the UCM to the EHF Extend solenoid and EHF Retract 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 resistance through the harness. (1) Fabricate two jumper wires, one that will connect between the EHF Extend solenoid connector X-19 pin 1 and X-19 pin 2 and a second jumper wire for EHF Retract solenoid connector X-40 pin 1 and X-40 pin 2. (2) Turn the key switch OFF. (3) Disconnect UCM connectors X-CN3A and X-CN2B. Disconnect solenoid connectors X-19 and X-40. (4) Use the jumper wire to short X-19 pin 1 to X-19 pin 2. (5) Measure the resistance between X-CN3A pin 19 and X-CN2B pin 8. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. (6) Use the second jumper wire to short X-40 pin 1 to X-40 pin 2. (7) Measure the resistance between X-CN3A pin 6 and X-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 solenoid signal or solenoid ground line. Check splice SP-193. Repair or replace the harness as required. Return to Step 1 to confirm elimination of the fault. 4. Test UCM (1) Leave the jumper wires installed in connectors X-19 and X-40. (2) Reconnect UCM connectors X-CN3A and X-CN2B. (3) Turn the key switch ON. (4) Activate the hydraulics while monitoring the fault code screen. Fault code 5391 should no longer be active. Fault code 5392 should become active. A. Fault code 5392 is active and fault code 5391 is no longer active. Temporarily replace the solenoid and retest. Return to Step 1 to confirm elimination of the fault. B. Fault code 5391 is still active. Fault code 5392 did not become active. Temporarily replace the UCM and retest. Return to Step 1 to confirm elimination of the fault. Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 32 (55.100.DP-C.20.E.32) 47711684 06/05/2014

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Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19)

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5392-EHF Pump Control PRV's (Directional) - EHF Pumps Solenoids Short to Ground L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5392 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST when the technician checks for active trouble codes. EHF Functions are disabled while Diagnostic Trouble Code 5392 is active. Cause: UCM has sensed a short to ground condition for the EHF Pump solenoid. The fault is active when EHF setting is activated, Hydraulics are disabled, and solenoid return voltage is low. Possible failure modes: 1. Shorted wire in circuit. 2. Failure of EHF Pump solenoid. 3. Faulty UCM Solution: 1. Verify that the fault code is still active (1) Use the Electronic Service Tool to clear all fault codes. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) To check for Active fault codes: Start and operate machine. A. The fault is not recorded again. OK to return the machine to service. B. Fault code 5392 is recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage.

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Electrical systems - FAULT CODES

(1)

(2)

(3)

EHF Extend UCM Connector X-CN3A pin 19 EHF Return UCM Connector X-CN2B pin 8 EHF Retract UCM Connector X-CN3A pin 6

Schematic legend (4)

(5)

EHF Extend Connector X-19 EHF Retract Connector X-40

(1) Inspect the UCM, EHF Extend solenoid and EHF Retract solenoid connections. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the UCM to the EHF Extend solenoid and EHF Retract 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 resistance of the solenoid wires to chassis ground (1) Turn the key switch OFF. (2) Disconnect solenoid connector X-19 and X-40. Disconnect UCM connector X-CN3A and X-CN2B. (3) 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. (4) 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. (5) 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. (6) 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. 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 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 (1) Turn the key switch OFF. (2) Reconnect UCM connectors X-CN3A and X-CN2B. Leave connectors X-19 and X-40 disconnected. (3) Turn the key switch ON. (4) Activate the hydraulics while monitoring the fault code screen. Fault code 5392 should no longer be active. Fault code 5391 should become active. A. Fault code 5391 is active and fault code 5392 is no longer active. Temporarily replace both solenoids and retest. Return to Step 1 to confirm elimination of the fault. B. Fault code 5392 is still active. Fault code 5391 did not become active. Temporarily replace the UCM and retest. Return to Step 1 to confirm elimination of the fault. Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 32 (55.100.DP-C.20.E.32) Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

5393-EHF Pump Control PRV's (Directional) - EHF Pumps Solenoids Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5393 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST when the technician checks for active trouble codes. EHF Function is disabled with Diagnostic Trouble Code 5393. Cause: UCM has sensed a short to positive condition for the EHF Pump solenoid. The fault is active when EHF setting is activated, Hydraulics are disabled, and either solenoid voltage feedback is greater than 5 V. Possible failure modes: 1. Shorted wire in circuit. 2. Faulty UCM Solution: 1. Verify that the fault code is still active (1) Use the Electronic Service Tool to clear all fault codes. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) To check for Active fault codes: Start and operate machine. A. The fault is not recorded again. OK to return the machine to service. B. Fault code 5393 is recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage.

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Electrical systems - FAULT CODES

(1)

(2)

(3)

EHF Extend UCM Connector X-CN3A pin 19 EHF Return UCM Connector X-CN2B pin 8 EHF Retract UCM Connector X-CN3A pin 6

Schematic legend (4)

(5)

EHF Extend Connector X-19 EHF Retract Connector X-40

(1) Inspect the UCM, EHF Extend solenoid and EHF Retract solenoid connections. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the UCM to the EHF Extend solenoid and EHF Retract 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 (1) Turn the key switch OFF. (2) Disconnect solenoid connector X-19 and X-40. Disconnect UCM connector X-CN3A and X-CN2B. (3) Turn the keyswitch ON. (4) 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. (5) 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. (6) 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. (7) 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 is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to Step 1 to confirm elimination of fault. 4. Test the UCM (1) Turn the key switch OFF. (2) Reconnect UCM connectors X-CN3A and X-CN2B. Leave connectors X-19 and X-40 disconnected. (3) Turn the key switch ON. (4) Activate the hydraulics while monitoring the fault code screen. Fault code 5393 should no longer be active. Fault code 5391 should become active. A. Fault code 5391 is active and fault code 5393 is no longer active. Temporarily replace both solenoids and retest. Return to Step 1 to confirm elimination of the fault. B. Fault code 5393 is still active. Fault code 5391 did not become active. Temporarily replace the UCM and retest. Return to Step 1 to confirm elimination of the fault. Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 32 (55.100.DP-C.20.E.32) 47711684 06/05/2014

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

5409-CAN Message Error - Aux Override Disabled Due To Aux Override Button Timeout (30 sec) L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5409 has an error priority of White. Aux Override is disabled while Diagnostic Trouble Code 5409 is active. Cause: The UCM has sensed an error with the Aux Override Button status. The fault is activate when ignition is on and CAN message from AIC is high for more than 30 seconds. Possible failure modes: 1. Failure of the Instrument Cluster. Solution: 1. Use the EST to verify fault code 5409 CAN Message Error - Aux Override Disabled Due To Aux Override Button Timeout (30 sec) is active. A. If the fault is active, erase it with the EST. 2. If the fault persists, it is an indication of an Instrument Cluster failure. Replace the Instrument Cluster.

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Electrical systems - FAULT CODES

5501-Loader Arm Spool Sensor - Sensor Short to Ground/ Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5501 has an error priority of White. Limp home loader functions are enabled while Diagnostic Trouble Code 5501 is active. Cause: The UCM has sensed that the loader position sensor signal, X-CN3B pin 13 has failed low. The fault is active when the engine is ON and loader position sensor signal is less than 0.2 V. Possible failure modes: 1. Short circuit in the wiring. 2. Open circuit in the wiring. 3. The loader valve spool 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5501 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 loader 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.

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Electrical systems - FAULT CODES

Turn the ignition switch OFF. Disconnect UCM connector X-CN3B. Disconnect the Loader Position Sensor from the harness. Measure the resistance between X-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. Use a jumper wire with alligator clips on both ends to short connector X-CN3B pin 13 to chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance of connector X-22 pin 4 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. Test the UCM. Reconnect UCM connector CN3B. Fabricate a jumper wire 20 cm (8 in) that will connect between X-22 pin 1 and X-22 pin 4. Turn the ignition switch ON and monitor the active fault screen. Use the jumper wire to short the Loader Position Sensor connector X-22 pin 1 to X-22 pin 4. Fault code 5502 should become active. Fault code 5501 should no longer be active. A. Fault code 5502 is active and fault code 5501 is no longer active. Temporarily replace the Loader Position Sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5501 is still active. Fault code 5502 is not active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. EH machines F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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Electrical systems - FAULT CODES

5502-Loader Arm Spool Sensor - Sensor Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5502 has an error priority of Amber. Limp home loader functions are enabled while Diagnostic Trouble Code 5502 is active. Cause: The UCM has sensed a higher than normal voltage on the loader valve spool input, X-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. 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 5502 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 connections. 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 Loader 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 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. Disconnect UCM connector X-CN3B. Disconnect the Loader Spool Position Sensor from the harness. Turn the ignition switch ON.

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Measure the voltage between X-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. Use a jumper wire with alligator clips on both ends to short connector X-CN3B pin 13 to 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. Reconnect UCM connector CN3B. Fabricate a jumper wire that will connect between X-22 pin 3 and X-22 pin 4. Use the jumper wire to short the Loader Position Sensor connector X-22 pin 3 to X-22 pin 4. Turn the ignition switch ON and monitor the active fault screen. Fault code 5501 should become active. Fault code 5502 should no longer be active. A. Fault code 5501 is active. Fault code 5502 is no longer active. Temporarily replace the Loader Position Sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5502 is still active. Fault code 5501 is not active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. EH machines F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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Electrical systems - FAULT CODES

5503-Hydraulic Enable (Mechanical Machines) - EH AUX Output, Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Mechanical hydraulic controls WE Mechanical hydraulic controls

Context: Diagnostic Trouble Code 5503 has an error priority of Red. The vehicle is disabled with Diagnostic Trouble Code 5503. Cause: Instrument Cluster has sensed a short circuit to another voltage source in the EH Aux Output circuit. The fault is active while Ignition is On, Aux Output Commanded state is low and EH Aux output is energized. Possible failure modes: 1. Faulty wiring or connectors. 2. Faulty Instrument Cluster. Solution: 1. Verify that the fault code is still active. Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence. (1) Use the Electronic Service Tool to clear all fault codes. (2) To check for fault code: Start and operate machine. A. Fault is not recorded again. OK to return the machine to service. B. Fault code is recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect Instrument Cluster connector X-C23 and the EH AUX PWM Controller connections. All connections should be secure, tight, free of corrosion, abrasion and/or damage. (2) 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.

RAPH12SSL0268FA

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(1)

Schematic Legend Instrument Cluster Connector (2) X-C23 pin 26

EH Aux PWM Controller Connector X-430 pin 1

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5504-Bucket Valve Spool Sensor - Sensor Short to Ground/ Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5504 has an error priority of Red. Loader Hydraulics are disabled while Diagnostic Trouble Code 5504 is active. Cause: The UCM has sensed that the loader arm position sensor does not agree with the direction of loader arm command. The fault is active while the engine is ON and the loader arm position sensor senses loader arm movement but the solenoids are not energized or loader arm movement is opposite of the energized solenoid. Possible failure modes: 1. Spool sticking inside the valve body. 2. Improper wiring in circuit, connector X-28 swapped with connector X-27. 3. Failure of the Loader Arm Spool Position Sensor. 4. Faulty UCM. Solution: 1. Verify that the spool is not stuck in the valve. Turn the ignition switch OFF. Remove the loader arm 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5504 is recorded again. Go to step 3. 3. Verify that the wiring and connectors are free of damage. Inspect the UCM, the loader solenoid and loader position sensor connections. 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 4.

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B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 2 to confirm elimination of fault. 4. Measure the voltage at the sensor. Disconnect the Loader 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 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 Loader Spool Position Sensor from the harness. Turn the key switch ON. Monitor the EST fault code screen. Fault code 5504 should be active. Use a jumper wire to short X-22 pin 1 to X-22 pin 4. Fault code 5505 should be active. A. Fault code 5504 is active while the sensor is disconnected and fault code 5505 is active while the X-22 pin 1 is shorted to X-22 pin 4. Temporarily replace the Loader Spool Position Sensor and retest. Return to step 2 to confirm elimination of the fault. B. Fault code 5505 is not active while the 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. EH machines F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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5505-Bucket Valve Spool Sensor - Sensor Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5505 has an error priority of Amber. Implement limp home operating mode is enabled while Diagnostic Trouble Code 5505 is active. Cause: The UCM has sensed a higher than normal voltage on the Bucket Valve Spool Sensor. The fault is active when the ignition is ON and the Bucket Valve Spool Sensor voltage is high. Possible failure modes: 1. Shorted wire in circuit. 2. Failure of Bucket Valve Spool Sensor. 3. UCM has internal failure. Solution: 1. 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 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 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 X-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 X-CN3B. Disconnect the Bucket Spool Position Sensor from the harness. Turn the ignition switch ON.

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Measure the voltage between X-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. Use a jumper wire with alligator clips on both ends to short connector X-CN3B pin 12 to chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. (2) Measure the resistance of connector X-21 pin 4 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. Test the UCM. Reconnect UCM connector CN3B. Fabricate a jumper wire that will connect between X-21 pin 3 and X-21 pin 4. Use the jumper wire to short the Bucket Spool Position Sensor connector X-21 pin 3 to X-21 pin 4.

RAPH12SSL0414EA

(1)

Schematic Legend Jumper wire inserted between X-21 pin 3 (2) and X-21 pin 4

Bucket Spool Position Sensor

Turn the ignition switch ON and monitor the active fault screen. Fault code 5504 should become active. Fault code 5505 should no longer be active. A. Fault code 5504 is active and fault code 5505 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 is still active. Fault code 5504 is not active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. EH machines F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) 47711684 06/05/2014

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Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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5507-Auxiliary Valve Spool Sensor - Sensor Short to Ground/ Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5507 has an error priority of White. Auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5507 is active. Cause: The UCM has sensed that the aux position sensor signal, X-CN3B pin 14 has failed low. The fault is active while the engine is ON and aux position sensor signal is less than 0.2 V. Possible failure modes: 1. Short circuit in the wiring. 2. Open circuit in the wiring. 3. The auxiliary valve spool 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5507 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the proportional aux solenoid connections, and the aux position sensor connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the proportional aux solenoids, and the aux 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 the fault. 3. Measure the voltage at the sensor. Disconnect the Aux 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 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.

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Turn the ignition switch OFF. Disconnect UCM connector X-CN3B. Disconnect the Aux Position Sensor from the harness. Measure the resistance between X-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 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. Use a jumper wire with alligator clips on both ends to connect X-CN3B pin 14 to 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.

RAPH12SSL0412EA

(1)

Schematic Legend Jumper wire inserted between X-23 pin 1 (2) and X-23 pin 4

Aux Position Sensor

Turn the ignition switch ON and monitor the active fault screen. Fault code 5508 should become active. Fault code 5507 should no longer be active. A. Fault code 5508 is active. Fault code 5507 is no longer active. Temporarily replace the Aux Position Sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5507 is still active. Fault code 5508 is not active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. EH machines F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) 47711684 06/05/2014

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Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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5508-Auxiliary Valve Spool Sensor - Sensor Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5508 has an error priority of White. Auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5508 is active. Cause: The UCM has sensed a higher than normal voltage on the auxiliary valve spool input, X-CN3B pin 14. The fault is active while ignition is ON and the aux position sensor signal is greater than 4.8 V. Possible failure modes: 1. The signal wire is shorted 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5508 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the proportional aux solenoid connections, and the aux position sensor connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the proportional aux solenoids, and the aux 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 the fault. 3. Measure the voltage at the sensor. Disconnect the Aux 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 X-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. Disconnect UCM connector X-CN3B. Disconnect the Aux Spool Position Sensor from the harness. Turn the ignition switch ON.

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Measure the voltage between X-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 X-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. Use the jumper wire to short the Aux Position Sensor connector X-23 pin 3 to X-23 pin 4.

RAPH12SSL0413EA

(1)

Schematic Legend Jumper wire inserted between X-23 pin 3 (2) and X-23 pin 4

Aux Position Sensor

Turn the ignition switch ON and monitor the active fault screen. Fault code 5507 should become active. Fault code 5508 should no longer be active. A. Fault code 5507 is active. Fault code 5508 is no longer active. Temporarily replace the Aux Position Sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5508 is still active. Fault code 5507 is not active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. EH machines F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine 47711684 06/05/2014

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Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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5511-Loader Arm Spool Sensor - Implausible State Sensor vs. Loader Arm Command, Stuck Spool/ PRV L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5511 has an error priority of Red. Loader hydraulics are disabled while Diagnostic Trouble Code 5511 is active. Cause: The UCM has sensed that the loader arm position sensor does not agree with the direction of loader arm the command. The fault is active while the engine is ON and the loader arm position sensor senses loader arm movement while the solenoids are not energized or 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. Failure of the Loader Arm Spool Position Sensor. 4. Faulty UCM. Solution: 1. Verify that the spool is not stuck in the valve. Turn the ignition switch OFF. Remove the loader arm 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. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5511 is recorded again. Go to step 3. 3. Verify that the wiring and connectors are free of damage. Inspect the UCM, the loader solenoid and loader position sensor connections. 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.

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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 connectors as required. Return to step 2 to confirm elimination of fault. 4. Measure the voltage at the sensor. Disconnect the Loader 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 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 Loader Spool Position Sensor from the harness. Turn the ignition switch ON. Monitor the EST fault code screen. Fault code 5511 should be active. Use a jumper wire to short X-22 pin 1 to X-22 pin 4. Fault code 5502 should be active. Fault code 5511 should no longer be active. A. Fault code 5511 is active while the sensor is disconnected and fault code 5502 is active while the X-22 pin 1 is shorted to X-22 pin 4. Temporarily replace the Loader Spool Position Sensor and retest. Return to step 2 to confirm elimination of the fault. B. Fault code 5502 is not active while the 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. EH machines F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) 47711684 06/05/2014

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Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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5512-Bucket Valve Spool Sensor - Implausible State Sensor vs. Loader Bucket Command L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5512 has an error priority of Red. Loader Hydraulics are disabled with Diagnostic Trouble Code 5512. 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 bucket movement when the solenoids are not energized or bucket movement opposite of the energized solenoid. Possible failure modes: 1. Improper wiring in circuit, connector X-25 swapped with connector X-26. 2. Spool sticking inside the valve body. 3. Failure of Bucket Spool Position Sensor. 4. 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. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5512 is recorded again. Go to step 3. 3. 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. Inspect the Bucket Valve Retract Spool solenoid and the Bucket Valve Extend solenoid. Verify all connections are secure, tight, free of corrosion, abrasion and damage.

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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 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 X-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 should be active. Use a jumper wire to connect X-21 pin 1 to X-21 pin 4. Fault code 5505 should be active. A. Fault code 5512 is active while the sensor is disconnected and fault code 5505 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 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. EH machines F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) 47711684 06/05/2014

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Electrical systems - FAULT CODES

5513-Auxiliary Valve Spool Sensor - Implausible State Sensor vs. Auxiliary Command L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5513 has an error priority of Red. Loader Hydraulics are disabled while Diagnostic Trouble Code 5513 is active. Cause: The UCM has sensed that the aux position sensor does not agree with the direction of aux the command. The fault is active when the engine is ON and the aux position sensor senses aux movement when the solenoids are not energized or aux movement is opposite of the energized solenoid. Possible failure modes: 1. Improper wiring in circuit, connector X-29 swapped with connector X-24. 2. Spool sticking inside the valve body. 3. Failure of the Aux Position Sensor. 4. 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 fault sensor values change 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 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5513 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 aux position sensor connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the proportional aux solenoids, and the aux position sensor. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. Inspect the Aux Retract solenoid and the Aux Extend solenoid. Verify all connections are secure, tight, free of corrosion, abrasion and damage.

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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. The Aux Valve Spools are connected properly. Go to step 4. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 2 to confirm elimination of fault. 4. Measure the voltage at the sensor. Disconnect the Aux 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 Aux Spool Position Sensor from the harness. Turn the ignition switch ON. Monitor the EST fault code screen. Fault code 5513 should be active. Use a jumper wire to short X-23 pin 1 to X-23 pin 4. Fault code 5508 should be active. A. Fault code 5513 is active while the sensor is disconnected and fault code 5508 is active while the X-23 pin 1 is shorted to X-23 pin 4. Temporarily replace the Aux Spool Position Sensor and retest. Return to step 2 to confirm elimination of the fault. B. Fault code 5508 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. EH machines F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) 47711684 06/05/2014

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Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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5601-Aux Valve (Directional) - Common Solenoid Return Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Fault code 5601 has an error priority of White. Auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5601 is active. Cause: The UCM has sensed higher than normal voltage on the proportional aux solenoid lines, X-CN1A pin 24 or X-CN1B pin 33. The fault is active while the ignition is on, hydraulics are disabled, and the solenoid voltage feedback is greater than 5 V. Possible failure modes: 1. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5601 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.

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RAPH12SSL0411FA

(1)

(2)

(3)

(4)

(5)

Schematic legend (6) Proportional Aux Retract Signal UCM connector X-CN1A pin 24 (7) Proportional Aux Return, Common Ground UCM Connector X-CN1A pin 22 (8) Proportional Aux Extend Signal UCM Connector X-CN1B pin 33 Control Valve Aux Position Sensor Signal (9) UCM Connector X-CN3B pin 14

Proportional Aux Extend Solenoid

Control Valve Aux Position Sensor

Control Valve Sensor Ground X-88 pin 9 Chassis Ground Sensor Supply X-88 pin 14 UCM connector X-CN1A pin 8

Proportional Aux Retract Solenoid

A. The connectors are secure and the harness is free of damage. Go to step 3. B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the signal wires. Turn the ignition switch OFF. Disconnect UCM connectors X-CN1A and X-CN1B. Turn the ignition switch ON. Measure the voltage between X-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 X-CN1A pin 22 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. Measure the voltage between X-CN1B pin 33 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition.

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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. EH machines F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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5602-Loader Auxiliary Valve (Directional) - Loader Auxiliary Solenoids Short to Ground L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Fault code 5602 has an error priority of White. Auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5602 is active. Cause: The UCM has sensed that the solenoid voltages are too low. The fault is active while the hydraulics are disabled and solenoid voltages on pin X-CN1A pin 33 and X-CN1B pin 24 are less than 2 V. Possible failure modes: 1. Shorted wire in the circuit. 2. 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 the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5602 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 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 should no longer be active. Fault code 5603 is now active. A. Fault code 5602 is no longer active. Fault code 5603 is now active. Replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5602 is active. Fault code 5603 did not become active. Go to step 4. 4. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF.

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Disconnect UCM connector X-CN1A and both solenoid connectors, X-29 and X-24. Measure the resistance between X-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 X-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 X-CN1A pin 24 and X-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 X-CN1A disconnected. Disconnect UCM connector X-CN1B. Measure the resistance between X-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 X-CN1B pin 33 and X-CN1A pin 22. 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. EH machines F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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5603-Loader Auxiliary Valve Solenoid Return Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5603 has an error priority of White. Auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5603 is active. Cause: The UCM has sensed an open circuit in the proportional aux solenoid return circuit, X-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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5603 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 connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connectors X-CN1A and X-CN1B. Measure the resistance between X-CN1A pin 24 and X-CN1A pin 22. The resistance should be less than 100 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN1B pin 33 and X-CN1A pin 22. The resistance should be less than 100 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 100 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. One or both resistance are greater than 100 Ω. There is an open circuit in the wiring. Go to step 4. 4. Measure the solenoid resistance.

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Measure the resistance across the extend solenoid terminals, pin 1 and pin 2. The resistance should be less than 20 Ω. Measure the resistance across the retract solenoid terminals, pin 1 and pin 2. The resistance should be less than 20 Ω. A. The resistance is less than 20 Ω. Go to step 5. B. The resistance is greater than 20 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the circuit. Leave UCM connectors X-CN1A and X-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 pin 2. Measure the resistance between X-CN1A pin 24 and X-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 and connect it between X-24 pin 1 and pin 2. Measure the resistance between X-CN1B pin 33 and X-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. EH machines F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 20 (55.100.DP-C.20.E.20) Wire harnesses - Electrical schematic sheet 11 (55.100.DP-C.20.E.11)

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5701-Pattern Switch - Short to Ground/ Open Circuit L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5701 has an error priority of White. The selected joystick pattern is locked and cannot be changed while Diagnostic Trouble Code 5701 is active. Cause: The UCM has sensed the voltage at X-CN1B pin 15, X-CN2B pin 20 and X-CN2B pin 21 is less than 1.5 V. Possible failure modes: 1. Shorted wire in circuit. 2. Open wire in circuit. 3. Faulty Drive Pattern Select Switch. 4. 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 5701 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and 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. 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 from X-95 pin 5 to chassis ground. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 12 V. Go to step 4. B. The voltage is less than 10 V. There is a problem in the battery supply to the switch. Repair as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF.

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Disconnect UCM connectors X-CN1B and X-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. Use a jumper wire with alligator clips on both ends to short connector X-CN2B pin 20 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 1 to chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect one end of the jumper wire to connector X-CN2B 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 to chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect one end of the jumper wire to connector X-CN1B pin 15 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 3 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. 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 another 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 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. 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. 47711684 06/05/2014

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Actuate the switch to the H Pattern. The resistance should change to a value less than 10 Ω. Measure the resistance between pin 5 and pin 6 on the Drive Pattern (ISO/ H Pattern) Switch. The resistance should be greater than 20,000 Ω. Actuate the switch to the ISO Pattern. The resistance should change to a value less than 10 Ω. A. The resistance is greater than 20,000 Ω when the switch is in the neutral state and the resistance changed to a value less than 10 Ω when the switch was actuated. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 20,000 Ω while the switch is in the neutral state or the resistance did not change to a value less than 10 Ω when the switch was actuated. Temporarily replace the Drive Pattern (ISO/ H Pattern) Switch and retest. Return to step 1 to confirm elimination of fault. EH machines F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 15 (55.100.DP-C.20.E.15) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08)

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5703-Pattern Switch - Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5703 has an error priority of White. The selected joystick pattern is locked and cannot be changed while Diagnostic Trouble Code 5703 is active. Cause: The UCM has sensed the voltage at two or more Drive Pattern Selector (ISO/ H Pattern) Switch pins (X-CN1B pin 15, X-CN2B pin 20 or X-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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5703 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 X-CN1B and X-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. 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. 47711684 06/05/2014

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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 X-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 X-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 the jumper wire between connector X-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. 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. 47711684 06/05/2014

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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. EH machines F5H engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 15 (55.100.DP-C.20.E.15) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Small EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08) Medium EH machines ISM engine Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08)

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5811-Loader Lockout Switch - Implausible State L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 5811 has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 5811. Cause: The UCM has sensed an implausible state of the loader lockout switch. The fault is active when the engine is running and both UCM inputs X-CN2B pin 26 and X-CN3B pin 19, are less than 1.5 V or greater than 3.5 V. Possible failure modes: 1. Faulty wiring or connectors. 2. Faulty Loader Lockout switch. 3. 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 the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5811 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 fuses. Repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 4. Test the UCM. Turn the ignition switch OFF. Disconnect and remove the loader lockout switch. 47711684 06/05/2014

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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 should no longer be active. Use the EST to monitor the loader lockout switch status. The switch status should change from OFF to ON. Connect the jumper between X-306 pin B and X-306 pin C. Monitor the fault code screen. Fault code 5811 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 pin A. The switch status displayed OFF when the jumper was not connected between X-306 pin B and pin C. Replace the loader lockout switch. Return to step 1 to confirm elimination of the fault. B. The switch status did not change or fault code 5811 remained active. Go to step 5. 5. Measure the resistance through the signal wires. Turn the ignition switch OFF. Use the jumper wire to short X-306 pin A to X-306 pin C. Disconnect UCM connectors X-CN2B and X-CN3B. Measure the resistance between X-CN2B pin 23 and X-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. Check connector X-ECC4A/4B. 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 X-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 X-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. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Case machines Wire harnesses - Electrical schematic sheet 15 (55.100.DP-C.20.E.15) New Holland machines Wire harnesses - Electrical schematic sheet 15 (55.100.DP-C.20.E.15) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Case machines 47711684 06/05/2014

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Wire harnesses - Electrical schematic sheet 15 (55.100.DP-C.20.E.15) New Holland machines Wire harnesses - Electrical schematic sheet 15 (55.100.DP-C.20.E.15)

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9004-Memory Error - Triple Redundant: Hour Meter - Location 1 Corrupt Context: Diagnostic Trouble Code 9004 has an error priority of White. There are no restrictions with Diagnostic Trouble Code 9004. Cause: The Instrument Cluster has sensed an internal memory corruption that has been automatically fixed. Possible failure modes: 1. Memory Fault of the Instrument Cluster. Solution: 1. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Use the EST to verify fault code 9004 Memory Error - Triple Redundant: Hour Meter - Location 1 is active. A. If the fault is active, erase it with the EST. 2. If the fault persists, it may be an indication of a potential future Instrument Cluster failure. Continue normal operations of the machine.

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9005-Memory Error - Triple Redundant: Hour Meter - Location 2 Corrupt Context: Diagnostic Trouble Code 9005 has an error priority of White. There are no restrictions with Diagnostic Trouble Code 9005. Cause: The Instrument Cluster has sensed an internal memory corruption that has been automatically fixed. Possible failure modes: 1. Memory Fault of the Instrument Cluster. Solution: 1. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Use the EST to verify fault code 9005 Memory Error - Triple Redundant: Hour Meter - Location 2 Corrupt is active. A. If the fault is active, erase it with the EST. 2. If the fault persists, it may be an indication of a potential future Instrument Cluster failure. Continue normal operations of the machine.

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9006-Memory Error - Triple Redundant: Hour Meter - Location 3 Corrupt Context: Diagnostic Trouble Code 9006 has an error priority of White. There are no restrictions with Diagnostic Trouble Code 9006. Cause: The Instrument Cluster has sensed an internal memory corruption that has been automatically fixed. Possible failure modes: 1. Memory Fault of the Instrument Cluster. Solution: 1. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Use the EST to verify fault code 9006 Memory Error - Triple Redundant: Hour Meter - Location 3 is active. A. If the fault is active, erase it with the EST. 2. If the fault persists, it may be an indication of a potential future Instrument Cluster failure. Continue normal operations of the machine.

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Electrical systems - FAULT CODES

9151-CAN Connection: CAN Communication Timed Out After 5 Seconds 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 9151, 9152, 9153 or 9154 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-Timeout of CAN message EEC1, 5 seconds without message (55.408)

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9152-CAN Connection - CAN Communication Timed Out After 5 Seconds 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 9151, 9152, 9153 or 9154 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-Timeout of CAN message EEC1, 5 seconds without message (55.408)

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Electrical systems - FAULT CODES

9153-CAN Connection - EEC1 Message Timed Out 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 9151, 9152, 9153 or 9154 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-Timeout of CAN message EEC1, 5 seconds without message (55.408)

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Electrical systems - FAULT CODES

9154-CAN Connection - TSC1 Message Timed Out 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 9151, 9152, 9153 or 9154 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-Timeout of CAN message EEC1, 5 seconds without message (55.408)

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Electrical systems - FAULT CODES

9156-Hyd Enable Switch - Hyd Enable Button Error from AIC L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 9156 has an error priority of amber. Loader limp home and ground drive limp home operating modes are enabled while Diagnostic Trouble Code 9156 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. Shorted wire in circuit. 2. Open wire in circuit. 3. Failure of the instrument cluster. 4. 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 is recorded again. Go to 1350-Hyd Enable Switch - Implausible State (Hardwire vs CAN) (55.640).

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Electrical systems - FAULT CODES

9158-H-Pattern Indicator Short to Ground L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 9158 has an error priority of White. ISO pattern will remain active while Diagnostic Trouble Code 9158 is active. Cause: The UCM has sensed that the H-Pattern indicator voltage signal has failed low. The fault is active while the H-Pattern indicator voltage, X-CN2A pin 23 is less than 5 V. Possible failure modes: 1. Signal wire short circuit to chassis ground. 2. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 9158 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. (2) 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 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. A. All voltage measurements are approximately 12 V. Go to step 4.

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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 X-CN2A and X-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. 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. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08)

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9159-ISO-Pattern Indicator Short to Ground L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 9159 has an error priority of White. H pattern will remain active while Diagnostic Trouble Code 9159 is active. Cause: The UCM has sensed that the ISO-Pattern indicator voltage signal has failed. The fault is active while the ISO-Pattern indicator voltage, X-CN2B pin 2 is less than 5 V. Possible failure modes: 1. The signal wire is shorted to chassis ground. 2. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 9159 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 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. A. All voltage measurements are approximately 12 V. Go to step 4.

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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 X-CN2A and X-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. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08) Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08)

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Electrical systems - FAULT CODES

9160-H-Pattern Indicator Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 9160 has an error priority of White. ISO pattern will remain active while Diagnostic Trouble Code 9160 is active. Cause: The UCM has sensed that the H-Pattern indicator voltage signal has failed. The fault is active while the H-Pattern indicator voltage, X-CN2A pin 23 is greater than 8 V. Possible failure modes: 1. The signal wire is shorted to another voltage source. 2. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 9160 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 switch from the right side column. Disconnect connector X-95. Disconnect UCM connector X-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. 4. Measure the resistance of the signal wire to other circuits. Turn the ignition switch OFF. 47711684 06/05/2014

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Disconnect UCM connector X-CN2A and X-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. Go to step 6. B. One or more resistance measurements are incorrect. Temporarily replace the switch and retest. Return to step 1 to confirm elimination of fault. 6. Test the switch LED. Set the digital voltmeter to measure diode voltage. Place the red probe on pin 7 and place the black probe on pin 8. The forward bias voltage should be approximately 0.7 V. A. The voltage is between 0.5 V and 0.8 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is less 0.5 V. The diode has an internal short circuit. Temporarily replace the switch and retest. Return to step 1 to confirm elimination of fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08) 47711684 06/05/2014

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Medium EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08)

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Electrical systems - FAULT CODES

9161-ISO-Pattern Indicator Short to Power L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

Context: Diagnostic Trouble Code 9161 has an error priority of White. H pattern will remain active while Diagnostic Trouble Code 9161 is active. Cause: The UCM has sensed that the ISO-Pattern indicator voltage signal has failed. The fault is active while the ISO-Pattern indicator voltage, X-CN2B pin 2 is greater than 8 V. Possible failure modes: 1. The signal wire is shorted to another voltage source. 2. 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 code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 9161 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 switch from the right side column. Disconnect connector X-95. Disconnect UCM connector X-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. 4. Measure the resistance of the signal wire to other circuits. Turn the ignition switch OFF. 47711684 06/05/2014

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Disconnect UCM connector X-CN2A and X-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. Go to step 6. B. One or more resistance measurements are incorrect. Temporarily replace the switch and retest. Return to step 1 to confirm elimination of fault. 6. Test the switch LED. Set the digital voltmeter to measure diode voltage. Place the red probe on pin 10 and place the black probe on pin 9. The forward bias voltage should be approximately 0.7 V. A. The voltage is between 0.5 V and 0.8 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is less 0.5 V. The diode has an internal short circuit. Temporarily replace the switch and retest. Return to step 1 to confirm elimination of fault. Small EH machines Wire harnesses - Electrical schematic sheet 19 (55.100.DP-C.20.E.19) Wire harnesses - Electrical schematic sheet 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic sheet 08 (55.100.DP-C.20.E.08) 47711684 06/05/2014

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9401-Memory Error - Double Redundant: Memory Corruption Detected and Repaired Context: Diagnostic Trouble Code 9401 has an error priority of White. There are no restrictions with Diagnostic Trouble Code 9401. Cause: The Instrument Cluster has sensed an internal memory corruption that has been automatically fixed. Possible failure modes: 1. Memory Fault in the Instrument Cluster. Solution: 1. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Use the EST to verify fault code 9401 Memory Error - Double Redundant: Memory Corruption Detected and Repaired is active. A. If the fault is active, erase it with the EST. 2. If the fault persists, it may be an indication of a potential future Instrument Cluster failure. Continue normal operations of the machine.

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9403-Memory Error - Double Redundant: Unrecoverable Memory Corruption Operable Context: On EH controled machines, error code 9403 and/or 1207 displays after updating the earlier instrument cluster software to version 1.3.0.0 Diagnostic Trouble Code 9403 has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 9403. 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 and/or 1207 is no longer displayed. A. Error code 9403 and/or 1207 is no longer displayed. OK to return the machine to service. B. Error code 9403 and/or 1207 are active, For non-EHF machines continue with step 2 C. Error code 9403 and/or 1207 are active, For EHF machines continue with step 3 2. Configure the machine to a model that offers EHF as an option and reconfigure to the original model. Example: The SR150 or L215 are models that do not offer the EHF option and is displaying fault code 9403 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. 47711684 06/05/2014

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(3) Wait 5 seconds and then Power Cycle the machine by exiting the seat. (4) Verify error code 9403 and/or 1207 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 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 and/or 1207 is no longer displayed. (5) When fault code 9403 and/or 1207 are no longer displayed, follow steps 1 - 4 again to reconfigure the machine back to the correct model.

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9404-Memory Error - Triple Redundant: Hour Meter - Hour Meter Failure Context: Diagnostic Trouble Code 9404 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. There are no restrictions with Diagnostic Trouble Code 9404. Cause: The Instrument Cluster has sensed an internal failure. Possible failure modes: 1. Failure of the Instrument Cluster. Solution: 1. Use the machine to recreate conditions for error. Use the EST to verify fault code 9404 Memory Error - Triple Redundant: Hour Meter - Hour Meter Failure is active. A. If the fault is active, continue with step 2. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 3. 2. Use the EST to reset the Instrument Cluster memory and clear the fault. A. If the fault clears, Continue normal operation. B. If the fault does not clear, the Instrument Cluster has failed. Replace the Instrument Cluster. 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 Display. Investigate nearby wiring. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

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9405-CAN - DM1 (EH Machines): Loss Of DM1 Message From UCM L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls 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-Timeout of CAN message EEC1, 5 seconds without message (55.408)

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9406-CAN - Can Communication Lost (EH Machines): Loss Of All CAN Communication From UCM L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

WE Electro hydraulic controls WE Electro hydraulic controls

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9407-Memory Error - ID Errors: Unrecoverable Hardware ID Context: Diagnostic Trouble Code 9407 has an error priority of Red. The vehicle is immediately disabled with Diagnostic Trouble Code 9407. Cause: The Instrument Cluster has sensed an internal failure. Possible failure modes: 1. 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 - ID Errors: Unrecoverable Hardware ID is active. A. If the fault is active, the Instrument Cluster has failed. Replace the Instrument Cluster. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 2. 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.

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9408-Memory Error - ID Errors: Unrecoverable Panel ID Context: Diagnostic Trouble Code 9408 has an error priority of Red. The vehicle is immediately disabled with Diagnostic Trouble Code 9408. Cause: The Instrument Cluster has sensed an internal failure. Possible failure modes: 1. Failure of the Instrument Cluster. Solution: 1. Use the machine to recreate conditions for error. Use the EST to verify fault code Memory Error - ID Errors: Unrecoverable Panel ID is active. A. If the fault is active, the Instrument Cluster has failed. Replace the Instrument Cluster. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 2. 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.

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9410-Loss of EGR inducement status message from EDC Context: CAN bus communications between modules on the data link have been lost. This fault code may be displayed with other CAN bus fault code messages. Cause: CAN bus communications between modules on the data link have been lost. Possible failure modes: 1. CAN data link wiring or circuits open. 2. CAN data link wiring or circuits shorted. 3. Faulty CAN Data Link device. 4. Faulty instrument cluster. 5. Faulty ECU. Solution: 1. Verify that the fault code is active. Use the Electronic Service Tool to verify that the CAN data link faults are ACTIVE. To check for fault codes: Start and operate the machine. Wiggle the harness to reveal an intermittent condition. If three or more fault codes are active, such as 1051 through 1059 or 3096, 3334, 3339 or 3358, this is an indication of a problem in the CAN bus circuit, continue with this procedure. If one or two CAN bus fault codes are active, this is an indication of an intermittent connection in the CAN circuit. Check the wiring and connectors to verify they are secure and free of damage, corrosion, abrasion or incorrect attachment. A. CAN bus fault codes are not recorded again and are no longer ACTIVE. OK to return the machine to service. B. CAN bus fault codes are present and ACTIVE. Refer to 1051-Timeout of CAN message EEC1, 5 seconds without message (55.408)

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1010-Battery 5V reference 1 circuit low Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0642. The Engine Control Unit (ECU) uses two power supply circuits to supply 5.0 V to the engine electrical components. The 5.0 V sensor power supply 1 circuit supplies the following sensors; Differential pressure sensor and the Rail pressure sensor. Cause: The ECU is sensing the power supply 1 circuit is less than 4.37 V. Possible failure modes: 1. The differential pressure sensor has failed. 2. The rail pressure sensor has failed. 3. The circuit wiring harness has failed. 4. The ECU has failed internally. Solution: 1. Use the Service Tool D to verify that the fault is present and active. A. If the fault code is present and active, continue with Step 2. B. If the fault code is no longer present or active, the fault may be intermittent and not currently active. 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. Inspect the wiring harness from the ECU to the rail 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. Use the Service Tool D to monitor the voltage range. Place the key switch ON. Disconnect the wiring harness from the rail pressure sensor. Monitor for voltage fluctuation in the circuit. A. If the voltage is less than 4.37 V, continue with Step 4. B. If the voltage reading changes to 4.5 - 5.5 V, the sensor has failed. Replace the sensor. 4. Use the Service Tool D to monitor the voltage range. Place the key switch ON. Disconnect the wiring harness from the differential pressure sensor. Monitor for voltage fluctuation in the circuit. A. If the voltage is less than 4.37 V, continue with Step 5.

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B. If the voltage reading changes to 4.5 - 5.5 V, the sensor has failed. Replace the sensor. 5. Check the wiring harness. Place the key switch OFF. Disconnect the wiring harness from the ECU. Use a multimeter to perform the following checks. From Connector X-031 pin 1 Connector X-026 pin 4

To Chassis ground Chassis ground

Value There should be no continuity. There should be no continuity.

A. If the wiring harness test is good, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to 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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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1011-Battery 5V reference 1 circuit high Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0643. The Engine Control Unit (ECU) uses two power supply circuits to supply 5.0 V to the engine electrical components. The 5.0 V sensor power supply 1 circuit supplies the following sensors; Differential pressure sensor and the Rail pressure sensor. Cause: The ECU is sensing the power supply 1 circuit is greater than 5.6 V. Possible failure modes: 1. The differential pressure sensor has failed. 2. The rail pressure sensor has failed. 3. The circuit wiring harness has failed. 4. The ECU has failed internally. Solution: 1. Use the Service Tool D to verify that the fault is present and active. A. If the fault code is present and active, continue with Step 2. B. If the fault code is no longer present or active, the fault may be intermittent and not currently active. 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. Inspect the wiring harness from the ECU to the rail 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. Use the Service Tool D to monitor the voltage range. Place the key switch ON. Disconnect the wiring harness from the rail pressure sensor. Monitor for voltage fluctuation in the circuit. A. If the voltage is greater than 5.6 V, continue with Step 4. B. If the voltage reading changes to 4.5 - 5.5 V, the sensor has failed. Replace the sensor. 4. Use the Service Tool D to monitor the voltage range. Place the key switch ON. Disconnect the wiring harness from the differential pressure sensor. Monitor for voltage fluctuation in the circuit. A. If the voltage is greater than 5.6 V, continue with Step 5.

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B. If the voltage reading changes to 4.5 - 5.5 V, the sensor has failed. Replace the sensor. 5. Check the wiring harness for a short to high source. Place the key switch OFF. Disconnect the harness from the ECU. Place the key switch ON. Use a multimeter to perform the following checks. From Connector X-002A pin 45 Connector X-002B pin 22

To Chassis ground Chassis ground

Value There should be no voltage. There should be no voltage.

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1012-Battery 5V reference 2 circuit low Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0652. The Engine Control Unit (ECU) uses two power supply circuits to supply 5.0 V to the engine electrical components. The 5.0 V sensor power supply 2 circuit supplies the following sensors; Intake throttle position sensor, Exhaust Gas Recirculation (EGR) position sensor, Boost pressure sensor, and the Camshaft speed sensor. Cause: The ECU is sensing the power supply 2 circuit is less than 4.37 V. Possible failure modes: 1. The intake throttle position sensor has failed. 2. The EGR position sensor has failed. 3. The boost pressure sensor has failed. 4. The camshaft speed sensor has failed. 5. The circuit wiring harness has failed. 6. The ECU has failed internally. Solution: 1. Use the Service Tool D to verify that the fault is present and active. A. If the fault code is present and active, continue with Step 2. B. If the fault code is no longer present or active, the fault may be intermittent and not currently active. Continue with Step 8. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the intake throttle position sensor connector. Inspect the wiring harness from the ECU to the EGR position sensor connector. Inspect the wiring harness from the ECU to the boost pressure sensor connector. Inspect the wiring harness from the ECU to the camshaft speed 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. Use the Service Tool D to monitor the voltage range. Place the key switch ON. Disconnect the wiring harness from the intake throttle position sensor. Monitor for voltage fluctuation in the circuit. A. If the voltage is less than 4.37 V, continue with Step 4. B. If the voltage reading changes to 4.5 - 5.5 V, the sensor has failed. Replace the sensor. 4. Use the Service Tool D to monitor the voltage range.

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Place the key switch ON. Disconnect the wiring harness from the EGR position sensor. Monitor for voltage fluctuation in the circuit. A. If the voltage is less than 4.37 V, continue with Step 5. B. If the voltage reading changes to 4.5 - 5.5 V, the sensor has failed. Replace the sensor. 5. Use the Service Tool D to monitor the voltage range. Place the key switch ON. Disconnect the wiring harness from the boost pressure sensor. Monitor for voltage fluctuation in the circuit. A. If the voltage is less than 4.37 V, continue with Step 6. B. If the voltage reading changes to 4.5 - 5.5 V, the sensor has failed. Replace the sensor. 6. Use the Service Tool D to monitor the voltage range. Place the key switch ON. Disconnect the wiring harness from the camshaft speed sensor. Monitor for voltage fluctuation in the circuit. A. If the voltage is less than 4.37 V, continue with Step 7. B. If the voltage reading changes to 4.5 - 5.5 V, the sensor has failed. Replace the sensor. 7. Check the wiring harness. Place the key switch OFF. Disconnect the wiring harness from the ECU. Use a multimeter to perform the following checks. From Connector X-002A pin 22 Connector X-002A pin 23 Connector X-002A pin 24 Connector X-002B pin 9

To Chassis Chassis Chassis Chassis

ground ground ground ground

Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If the wiring harness test is good, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. B. If the wiring harness test fails, locate and repair the broken conductor. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) 47711684 06/05/2014

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EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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1013-Battery 5V reference 2 circuit high Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0653. The Engine Control Unit (ECU) uses two power supply circuits to supply 5.0 V to the engine electrical components. The 5.0 V sensor power supply 2 circuit supplies the following sensors; Intake throttle position sensor, Exhaust Gas Recirculation (EGR) position sensor, Boost pressure sensor, and the Camshaft speed sensor. Cause: The ECU is sensing the power supply 2 circuit is greater than 5.6 V. Possible failure modes: 1. The intake throttle position sensor has failed. 2. The EGR position sensor has failed. 3. The boost pressure sensor has failed. 4. The camshaft speed sensor has failed. 5. The circuit wiring harness has failed. 6. The ECU has failed internally. Solution: 1. Use the Service Tool D to verify that the fault is present and active. A. If the fault code is present and active, continue with Step 2. B. If the fault code is no longer present or active, the fault may be intermittent and not currently active. Continue with Step 8. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the intake throttle position sensor connector. Inspect the wiring harness from the ECU to the EGR position sensor connector. Inspect the wiring harness from the ECU to the boost pressure sensor connector. Inspect the wiring harness from the ECU to the camshaft speed 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. Use the Service Tool D to monitor the voltage range. The normal operating range for the power supply circuit is 4.5 - 5.5 V. Place the key switch ON. Disconnect the wiring harness from the intake throttle position sensor. Monitor for voltage fluctuation in the circuit. A. If the voltage is greater than 5.6 V, continue with Step 4. B. If the voltage reading changes to 4.5 - 5.5 V, the sensor has failed. Replace the sensor. 47711684 06/05/2014

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4. Use the Service Tool D to monitor the voltage range. The normal operating range for the power supply circuit is 4.5 - 5.5 V. Place the key switch ON. Disconnect the wiring harness from the EGR position sensor. Monitor for voltage fluctuation in the circuit. A. If the voltage is greater than 5.6 V, continue with Step 5. B. If the voltage reading changes to 4.5 - 5.5 V, the sensor has failed. Replace the sensor. 5. Use the Service Tool D to monitor the voltage range. The normal operating range for the power supply circuit is 4.5 - 5.5 V. Place the key switch ON. Disconnect the wiring harness from the boost pressure sensor. Monitor for voltage fluctuation in the circuit. A. If the voltage is greater than 5.6 V, continue with Step 6. B. If the voltage reading changes to 4.5 - 5.5 V, the sensor has failed. Replace the sensor. 6. Use the Service Tool D to monitor the voltage range. The normal operating range for the power supply circuit is 4.5 - 5.5 V. Place the key switch ON. Disconnect the wiring harness from the camshaft speed sensor. Monitor for voltage fluctuation in the circuit. A. If the voltage is greater than 5.6 V, continue with Step 7. B. If the voltage reading changes to 4.5 - 5.5 V, the sensor has failed. Replace the sensor. 7. Check the wiring harness. Place the key switch OFF. Disconnect the wiring harness from the ECU. Place the key switch ON. Use a multimeter to perform the following checks. From Connector X-002A pin 22 Connector X-002A pin 23 Connector X-002A pin 24 Connector X-002B pin 9

To Chassis Chassis Chassis Chassis

ground ground ground ground

Value There should be no voltage. There should be no voltage. There should be no voltage. There should be no voltage.

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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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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1014-Vehicle system voltage too high Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0563. The Engine Control Unit (ECU) constantly receives battery voltage at ECU connector X-002B pin 46. When the key switch is in the ON position, the main relay is activated, allowing voltage to be supplied to the ECU connector X-002B at pin 5 and pin 6. Cause: The ECU is sensing greater than 16.64 V. Possible failure modes: 1. The charging system is faulty. 2. The wiring harness is faulty. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to verify the status of "VB" with the data monitor. Engine status

Voltage output There should be approximately 8.0 V. There should be less than 16 V.

Cranking Engine start up

A. If there is greater than 16.64 V, continue with Step 2. B. If the voltage is in range, the fault may be intermittent and not currently active. Continue with Step 4. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the battery connection. Inspect the wiring harness from the battery to the alternator connection. 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 battery voltage to the ECU. Place the key switch OFF. Disconnect the engine harness from the ECU. Place the key switch ON. Use a multimeter to check for voltage from ECU harness connector X-002B pin 5 to pin 1. Use a multimeter to check for voltage from ECU harness connector X-002B pin 6 to pin 2. There should be 8 - 18 V. A. If the voltage is correct, check the alternator. See Alternator - Preliminary test — Alternator Output (55.301). B. If the voltage is greater than 16.64 V, the battery has failed internally. Replace the battery. 47711684 06/05/2014

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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. Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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1015-Vehicle system voltage too low Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0562. The Engine Control Unit (ECU) constantly receives battery voltage at ECU connector X-002B pin 46. When the key switch is in the ON position, the main relay is activated, allowing voltage to be supplied to the ECU connector X-002B at pin 5 and pin 6. Cause: The ECU is sensing less than 7.99 V. Possible failure modes: 1. The charging system is faulty. 2. The wiring harness is faulty. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the status of "VB" with the data monitor. Engine status

Voltage output There should be approximately 8.0 V. There should be less than 16 V.

Cranking Engine start up A. If there is less than 7.99 V, continue with Step 2.

B. If the voltage is in range, the fault may be intermittent and not currently active. 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 battery connection. Inspect the wiring harness from the battery to the alternator connection. 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 battery voltage to the ECU. Place the key switch OFF. Disconnect the engine harness from the ECU. Place the key switch ON. Use a multimeter to check for voltage from ECU harness connector X-002B pin 5 to pin 1. Use a multimeter to check for voltage from ECU harness connector X-002B pin 6 to pin 2. There should be 8 - 18 V. A. If the voltage is correct, check the alternator. See Alternator - Preliminary test — Alternator Output (55.301). B. If the voltage is less than 7.99 V, continue with Step 4. 47711684 06/05/2014

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4. Check the wiring harness. Place the key switch ON. Use a multimeter to check for voltage from ECU harness connector X-002B pin 5 to chassis ground. Use a multimeter to check for voltage from ECU harness connector X-002B pin 6 to chassis ground. There should be 8 - 18 V. A. If the voltage is correct, there is a problem between chassis ground and connector X-002B pin 1 and/or pin 2. Locate and repair the broken conductor. B. If the voltage is less than 7.99 V, continue with Step 5. 5. Check the battery voltage. Use a multimeter to check the battery voltage between the positive terminal to the negative terminal. There should be 8 - 18 V. A. If the voltage is correct, there is a problem in the wiring harness. Locate and repair the damaged conductor. B. If the voltage is less than 7.99 V, charge the battery. If the battery does not hold a charge, replace the battery. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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1041-Engine overrun Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0219. The engine speed is set to a calibrated limit inside the ECU. The purpose of this fault code is to record when the engine is operated at high-speed rotation due to user operation (mis-shift). Cause: The engine speed has exceeded the calibrated limit. Possible failure modes: 1. Operator error. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check for check for noise by conducting the data monitor "Engine Speed Active Flag" and "Cam Speed Active Flag".

NHIL13ENG0085AA

NHIL13ENG0086AA

A. If the fault is active, ask the customer under what condition this fault code was set. If it was due to operator error, clear the fault code. B. If the fault code is not active, return the machine to service. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units 47711684 06/05/2014

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Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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1816-Capacitor charge-up circuit malfunction (Insufficient charge) Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0611. The Engine Control Unit (ECU) has four injector driver circuits. Each of these circuits regulates an injector. Cause: The injector charge circuit has failed. Possible failure modes: 1. The software is faulty. 2. The ECU has failed internally. Solution: 1. Use the Service Tool D to verify the fault is active and present. Measure the “Injection Actuation Waveform” for each cylinder. Run the engine. The measured waveform for each injector will look like this at idle.

NHIL13ENG0084AA

A. If the graph is incorrect, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU is working properly. B. If the graph is correct, continue with Step 2. 2. Place the key switch OFF, and then back ON. Clear the fault code. Place the key switch OFF, and then back ON. Start the engine. A. If the fault code is still active, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU is working properly. B. If the fault code is not active, the fault may be intermittent and not currently active. Continue with Step 3. 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.

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1817-Capacitor charge-up circuit malfunction (Excessive charge) Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0611. The Engine Control Unit (ECU) has four injector driver circuits. Each of these circuits regulates an injector. Cause: The injector charge circuit has failed. Possible failure modes: 1. The software is faulty. 2. The ECU has failed internally. Solution: 1. Use the Service Tool D to verify the fault is active and present. Measure the “Injection Actuation Waveform” for each cylinder. Run the engine. The measured waveform for each injector will look like this at idle.

NHIL13ENG0084AA

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1818-Engine Control Unit (ECU) watchdog fault Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0607. The Engine Control Unit (ECU) is an electronic device that monitors its ability to read and write memory. This allows the ECU to control, and monitor multiple sensors, actuators, and other parameters within the engine compartment. Cause: The ECU has detected the Central Processing Unit (CPU) can not communicate with the Instrument Control Unit (ICU). Possible failure modes: 1. The software could be faulty. 2. The ECU has failed internally. Solution: 1. Use the Service Tool D to verify the fault is active. Place the key switch OFF, and then back ON. Clear the fault code. Place the key switch OFF, and then back ON. Start the engine. A. If the fault code is still active, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU is working properly. B. If the fault code 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 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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3007-Coolant temperature sensor - Signal above range maximum Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0217 and/or P0118. The Engine Control Unit (ECU) provides a sensor reference voltage of 5.0 V from the ECU connector X-002A pin 39 and a ground reference from the ECU connector X-002A pin 7. The sensor resistance and signal level will vary with the coolant (water) temperature at the ECU connector X-002A pin 39. The higher the coolant (water) temperature is, the lower the resistance and signal level will be. The lower the coolant temperature is, the higher the resistance and signal level will be. Cause: The ECU is sensing a signal level greater than 4.7 V in the coolant temperature sensor circuit. Possible failure modes: 1. The coolant temperature sensor has failed internally. 2. The coolant temperature sensor wiring has failed. 3. There is a fault in the cooling system. 4. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the "Coolant Temperature" and "Coolant Water Temp. Sensor Output Voltage". Voltage output

Coolant temperature 20 °C 40 °C 60 °C 80 °C

2.2 1.3 0.7 0.4

(68.0 °F) (104.0 °F) (140.0 °F) (176.0 °F)

2.5 V 1.7 V 1.0 V 0.7 V

A. If there is greater than 4.7 V, continue with Step 2. B. If the voltage is in range, the fault may be intermittent and not currently active. Continue with Step 8. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the coolant temperature 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 sensor. Place the key switch OFF. Disconnect the wiring harness from the sensor. Measure the resistance from the coolant temperature sensor connector from pin 1 to pin 2. Resistance value

Coolant temperature 20 °C 40 °C 60 °C 80 °C

(68.0 °F) (104.0 °F) (140.0 °F) (176.0 °F)

2.0 0.9 0.4 0.2

3.0 Ω 1.5 Ω 0.8 Ω 0.4 Ω

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X-021 pin 1

X-021 pin 2

Value There should be approximately 4.5 - 5.5 V.

A. If the voltage reading is out of the range, continue with Step 5. B. If the voltage reading is in range, continue with Step 7. 5. Check the wiring harness for a short to high source. Place the key switch OFF. Carefully disconnect the wiring harness from the ECU. Place the key switch ON. Use a multimeter to check for voltage in the wiring harness. From Connector X-021 pin 1 Connector X-021 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 high source in the wiring harness. Locate and repair the broken conductor. B. If there is no voltage, continue with Step 6. 6. Check the wiring harness for an open circuit condition. Place the key switch OFF. Use a multimeter to perform the following checks on the wiring harness. From Connector X-021 pin 1 Connector X-021 pin 2

To Connector X-002A pin 39 Connector X-002A pin 7

Value There should be continuity. There should be continuity.

Action Replenish the cooling water. Check and repair water leaking points. Check and clean the belt. • If installing a new belt, tighten to: 400 - 490 N (89.9 - 110 lb).

Radiator

• If the belt is OK to reuse, tighten to: 265 - 355 N (59.6 - 79.8 lb). If the radiator or the fins are clogged, clean the radiator. 47711684 06/05/2014

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Check Hoses Thermostat

Action If the hoses are clogged, clean as needed. If there is damage, replace the hoses. Use a thermal gun to monitor the temperature. • The valve should OPEN between 80 - 84 °C (176.0 183 °F). • The valve should FULLY OPEN at 95 °C (203.0 °F). If the check engine light comes on and the temperature approaches the caution or maximum reading on your gauge, replace the thermostat.

A. If there is damage to the cooling system, repair as needed. B. If there is no damage, the fault may be electrical. Check for any fault codes present. If there are no other fault codes present, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU is working properly. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05)

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3008-Coolant temperature sensor - Signal below range minimum Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0117. The Engine Control Unit (ECU) provides a sensor reference voltage of 5.0 V from the ECU connector X-002A pin 39 and a ground reference from the ECU connector X-002A pin 7. The sensor resistance and signal level will vary with the coolant (water) temperature at the ECU connector X-002A pin 39. The higher the coolant (water) temperature is, the lower the resistance and signal level will be. The lower the coolant temperature is, the higher the resistance and signal level will be. Cause: The ECU is sensing a signal level less than 0.08 V in the coolant temperature sensor circuit. Possible failure modes: 1. The coolant temperature sensor has failed internally. 2. The coolant temperature sensor wiring is shorted to a low source. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the "Coolant Temperature" and "Coolant Water Temp. Sensor Output Voltage". See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000). Voltage output

Coolant temperature 20 °C 40 °C 60 °C 80 °C

2.2 1.3 0.7 0.4

(68.0 °F) (104.0 °F) (140.0 °F) (176.0 °F)

2.5 V 1.7 V 1.0 V 0.7 V

A. If there is less than 0.08 V, continue with Step 2. B. If the voltage is in range, the fault may be intermittent and not currently active. 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 coolant temperature 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 harness or connectors as required. 3. Check the sensor. Place the key switch OFF. Disconnect the wiring harness from the sensor. Measure the resistance from the coolant temperature sensor connector from pin 1 to pin 2. Resistance value

Coolant temperature 20 °C 40 °C 60 °C 80 °C

(68.0 °F) (104.0 °F) (140.0 °F) (176.0 °F)

2.0 0.9 0.4 0.2

3.0 Ω 1.5 Ω 0.8 Ω 0.4 Ω

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To X-021 pin 2

Value There should be approximately 4.5 - 5.5 V.

A. If the voltage reading is out of the range, continue with Step 5. B. If the voltage reading is in range, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. 5. Check the wiring harness for a short to low source. Place the key switch OFF. Carefully disconnect the wiring harness from the ECU. Use a multimeter to perform the following checks on the wiring harness. From Connector X-021 pin 1 Connector X-021 pin 2 Connector X-021 pin 2

To Chassis ground Chassis ground Connector X-021 pin 1

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 to low source in the wiring harness. Locate and repair the broken conductor. B. If there is no continuity, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05)

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3010-Intake manifold boost temperature sensor circuit - Signal above range maximum Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0113. The Engine Control Unit (ECU) provides a sensor reference voltage of 5.0 V from the ECU connector X-002B pin 28 and a ground reference from the ECU connector X-002A pin 16. The sensor resistance and signal level will vary with the ambient air temperature at the ECU connector X-002B pin 28. The higher the ambient air temperature is, the lower the resistance and signal level will be. The lower the ambient air temperature is, the higher the resistance and signal level will be. Cause: The ECU is sensing a signal level greater than 4.9 V in the intake air temperature sensor circuit. Possible failure modes: 1. The intake (inlet) air temperature sensor has failed internally. 2. The intake (inlet) air temperature sensor wiring is shorted to a high source. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the "Manifold Intake Air Temperature (EGR Temperature) Sensor Voltage Output". See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000). There should be less than 4.9 V. A. If there is greater than 4.9 V, continue with Step 2. B. If there is less than 4.9 V, the fault may be intermittent and not currently active. 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 intake air temperature 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 harness or connectors as required. 3. Check the sensor. Disconnect the wiring harness from the intake air temperature sensor. Use a multimeter to measure the resistance of the sensor. From Pin 1

To Pin 2

Value There should be between 6K - 37K Ω at 0 - 60 °C (32.0 - 140 °F).

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Place the key switch ON. Use a multimeter to perform the following check on the wiring harness. From Connector X-020 pin 1

To Connector X-020 pin 2

Value There should be approximately 4.5 - 5.5 V.

A. If the voltage reading is out of the range, continue with Step 5. B. If the voltage reading is in range, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. 5. Check the wiring harness for a short to high condition. Place the key switch OFF. Carefully disconnect the wiring harness from the ECU. Place the key switch ON. Use a multimeter to check for voltage in the wiring harness. From Connector X-020 pin 1 Connector X-020 pin 2

To Chassis ground Chassis ground

Value There should be no voltage. There should be no voltage.

A. If there is no voltage, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. B. If there is voltage, there is a short to high condition in the wiring harness. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05)

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3011-Intake manifold boost temperature sensor circuit - Signal below range minimum Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0112. The Engine Control Unit (ECU) provides a sensor reference voltage of 5.0 V from the ECU connector X-002B pin 28 and a ground reference from the ECU connector X-002A pin 16. The sensor resistance and signal level will vary with the ambient air temperature at the ECU connector X-002B pin 28. The higher the ambient air temperature is, the lower the resistance and signal level will be. The lower the ambient air temperature is, the higher the resistance and signal level will be. Cause: The ECU is sensing a signal level less than 0.25 V in the intake air temperature sensor circuit. Possible failure modes: 1. The intake (inlet) air temperature sensor has failed internally. 2. The intake (inlet) air temperature sensor circuit wiring is open or shorted to ground. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the "Manifold Intake Air Temperature (EGR Temperature) Sensor Voltage Output". See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000). There should be greater than 0.25 V. A. If there is less than 0.25 V, continue with Step 2. B. If there is greater than 0.25 V, the fault may be intermittent and not currently active. Continue with Step 7. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the intake air temperature 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 sensor. Disconnect the wiring harness from the intake air temperature sensor. Use a multimeter to measure the resistance of the sensor. From Pin 1

To Pin 2

Value There should be between 6K - 37K Ω at 0 - 60 °C (32.0 - 140 °F).

A. If the measured resistance is in the specified range, leave the sensor connector disconnected and continue with Step 4. B. If the measured resistance is not in the specified range, the intake air temperature sensor has failed internally. Replace the sensor. 4. Check the signal and ground reference circuit. 47711684 06/05/2014

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Place the key switch ON. Use a multimeter to perform the following check on the wiring harness. From Connector X-020 pin 1

To Connector X-020 pin 2

Value There should be approximately 4.5 - 5.5 V.

A. If the voltage reading is out of the range, continue with Step 5. B. If the voltage reading is in range, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. 5. Check the wiring harness for a short to low condition. Place the key switch OFF. Carefully disconnect the wiring harness from the ECU. Use a multimeter to perform the following checks on the wiring harness. From Connector X-020 pin 1 Connector X-020 pin 2 Connector X-020 pin 2

To Chassis ground Chassis ground Connector X-020 pin 1

Value There should be no continuity. There should be no continuity. There should be no continuity.

A. If there is no continuity, continue with Step 6. B. If there is continuity, there is a short to low condition in the wiring harness. Locate and repair the broken conductor. 6. Check the wiring harness for an open circuit condition. Place the key switch OFF. Use a multimeter to perform the following checks on the wiring harness. From Connector X-020 pin 1 Connector X-020 pin 2

To Connector X-002B pin 28 Connector X-002A pin 16

Value There should be continuity. There should be continuity.

A. If there is continuity, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. B. If there is no continuity, there is an open circuit in the wiring harness Locate and repair the broken conductor. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05)

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3015-Fuel temperature sensor - Signal above range maximum Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0183. The Engine Control Unit (ECU) provides a sensor reference voltage of 5.0 V from the ECU connector X-002A pin 31 and a ground reference from the ECU connector X-002A pin 7. The sensor resistance and signal level will vary with the fuel temperature at the ECU connector X-002A pin 31. The higher the fuel temperature is, the lower the resistance and signal level will be. The lower the fuel temperature is, the higher the resistance and signal level will be. Cause: The ECU is sensing a signal level greater than 4.7 V in the fuel temperature sensor circuit. Possible failure modes: 1. The fuel temperature sensor has failed internally. 2. The fuel temperature sensor wiring is shorted to a high source. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the "Fuel temperature" and "Fuel temperature Sensor Output Voltage". See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000) Fuel temperature 20 °C 40 °C 60 °C 80 °C

Voltage output 2.2 1.3 0.7 0.4

(68.0 °F) (104.0 °F) (140.0 °F) (176.0 °F)

2.5 V 1.7 V 1.0 V 0.7 V

A. If there is greater than 4.7 V, continue with Step 2. B. If the voltage is in range, the fault may be intermittent and not currently active. 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 fuel temperature 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 sensor. Place the key switch OFF. Disconnect the wiring harness from the sensor. Measure the resistance from the fuel temperature sensor connector from pin 1 to pin 2. Fuel temperature 20 °C 40 °C 60 °C 80 °C

(68.0 °F) (104.0 °F) (140.0 °F) (176.0 °F)

Resistance value 2.0 0.9 0.4 0.2

3.0 Ω 1.5 Ω 0.8 Ω 0.4 Ω

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To Connector X-032 pin 2

Value There should be approximately 4.5 - 5.5 V.

A. If the voltage reading is out of the range, continue with Step 5. B. If the voltage reading is in range, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. 5. Check the wiring harness for a short to high source. Place the key switch OFF. Disconnect the wiring harness from the ECU. Place the key switch ON. Use a multimeter to perform the following checks on the wiring harness. From Connector X-032 pin 1 Connector X-032 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 high source in the wiring harness. Locate and repair the broken conductor. B. If there is no voltage, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05)

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3016-Fuel temperature sensor - Signal below range minimum Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0182. The Engine Control Unit (ECU) provides a sensor reference voltage of 5.0 V from the ECU connector X-002A pin 31 and a ground reference from the ECU connector X-002A pin 7. The sensor resistance and signal level will vary with the fuel temperature at the ECU connector X-002A pin 31. The higher the fuel temperature is, the lower the resistance and signal level will be. The lower the fuel temperature is, the higher the resistance and signal level will be. Cause: The ECU is sensing a signal level less than 0.08 V in the fuel temperature sensor circuit. Possible failure modes: 1. The fuel temperature sensor has failed internally. 2. The fuel temperature sensor wiring is open or shorted to a low source. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the "Fuel temperature" and "Fuel temperature Sensor Output Voltage". See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000) Fuel temperature 20 °C 40 °C 60 °C 80 °C

Voltage output 2.2 1.3 0.7 0.4

(68.0 °F) (104.0 °F) (140.0 °F) (176.0 °F)

2.5 V 1.7 V 1.0 V 0.7 V

A. If there is less than 0.08 V, continue with Step 2. B. If the voltage is in range, the fault may be intermittent and not currently active. Continue with Step 7. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the fuel temperature 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 sensor. Place the key switch OFF. Disconnect the wiring harness from the sensor. Measure the resistance from the fuel temperature sensor connector from pin 1 to pin 2. Fuel temperature 20 °C 40 °C 60 °C 80 °C

(68.0 °F) (104.0 °F) (140.0 °F) (176.0 °F)

Resistance value 2.0 0.9 0.4 0.2

3.0 Ω 1.5 Ω 0.8 Ω 0.4 Ω

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To Connector X-032 pin 2

Value There should be approximately 4.5 - 5.5 V.

A. If the voltage reading is out of the range, continue with Step 5. B. If the voltage reading is in range, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. 5. Check the wiring harness for a short to low source. Place the key switch OFF. Carefully disconnect the wiring harness from the ECU. Use a multimeter to perform the following checks on the wiring harness. From Connector X-032 pin 1 Connector X-032 pin 2 Connector X-032 pin 2

To Chassis ground Chassis ground Connector X-032 pin 1

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 to low source in the wiring harness. Locate and repair the broken conductor. B. If there is no continuity, continue with Step 6. 6. Check the wiring harness for an open circuit. Place the key switch OFF. Use a multimeter to perform the following checks on the wiring harness. From Connector X-032 pin 1 Connector X-032 pin 2

To Connector X-002A pin 31 Connector X-002A pin 39

Value There should be continuity. There should be continuity.

A. If there is no continuity, there is an open circuit in the wiring harness. Locate and repair the broken conductor. B. If there is continuity, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) EH Units 47711684 06/05/2014

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Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05)

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3019-Intake manifold boost pressure sensor circuit - Signal above range maximum Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0238. The Engine Control Unit (ECU) provides a 5.0 V reference signal to the boost pressure sensor from ECU connector X-002A pin 23, and a ground reference circuit at the ECU connector X-002A pin 14. The boost pressure sensor sends a signal to the ECU connector X-002A pin 61, relative to the pressure changes. Cause: The ECU is sensing the boost pressure sensor signal is greater than 4.6 V. Possible failure modes: 1. The boost pressure sensor has failed internally. 2. The boost pressure sensor circuit wiring is shorted to high source. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the "Boost Pressure" and "Boost Pressure Sensor Output Voltage". See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000). Engine Condition Key switch ON. After engine startup, changing the accelerator position.

Pressure 1 bar (14.5 psi) 1 - 1.71 bar (14.5 - 24.8 psi)

Voltage output 1.2 - 3.1 V 1.2 - 4.2 V

A. If there is greater than 4.6 V, continue with Step 2. B. If the voltage is in range, the fault may be intermittent and not currently active. 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 boost 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 5.0 V supply and ground reference circuit. Disconnect the wiring harness from the boost pressure sensor. Place the key switch ON. Use a multimeter to check for voltage from the wiring harness sensor connector pin 2 to pin 3. 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 reading is in range, continue with Step 4. 4. Check the signal circuit. 47711684 06/05/2014

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Insert a jumper wire between the wiring harness sensor connector pin 1 and pin 2. Place the key switch ON. Monitor the diagnostic screen for fault code 3037 (P0237). A. If fault code 3037 is not present, remove the jumper wire. Continue with Step 5. B. If fault code 3037 is present, the sensor has failed. Replace the sensor. 5. Check the wiring harness for a short to high source. Place the key switch OFF. Carefully disconnect the wiring harness from the ECU. Place the key switch ON. Use a multimeter to perform the following checks. From Connector X-012 pin 1 Connector X-012 pin 2 Connector X-012 pin 3

To Chassis ground Chassis ground Chassis ground

Result There should be no voltage. There should be no voltage. There should be no voltage.

A. If the wiring harness test is good, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to 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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05)

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3024-Atmospheric pressure sensor inside Engine Control Unit (ECU) - Signal above range maximum Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P2229. The atmospheric temperature sensor is integrated within the Engine Control Unit (ECU). The sensor responds to changes in altitude and atmospheric conditions. The sensor provides the ECU an indication of barometric pressure. The sensor provides a voltage signal to the ECU relative to the atmospheric pressure changes. The ECU monitors the atmospheric pressure sensor signal for a voltage outside of the normal range. Cause: The ECU is sensing the atmospheric pressure sensor is greater than 4.4 V. Possible failure modes: 1. The atmospheric pressure sensor has failed, located internally to the ECU. Solution: 1. Use the Service Tool D to verify the fault is active. See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000). Use the Service Tool D to check "Atmospheric Pressure" and "Atmospheric Pressure Sensor Output Voltage". Actual atmospheric pressure 14.5 bar (210.2 psi)

Value 3.5 - 3.8 V

A. If the values are incorrect, try to erase the fault. If the fault is still active, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU is working properly. B. If the values are correct. 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 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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3025-Atmospheric pressure sensor inside Electronic Control Unit (ECU) - Signal below range minimum Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is PP2228. The atmospheric temperature sensor is integrated within the Engine Control Unit (ECU). The sensor responds to changes in altitude and atmospheric conditions. The sensor provides the ECU an indication of barometric pressure. The sensor provides a voltage signal to the ECU relative to the atmospheric pressure changes. The ECU monitors the atmospheric pressure sensor signal for a voltage outside of the normal range. Cause: The ECU is sensing the atmospheric pressure sensor is less than 1.6 V. Possible failure modes: 1. The atmospheric pressure sensor has failed, located internally to the ECU. Solution: 1. Use the Service Tool D to verify the fault is active. See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000). Use the Service Tool D to check "Atmospheric Pressure" and "Atmospheric Pressure Sensor Output Voltage". Actual atmospheric pressure 14.5 bar (210.2 psi)

Value 3.5 - 3.8 V

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3037-Intake manifold boost pressure sensor circuit - Signal below range minimum Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0237. The Engine Control Unit (ECU) provides a 5.0 V reference signal to the boost pressure sensor from ECU connector X-002A pin 23, and a ground reference circuit at the ECU connector X-002A pin 14. The boost pressure sensor sends a signal to the ECU connector X-002A pin 61, relative to the pressure changes. Cause: The ECU is sensing the boost pressure sensor signal is less than 0.25 V. Possible failure modes: 1. The boost pressure sensor has failed internally. 2. The boost pressure sensor circuit wiring is open or shorted to ground. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the "Boost Pressure" and "Boost Pressure Sensor Output Voltage". See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000). Engine Condition Key switch ON. After engine startup, changing the accelerator position.

Pressure 1 bar (14.5 psi) 1 - 1.71 bar (14.5 - 24.8 psi)

Voltage output 1.2 - 3.1 V 1.2 - 4.2 V

A. If there is less than 0.25 V, continue with Step 2. B. If the voltage is in range, the fault may be intermittent and not currently active. 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 boost 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 5.0 V supply and ground reference circuit. Disconnect the wiring harness from the boost pressure sensor. Place the key switch ON. Use a multimeter to check for voltage from the wiring harness sensor connector pin 2 to pin 3. 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 reading is in range, continue with Step 4. 4. Check the signal circuit. 47711684 06/05/2014

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Insert a jumper wire between the wiring harness sensor connector pin 1 and pin 3. Place the key switch ON. Monitor the diagnostic screen for fault code 3019 (P0238). A. If fault code 3019 is not present, remove the jumper wire. Continue with Step 5. B. If fault code 3019 is present, the sensor has failed. Replace the sensor. 5. Check the wiring harness for an open or short to low source. Place the key switch OFF. Carefully disconnect the wiring harness from the ECU. Use a multimeter to perform the following checks. Connector Connector Connector Connector Connector Connector

From X-012 pin 1 X-012 pin 2 X-012 pin 3 X-012 pin 1 X-012 pin 2 X-012 pin 3

To Connector X-002A pin 61 Connector X-002A pin 14 Connector X-002A pin 23 Chassis ground Chassis ground Chassis ground

Result There should be continuity. There should be continuity. There should be continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If the wiring harness test is good, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to 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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05)

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3088-Crank speed sensor - High voltage Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0337 and/or P0385. The Engine Control Unit (ECU) receives a pulse signal from the crankshaft (engine speed/NE) sensor at the ECU connector X-002A pin 43. The ground reference circuit is provided at the ECU connector X-002A pin 19. As the toothed wheel passes in front of the crankshaft sensor, a pulse signal is produced that varies according to engine speed. The ECU uses the pulse signal to interpret engine RPM. Cause: The number of pulses is inconsistent to the ECU. Possible failure modes: 1. The crankshaft sensor has failed internally. 2. The crankshaft sensor circuit wiring is damaged. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the "Engine Speed Active Flag". See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000).

NHIL13ENG0087AA

A. If the waveform does not compare to the graph, continue with Step 2. B. If the voltage is in range, the fault may be intermittent and not currently active. Continue with Step 7. 2. Use the Service Tool D to check for camshaft sensor fault codes 3090 and 3955. A. If fault codes 3090 and 3955 are not present, continue with Step 3. B. If fault codes 3090 and 3955 are present, continue with the active troubleshooting procedure. Then determine if this fault has been corrected. 3. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the crankshaft 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 4.

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B. The connectors or the wiring harness has damage. Repair or replace the wiring harness or connectors as required. 4. Check the sensor. Disconnect the wiring harness from the crankshaft sensor. Use a multimeter to measure the resistance on the crankshaft sensor between pin 1 to pin 2. There should be approximately 109.5 - 143.5 Ω at 20 °C (68.0 °F). A. If the resistance is incorrect, the sensor has failed. Replace the sensor. B. If the resistance is good, continue with Step 5. 5. Check the wiring harness. Place the key switch OFF. Disconnect the wiring harness from the ECU. Use a multimeter to perform the following checks. Connector Connector Connector Connector Connector

From X-023 pin 1 X-023 pin 2 X-023 pin 1 X-023 pin 2 X-023 pin 1

To Connector X-002A pin 43 Connector X-002A pin 19 Chassis ground Chassis ground Connector X-023 pin 2

Result There should be continuity. There should be continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If the wiring harness test is good, continue with Step 6. B. If the wiring harness test fails, locate and repair the broken conductor. 6. Check the flywheel, and crankshaft speed sensor. See Flywheel housing - Test (10.103) for specifications on the flywheel, and the flywheel housing. A. If any of the specifications are incorrect, repair and/or replace as needed. B. If the specifications are correct, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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3089-Crankshaft speed sensor - Invalid signal Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0336. The Engine Control Unit (ECU) receives a pulse signal from the crankshaft (engine speed/NE) sensor at the ECU connector X-002A pin 43. The ground reference circuit is provided at the ECU connector X-002A pin 19. As the toothed wheel passes in front of the crankshaft sensor, a pulse signal is produced that varies according to engine speed. The ECU uses the pulse signal to interpret engine RPM. Cause: The crankshaft signal to the ECU is erratic. Possible failure modes: 1. The crankshaft sensor has failed internally. 2. The crankshaft sensor circuit wiring is faulty. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the "Engine Speed Active Flag". See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000).

NHIL13ENG0087AA

A. If the waveform does not compare to the graph, continue with Step 2. B. If the waveform is in range, the fault may be intermittent and not currently active. 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 crankshaft 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 sensor. Disconnect the wiring harness from the crankshaft sensor. Use a multimeter to measure the resistance on the crankshaft sensor between pin 1 to pin 2. 47711684 06/05/2014

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There should be approximately 109.5 - 143.5 Ω at 20 °C (68.0 °F). A. If the resistance is incorrect, the sensor has failed. Replace the sensor. B. If the resistance is good, continue with Step 4. 4. Check the wiring harness. Place the key switch OFF. Disconnect the wiring harness from the ECU. Use a multimeter to perform the following checks. Connector Connector Connector Connector Connector

From X-023 pin 1 X-023 pin 2 X-023 pin 1 X-023 pin 2 X-023 pin 1

To Connector X-002A pin 43 Connector X-002A pin 19 Chassis ground Chassis ground Connector X-023 pin 2

Result There should be continuity. There should be continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If the wiring harness test is good, continue with Step 5. B. If the wiring harness test fails, locate and repair the broken conductor. 5. Check the flywheel, and crankshaft speed sensor. See Flywheel housing - Test (10.103) for specifications on the flywheel, and the flywheel housing. A. If any of the specifications are incorrect, repair and/or replace as needed. B. If the specifications are correct, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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3090-Camshaft speed sensor - No signal Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0342. The Engine Control Unit (ECU) receives a signal at the ECU connector X-002A pin 42, indicating the position of the camshaft sensor also known as G sensor. This signal is produced when a toothed wheel attached to the high pressure pump passes the camshaft sensor. The ECU provides a 5.0 V reference signal from the ECU connector X-002B at pin 9, and a ground reference signal from the ECU connector X-002A pin 18. Cause: The camshaft signal to the ECU is erratic. Possible failure modes: 1. The camshaft sensor has failed internally. 2. The camshaft sensor circuit wiring is faulty. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the "Cam Speed Active Flag" value. See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000).

NHIL13ENG0086AA

A. If the waveform does not compare to the graph, continue with Step 2. B. If the waveform is in range, the fault may be intermittent and not currently active. 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 camshaft 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 5.0 V and ground reference circuit. Disconnect the wiring harness from the camshaft sensor. Place the key switch ON. 47711684 06/05/2014

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Use a multimeter to check for voltage on the wiring harness sensor connector between pin 2 to pin 3. There should be approximately 4.5 - 5.5 V. A. If the voltage reading is correct, continue with Step 4. B. If the voltage reading is incorrect, continue with Step 5. 4. Check the signal circuit. Place the key switch OFF. Disconnect the wiring harness from the ECU. Use a multimeter to perform the following checks. Connector Connector Connector Connector

From X-022 pin 1 X-022 pin 1 X-022 pin 1 X-022 pin 1

To Connector X-002A pin 42 Chassis ground Connector X-022 pin 2 Connector X-022pin 3

Result There should be continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If the wiring harness test is good, the sensor has failed. Replace the sensor. B. If the wiring harness test fails, locate and repair the broken conductor. 5. Check the wiring harness. Place the key switch OFF. Disconnect the wiring harness from the ECU. Use a multimeter to perform the following checks. Connector Connector Connector Connector Connector

From X-022 pin 2 X-022 pin 3 X-022 pin 2 X-022 pin 3 X-022 pin 2

To Connector X-002B pin 9 Connector X-002A pin 18 Chassis ground Chassis ground Connector X-022 pin 3

Result There should be continuity. There should be continuity. There should be no continuity. There should be no continuity. There should be no continuity.

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3102-Rail pressure sensor - Signal below range minimum Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0192. The Engine Control Unit (ECU) provides a reference of 5.0 V at ECU connector X-002A pin 45 and a ground reference at ECU connector X-002 pin 16. The rail pressure sensor measures the fuel pressure to the fuel injectors. The voltage signal at the ECU connector X-002A pin A40 and X-002A pin 41 are used by the ECU to determine how long the injectors will be open to deliver a specific amount of fuel. Cause: The rail pressure sensor signal is less than 0.2 V. Possible failure modes: 1. The rail pressure sensor has failed internally. 2. The rail pressure sensor wiring is open or shorted to a low source. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the "Actual Rail Pressure" and "Rail Pressure Sensor Output Voltage". See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000). Engine Condition Fuel pressure at key switch ON. Fuel pressure after engine startup.

Rail pressure Voltage output 0.7 - 1.1 V 0 bar (0.0 psi) 300 - 2000 bar (4350.0 - 29000 psi) 1.1 - 4.0 V

A. If there is less than 0.2 V, continue with Step 2. B. If the voltage is in range, the fault may be intermittent and not currently active. 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 rail 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 harness or connectors as required. 3. Check the signal and ground reference circuit. Disconnect the wiring harness from the rail pressure sensor. Place the key switch ON. Use a multimeter to perform the following check on the wiring harness. From Connector X-031 pin 1

To Connector X-031 pin 3

A. If the voltage reading is not in range, continue with Step 5. B. If the voltage is in range, continue with Step 4. 4. Check the signal circuit to the rail pressure sensor. 47711684 06/05/2014

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Value There should be approximately 4.8 - 5.2 V.

Electrical systems - FAULT CODES

Place a jumper wire between connector X-031 pin 1 and pin 2. Place the key switch ON. Monitor the diagnostic screen to see if fault code 3112 (P0193) is present. A. If the fault code 3112 is not present, continue with Step 5. B. If fault code 3112 is present, the circuit is working properly. Replace the sensor. 5. Check the wiring harness for an open or short to low source. Place the key switch OFF. Carefully disconnect the wiring harness from the ECU. Use a multimeter to perform the following checks. From Connector X-031 pin 1 Connector X-031 pin 2 Connector X-031 pin 2 Connector X-031 pin 3 Connector X-002A pin 45 Connector X-002A pin 40 Connector X-002A pin 41 Connector X-002A pin 16

To Connector X-002A pin 45 Connector X-002A pin 40 Connector X-002A pin 41 Connector X-002A pin 16 Chassis ground Chassis ground Chassis ground Chassis ground

Result There should be continuity. There should be continuity. There should be continuity. There should be continuity. There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

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3112-Rail pressure sensor - Signal above range maximum Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0193. The Engine Control Unit (ECU) provides a reference of 5.0 V at ECU connector X-002A pin 45 and a ground reference at ECU connector X-002 pin 16. The rail pressure sensor measures the fuel pressure to the fuel injectors. The voltage signal at the ECU connector X-002A pin A40 and X-002A pin 41 are used by the ECU to determine how long the injectors will be open to deliver a specific amount of fuel. Cause: The rail pressure sensor signal is greater than 4.8 V. Possible failure modes: 1. The rail pressure sensor has failed internally. 2. The rail pressure sensor wiring is shorted to a high source. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check "Actual Rail Pressure" and "Rail Pressure Sensor Output Voltage". See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000). Engine Condition Fuel pressure at key switch ON. Fuel pressure after engine startup.

Rail pressure Voltage output 0.7 - 1.1 V 0 bar (0.0 psi) 300 - 2000 bar (4350.0 - 29000 psi) 1.1 - 4.0 V

A. If there is greater than 4.8 V, continue with Step 2. B. If the voltage is in range, the fault may be intermittent and not currently active. 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 rail 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 harness or connectors as required. 3. Check the signal and ground reference circuit. Disconnect the wiring harness from the rail pressure sensor. Place the key switch ON. Use a multimeter to perform the following check on the wiring harness. From Connector X-031 pin 1

To Connector X-031 pin 3

A. If the voltage reading is not in range, continue with Step 5. B. If the voltage is in range, continue with Step 4. 4. Check the signal circuit to the rail pressure sensor. 47711684 06/05/2014

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Value There should be approximately 4.8 - 5.2 V.

Electrical systems - FAULT CODES

Place a jumper wire between connector X-031 pin 3 and pin 2. Place the key switch ON. Monitor the diagnostic screen to see if fault code 3102 (P0192) is present. A. If the fault code 3102 is not present, continue with Step 5. B. If fault code 3102 is present, the circuit is working properly. Replace the sensor. 5. Check the wiring harness for a short to high source. Place the key switch OFF. Carefully disconnect the wiring harness from the ECU. Place the key switch ON. Use a multimeter to perform the following checks. From Connector X-002A pin 45 Connector X-002A pin 40 Connector X-002A pin 41 Connector X-002A pin 16

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.

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3210-Injector bank 1 circuit (Cylinder 1 and 4) - Short circuit Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0201 and/or P0204. The Engine Control Unit (ECU) has four injector driver circuits. Each of these circuits regulates an injector. Cause: The injector 1 power circuit signal is open. Possible failure modes: 1. The cylinder injector 1 has failed internally. 2. The cylinder injector 4 has failed internally. 3. The injector circuit wiring is open. 4. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the fault code is present. A. If the fault is present, continue with Step 2. B. If the fault is no longer present, the fault may be intermittent and not currently active. Continue with Step 7. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the injector 1 connector. Inspect the wiring harness from the ECU to the injector 4 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 harness or connectors as required. 3. Check the cylinder injector 1 coil resistance through the wiring harness. Place the key switch OFF. Disconnect the wiring harness from the ECU. Use a multimeter to measure resistance from the wiring harness connector X-002A pin 49 to pin 74. There should be approximately 0.37 - 0.57 Ω at 20 °C (68.0 °F). A. If the resistance reading is not in range, continue with Step 5. B. If the resistance is in range, continue with Step 4. 4. Check the cylinder injector 4 coil resistance through the wiring harness. Place the key switch OFF. Use a multimeter to measure resistance from the wiring harness connector X-002A pin 51 to pin 73. There should be approximately 0.37 - 0.57 Ω at 20 °C (68.0 °F). A. If the resistance reading is not in range, continue with Step 6. 47711684 06/05/2014

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B. If the resistance is in range, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. 5. Check the injector 1 coil resistance. Place the key switch OFF. Disconnect the wiring harness from the injector. Use a multimeter to measure the resistance between the injector coil pin 1 to pin 2. There should be approximately 0.37 - 0.57 Ω at 20 °C (68.0 °F). A. If the resistance reading is not in range, replace the injector. When the injector is replaced, the new injector Quick Response Code (QR) will need to be entered into the ECU using Service Tool D. See Electrical system Computer support tools - Overview — Utility (55.000). B. If the resistance reading is in range, the wiring harness has failed. Locate and repair the broken conductor. 6. Check the injector 4 coil resistance. Place the key switch OFF. Disconnect the wiring harness from the injector. Use a multimeter to measure the resistance between the injector coil pin 1 to pin 2. There should be approximately 0.37 - 0.57 Ω at 20 °C (68.0 °F). A. If the resistance reading is not in range, replace the injector. When the injector is replaced, the new injector Quick Response Code (QR) will need to be entered into the ECU using Service Tool D. See Electrical system Computer support tools - Overview — Utility (55.000). B. If the resistance reading is in range, the wiring harness has failed. Locate and repair the broken conductor. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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3218-Injector bank 2 circuit (Cylinder 2 and 3) - Short circuit Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0202 and/or P0203. The Engine Control Unit (ECU) has four injector driver circuits. Each of these circuits regulates an injector. Cause: The injector 2 power circuit signal is open. Possible failure modes: 1. The cylinder injector 2 has failed internally. 2. The cylinder injector 3 has failed internally. 3. The injector circuit wiring is open. 4. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the fault code is present. A. If the fault is present, continue with Step 2. B. If the fault is no longer present, the fault may be intermittent and not currently active. Continue with Step 7. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the injector 2 connector. Inspect the wiring harness from the ECU to the injector 3 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 harness or connectors as required. 3. Check the cylinder injector 2 coil resistance through the wiring harness. Disconnect the wiring harness from the ECU. Place the key switch OFF. Use a multimeter to measure resistance from the wiring harness connector X-002A pin 1 to pin 3. There should be approximately 0.37 - 0.57 Ω at 20 °C (68.0 °F). A. If the resistance reading is not in range, continue with Step 5. B. If the resistance is in range, continue with Step 4. 4. Check the cylinder injector 3 coil resistance through the wiring harness. Place the key switch OFF. Use a multimeter to measure resistance from the wiring harness connector X-002A pin 25 to pin 26. There should be approximately 0.37 - 0.57 Ω at 20 °C (68.0 °F). A. If the resistance reading is not in range, continue with Step 6. 47711684 06/05/2014

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B. If the resistance is in range, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. 5. Check the injector 2 coil resistance. Disconnect the wiring harness from the injector. Place the key switch OFF. Use a multimeter to measure the resistance between the injector coil pin 1 to pin 2. There should be approximately 0.37 - 0.57 Ω at 20 °C (68.0 °F). A. If the resistance reading is not in range, replace the injector. When the injector is replaced, the new injector Quick Response Code (QR) will need to be entered into the ECU using Service Tool D. See Electrical system Computer support tools - Overview — Utility (55.000). B. If the resistance reading is in range, the wiring harness has failed. Locate and repair the broken conductor. 6. Check the injector 3 coil resistance. Disconnect the wiring harness from the injector. Place the key switch OFF. Use a multimeter to measure the resistance between the injector coil pin 1 to pin 2. There should be approximately 0.37 - 0.57 Ω at 20 °C (68.0 °F). A. If the resistance reading is not in range, replace the injector. When the injector is replaced, the new injector Quick Response Code (QR) will need to be entered into the ECU using Service Tool D. See Electrical system Computer support tools - Overview — Utility (55.000). B. If the resistance reading is in range, the wiring harness has failed. Locate and repair the broken conductor. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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3258-Starter relay circuit - Shorted to high source Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P2628. The crank (starter) relay supplies power to the starter to crank the engine. Cause: The Engine Control Unit (ECU) senses the crank (starter) relay is shorted to a high source. Possible failure modes: 1. The crank relay has failed. 2. The crank relay circuit is shorted to a high source. 3. The ECU has an internal failure. Solution: 1. Use the Service Tool D data monitor function to verify the "Starter Switch" data when the key switch is ON. The monitor should state: Key switch ON, signal OFF. The monitor should state: Key switch START, signal ON. A. If the signal check is incorrect, continue with Step 2. B. If the signal check is correct, continue with Step 5. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the crank relay 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 wiring. Place the key switch OFF. Disconnect the wiring harness from the ECU. Remove the crank relay. Place the key switch ON. Use a multimeter to check for voltage from connector X-002A pin 92 to chassis ground. There should be no voltage. A. If there is no voltage continue with Step 4. B. If there is voltage, there is a short to high source in the wiring. Locate and repair broken conductor. 4. Check the relay. Remove the relay. Use a multimeter to perform the following checks. 47711684 06/05/2014

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From Relay pin 86

To Relay pin 85

Value There should be continuity

A. If the relay test is good, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. B. If the relay test fails, replace the relay. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07)

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3259-Starter relay circuit - Shorted to low source Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P2629. The crank (starter) relay supplies power to the starter to crank the engine. Cause: The Engine Control Unit (ECU) senses the crank (starter) relay is shorted to a low source. Possible failure modes: 1. The crank relay has failed. 2. The crank relay circuit is shorted to a low source. 3. The ECU has an internal failure. Solution: 1. Use the Service Tool D data monitor function to verify the "Starter Switch" data when the key switch is ON. The monitor should state: Key switch ON, signal OFF. The monitor should state: Key switch START, signal ON. A. If the signal check is incorrect, continue with Step 2. B. If the signal check is correct, continue with Step 5. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the crank relay 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 wiring. Place the key switch OFF. Disconnect the wiring harness from the ECU. Remove the crank relay. Use a multimeter to check for voltage from connector X-002A pin 92 to chassis ground. There should be no continuity. A. If there is no continuity, continue with Step 4. B. If there is continuity, there is a short to low source in the wiring. Locate and repair broken conductor. 4. Check the relay. Remove the relay. Use a multimeter to perform the following checks. From Relay pin 86

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Value There should be resistance.

Electrical systems - FAULT CODES

A. If there is resistance, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. B. If there is infinite or 0 Ω, replace the relay. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07)

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3267-Engine Control Unit (ECU) fuel pump output - Shorted to high source Control Module : ECU NOTE: The high pressure pump is also known as the Suction Control Valve (SCV). Context: When retrieving this fault code using Service Tool D, display code is P0629. The Engine Control Unit (ECU) provides an electric current to the solenoid valve, located on the high pressure pump. The current is monitored between the ECU connector X-002B pin 7 and pin 20 The ECU commands the supply pump to supply fuel to obtain a target fuel pressure. Cause: The ECU is sensing the high pressure pump control current is greater than 2,700 mA. Possible failure modes: 1. The high pressure pump has failed. 2. The wiring harness has failed. 3. The ECU has failed internally. Solution: 1. Use the Service Tool D to verify the fault is active. Use the Service Tool D to check the “SCV Current” at idle. See Electrical system Computer support tools Overview (55.000). There should be 1,500 - 1,900 mA. A. If the amperage is greater than 2,700 mA, continue with Step 2. B. If the amperage is in range, the fault may be intermittent and not currently active. Continue with Step 5. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the high pressure pump solenoid 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 high pressure pump resistance. Place the key switch OFF. Disconnect the wiring harness from the high pressure pump. Use a multimeter to measure the resistance from the high pressure pump solenoid pin 1 to pin 2. The resistance should be 2.0 - 4.0 Ω. A. If the resistance is correct, continue with Step 4. B. If the resistance is incorrect, replace the supply pump. 4. Check the wiring harness for a short to high source. Place the key switch OFF. 47711684 06/05/2014

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Disconnect the wiring harness from the ECU. Place the key switch ON. Use a multimeter to check for voltage from the wiring harness connector X-033 pin 1 to chassis ground. Use a multimeter to check for voltage from the wiring harness connector X-033 pin 2 to chassis ground. There should be no voltage. A. If there is no voltage, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU is working properly. B. If there is voltage, there is a short to high source in the wiring harness. Locate and repair the damaged 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. Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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3268-Engine Control Unit (ECU) fuel pump output - Shorted to low source Control Module : ECU NOTE: The high pressure pump is also known as the Suction Control Valve (SCV). Context: When retrieving this fault code using Service Tool D, display code is P0627. The Engine Control Unit (ECU) provides a 5.0 V reference from the ECU connector X-002B pin 20 and a ground reference from ECU connector X-002B pin 7 to the high pressure pump sensor. Cause: The ECU is sensing the high pressure pump control current is less than 400 mA. Possible failure modes: 1. The high pressure pump has failed. 2. The wiring harness has failed. 3. The ECU has failed internally. Solution: 1. Use the Service Tool D to verify the fault is active. Use the Service Tool D to check the “SCV Current” at idle. See Electrical system Computer support tools Overview (55.000). There should be 1,500 - 1,900 mA. A. If the amperage is less than 4.0 mA, continue with Step 2. B. If the amperage is in range, the fault may be intermittent and not currently active. Continue with Step 5. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the high pressure pump 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 high pressure pump sensor resistance. Place the key switch OFF. Disconnect the wiring harness from the high pressure pump. Use a multimeter to measure the resistance from the high pressure pump sensor pin 1 to pin 2. The resistance should be 2.0 - 4.0 Ω. A. If the resistance is correct, continue with Step 4. B. If the resistance is incorrect, replace the supply pump. 4. Check the wiring harness. Place the key switch OFF.

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Disconnect the wiring harness from the ECU. Use a multimeter to perform the following checks. From Connector X-002B pin 20 Connector X-002B pin 7 Connector X-033 pin 1 Connector X-033 pin 2 Connector X-033 pin 1

To Chassis ground Chassis ground Connector X-002B pin 20 Connector X-002B pin 7 Connector X-033 pin 2

Value There should be no continuity. There should be no continuity. There should be continuity. There should be continuity. There should be continuity.

A. If the wiring harness test passes, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU is working properly. B. If the wiring harness test fails, locate and repair the damaged 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. Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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3293-Common rail pressure exceeds hi upper limit Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P2293. The Engine Control Unit (ECU) monitors the rail pressure signal to meter fuel to the injectors. Cause: The ECU is sensing actual pressure is excessive when compared to command pressure. Possible failure modes: 1. The pump supply is not installed correctly. 2. The pump supply has failed. 3. There is a fault in the fuel system. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the rail pressure. See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000). Rail pressure 250 - 350 bar (3625.0 - 5075.0 psi) 1400 - 2300 bar (20300.0 - 33350.0 psi)

Engine Condition Engine idling at 1,000 RPM. Accelerator to 100 %.

NHIL13ENG0089AA

The signal graph should approximately match at idle, and at full acceleration. A. If the graph does not match during either check, continue with Step 2. B. If the graph is correct during the checks, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check for air in the system. Replace the fuel hose with a clear transparent hose. Check for air in the system. A. If air is in the system, bleed the air out of the system. B. If air is not in the system, continue with Step 3. 3. Check the fuel system. See Fuel injection system - Inspect (10.218). 47711684 06/05/2014

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A. If there is an issue with the fuel system check, repair or replace faulty components or lines. B. If the fuel system check is good, continue with Step 4. 4. Check the supply pump timing. A. If the timing is incorrect, see High pressure pump - Timing adjust (10.218). B. If the timing is correct, continue with Step 5. 5. Monitor the Suction Control Vale (SCV), see Fuel injection system - Electrical test (55.010). A. If there is a large discrepancy in the test readings, replace the supply pump. B. If the test is good, there may have been a momentary malfunction. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation.

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3305-Common rail pressure below target pressure Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P1221. The Engine Control Unit (ECU) monitors the rail pressure signal to meter fuel to the injectors. Cause: The ECU is sensing the rail pressure is at or below the control limit. Possible failure modes: 1. The pump supply is not installed correctly. 2. The pump supply has failed. 3. There is a fault in the fuel system. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the rail pressure. Rail pressure 250 - 350 bar (3625.0 - 5075.0 psi) 1400 - 2300 bar (20300.0 - 33350.0 psi)

Engine Condition Engine idling at 1,000 RPM. Accelerator to 100 %.

NHIL13ENG0089AA

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3309-Common rail pressure exceeds upper limit Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0088. The Engine Control Unit (ECU) monitors the rail pressure signal to meter fuel to the injectors. Cause: The ECU is sensing actual pressure is excessive when compared to command pressure. Possible failure modes: 1. The pump supply is not installed correctly. 2. The pump supply has failed. 3. There is a fault in the fuel system. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the rail pressure. See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000). Rail pressure 250 - 350 bar (3625.0 - 5075.0 psi) 1400 - 2300 bar (20300.0 - 33350.0 psi)

Engine Condition Engine idling at 1,000 RPM. Accelerator to 100 %.

NHIL13ENG0089AA

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3334-Controller Area Network (CAN) message not received from vehicle controller - TSC1-PE Active Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is U1301. The Controller Area Network (CAN) is made up of a twisted pair of wires, identified as CAN HI (yellow) and CAN LO (green). These two wires are used to form a "linear bus" network, in that the wires run in parallel from one end of the vehicle to the other, and each module is connected to both wires as a "node". These two wires are connected together at each end of the network using a 120 ohms resistor, which is known as a "termination" resistor. Because there is a 120 ohms resistor at each end of the network, the resistance should always be 60 ohms between the CAN HI and CAN LO wires. Cause: The ECU can not receive CAN 2 target speed data. Possible failure modes: 1. The wiring harness is faulty. 2. The ECU has failed internally. Solution: 1. Use the Scan Tool D to conduct data measurement, such as a data monitor. At the same time, check the waveform between ECU connector X-002B pin 38 and pin 39.

NHIL13ENG0097AA

A. If the graph is correct, continue with Step 2. B. If the graph is incorrect, continue with Step 3. 2. Verify that the wiring and connectors are free of damage. Inspect the harness from the ECU to the CAN diagnostic connector. Inspect the harness from the ECU to the instrument cluster connector. Verify that the 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 CAN circuit. Place the key switch OFF.

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Use a multimeter to measure the resistance from the CAN diagnostic connector X-DIAG pin C to pin D. There should be approximately 55 - 65 Ω. A. If the resistance is infinite, continue with Step 4. B. If the resistance reading is correct, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the proper operation of the ECU. 4. Check the ECU terminating resistor. Place the key switch OFF. Disconnect the harness from the ECU. Use a multimeter to measure the resistance on the ECU connector X-002B between pin 38 to pin 39. There should be approximately 108 - 132 Ω. A. If the resistance is correct, continue with Step 5. B. If the resistance reading is incorrect, the internal resistor has failed. Replace the ECU. 5. Check the wiring harness for an open circuit. Place the key switch OFF. Use a multimeter to perform the following checks on the wiring harness. From Connector X-00B2 pin 38 Connector X-002B pin 39

To Connector X-DIAG pin C Connector X-DIAG pin D

Value There should be continuity. There should be continuity.

A. If the wiring harness test passes, check the instrument cluster CAN wiring and terminator. B. If the wiring harness test fails, locate and repair the broken conductor. Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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3691-Glow plug circuit - No load error for low voltage system Control Module : ECU NOTE: Make sure the engine is cold, there are cases in which the glow plug relay will not come ON. Context: When retrieving this fault code using Service Tool D, display code is P0542. The Engine Control Unit (ECU) sends a 12.0 V signal from ECU connector X-002A pin 90 to the positive terminal of the glow plug relay control circuit. This will energize the relay load circuit to switch ON. The negative terminal of the relay control circuit is frame grounded. Cause: The glow plug relay positive control circuit is shorted to a high source. Possible failure modes: 1. The glow plug relay has failed internally. 2. The glow plug relay circuit wiring is open or shorted to a high source. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the "Glow Relay" status. See Electrical system Computer support tools Overview Data Monitoring Screen (55.000). The relay status should be ON when activated. The status should turn OFF after 30 s. Use the Service Tool D to activate the glow plug relay test. See Electrical system Computer support tools Overview — Active Test (55.000). The status should turn ON and OFF. A. If the relay status is incorrect, continue with Step 2. B. If the relay status check is correct, 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 glow plug relay 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 relay. Place the key switch OFF. Remove the engine glow relay. Use a multimeter to perform the following checks. From Pin 86 Pin 30 Pin 30

To Pin 85 Pin 87A Pin 87

A. If relay test is good, continue with Step 4. 47711684 06/05/2014

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Value There should be resistance. There should be continuity. There should be no continuity.

Electrical systems - FAULT CODES

B. If the relay test fails, replace the relay. 4. Check for a short to high source. Place the key switch OFF. Disconnect the wiring harness from the ECU. Place the key switch ON. Use a multimeter to check for voltage from wiring harness connector X-002A pin 90 to chassis ground. There should be no voltage. A. If there is voltage, there is a short to high source. Locate and repair broken conductor. B. If there is no voltage, continue with Step 5. 5. Check for an open circuit. Place the key switch OFF. Use a multimeter to check for continuity from wiring harness connector X-002A pin 90 to connector X-003 pin 1. There should be continuity. A. If there is no continuity, there is an open in the wiring harness. Locate and repair broken conductor. B. If there is continuity, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the proper operation of the ECU. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Mechanical Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) EH Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05)

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3694-Glow plug circuit. - Short circuit to ground error for low voltage system Control Module : ECU NOTE: Make sure the engine is cold, there are cases in which the glow plug relay will not come ON. Context: When retrieving this fault code using Service Tool D, display code is P0541. The Engine Control Unit (ECU) sends a 12.0 V signal from ECU connector X-002A pin 90 to the positive terminal of the glow plug relay control circuit. This will energize the relay load circuit to switch ON. The negative terminal of the relay control circuit is frame grounded. Cause: The glow plug relay circuit is shorted to ground. Possible failure modes: 1. The glow plug relay has failed internally. 2. The glow plug relay circuit wiring is shorted to ground. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the "Glow Relay" status. See Electrical system Computer support tools Overview Data Monitoring Screen (55.000). The relay status should be ON when activated. The status should turn OFF after 30 s. Use the Service Tool D to activate the glow plug relay test. See Electrical system Computer support tools Overview — Active Test (55.000). The status should turn ON and OFF. A. If the relay status check is incorrect, continue with Step 2. B. If the relay status is correct, continue with Step 5. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the glow plug relay 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 relay. Place the key switch OFF. Remove the engine glow relay. Use a multimeter to perform the following checks. From Pin 86 Pin 30 Pin 30

To Pin 85 Pin 87A Pin 87 47711684 06/05/2014

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Value There should be resistance. There should be continuity. There should be no continuity.

Electrical systems - FAULT CODES

A. If relay test is good, continue with Step 4. B. If the relay test fails, replace the relay. 4. Check the relay coil power circuit. Place the key switch OFF. Disconnect the wiring harness from the ECU. Use a multimeter to check for continuity from wiring harness connector X-002A pin 90 to chassis ground. There should be no continuity. A. If there is continuity, there is a short to ground in the wiring harness. Locate and repair broken conductor. B. If there is no continuity, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the proper operation of the ECU. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) EH Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05)

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3764-Engine controller main relay circuit (Terminal 30) - Early opening defect of main relay Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0686. The Engine Control Unit (ECU) controls the ECU main relay operation dependant on the key switch. When the key switch is turned to the ON position, the ECU will provide ground on the control circuit of the ECU main relay. Cause: The ECU has sensed the ECU main relay circuit has failed. Possible failure modes: 1. The ECU main relay failed. 2. The key switch failed. 3. The wiring harness failed. 4. The ECU has failed internally. Solution: 1. Check for voltage at the ECU. Place the key switch OFF. Disconnect the wiring harness from the ECU. Use a multimeter to perform the following checks. There should be no voltage with the key switch OFF. From Connector X-002B pin 5 Connector X-002B pin 6

To Chassis ground Chassis ground

Value There should be no voltage. There should be no voltage.

A. If there is voltage, continue with Step 2. B. If there is no voltage, the fault may be intermittent and not currently active. Continue with Step 6. 2. Use the Service Tool D data monitor function to verify the "Key Switch" status. Place the key switch ON. Place the key switch OFF. The "Key Switch" data should state OFF when the key switch is OFF. A. If the status is incorrect, continue with Step 3. B. If the status is correct, Continue with Step 4. 3. Check the key switch circuit. Place the key switch OFF. Use a multimeter to perform the following checks. There should be no voltage with the key switch OFF.

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From Connector X-002B pin 47 Connector X-002B pin 48

To Chassis ground Chassis ground

Value There should be no voltage. There should be no voltage.

A. If there is no voltage, continue with Step 4. B. If there is voltage, check the wiring harness for damage. If no damage is found, check the key switch. Repair or replace as needed. 4. Check the relay wiring control circuit. Place the key switch OFF. Use a multimeter to perform the following checks. There should be voltage with the key switch OFF. From Connector X-002B pin 33

Chassis ground

Connector X-002B pin 34

Chassis ground

Value There should be approximately 12.0 V. There should be approximately 12.0 V.

A. If the voltage reading is correct, continue with Step 6. B. If the voltage is incorrect, continue with Step 5. 5. Check the ECU main relay coil. Remove the ECU main relay. Use a multimeter to perform the following checks. From Relay terminal pin 85

To Relay terminal pin 86

Value There should be continuity.

A. If the relay test is good, check the wiring between the ECU connector X-002B pin 33 and pin 34 to the relay connector. Locate and repair broken conductor. B. If the relay test fails, replace the relay. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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3797-Differential pressure sensor - Signal too high Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P2455. The Engine Control Unit (ECU ) supplies the differential pressure sensor with a 5.0 V reference at ECU connector X-002B pin 22, and a ground reference at ECU connector X-002A pin 10. The ECU monitors the differential pressure signal at ECU connector X-002A pin 37. Cause: The ECU has sensed the differential pressure sensor signal is greater than 2.7 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. Use the Service Tool D to check "Differential Pressure" and "Differential Pressure Sensor Output Voltage". See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000). Engine Condition Key switch ON. After engine startup, changing the accelerator position.

Pressure 0 bar (0.0 psi) 0.25 bar (3.6 psi)

Voltage output 0.3 - 0.7 V 0.3 - 2.7 V

A. If there is greater than 2.7 V, continue with Step 2. B. If the voltage is in range, the fault may be intermittent and not currently active. 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 X-026 pin 5 and pin 2. Place the key switch ON. Monitor the diagnostic screen for fault code 3798 (P2454). A. If the fault code 3798 is present, remove the jumper wire. Continue with Step 4. B. If the fault code 3798 is not present, remove the jumper wire. Continue with Step 5. 4. Check the 5.0 V supply and ground reference circuit. Place the key switch ON.

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Use a multimeter to check for voltage from the wiring harness sensor connector X-026 pin 4 to pin 5. 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. Carefully disconnect the wiring harness from the ECU. Use a multimeter to check to perform the following checks. From Connector X-026 pin 2 Connector X-026 pin 4 Connector X-026 pin 5

To Chassis ground Chassis ground Chassis ground

Result There should be no voltage. There should be no voltage. There should be no voltage.

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3798-Differential pressure sensor - Signal too low Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P2454. The Engine Control Unit (ECU ) supplies the differential pressure sensor with a 5.0 V reference at ECU connector X-002B pin 22, and a ground reference at ECU connector X-002A pin 10. The ECU monitors the differential pressure signal at ECU connector X-002A pin 37. Cause: The ECU has sensed the differential pressure sensor signal is less than 0.25 V. Possible failure modes: 1. The differential pressure sensor has failed. 2. The differential pressure sensor circuit is shorted to a low source or open. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check "Differential Pressure" and "Differential Pressure Sensor Output Voltage". See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000). Engine Condition Key switch ON. After engine startup, changing the accelerator position.

Pressure 0 bar (0.0 psi) 0.25 bar (3.6 psi)

Voltage output 0.3 - 0.7 V 0.3 - 2.7 V

A. If there is less than 0.2 V, continue with Step 2. B. If the voltage is in range, the fault may be intermittent and not currently active. 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 X-026 pin 4 and pin 2. Place the key switch ON. Monitor the diagnostic screen for fault code 3797 (P2455). A. If the fault code 3797 is present, remove the jumper wire. Continue with Step 4. B. If the fault code 3797 is not present, remove the jumper wire. Continue with Step 5. 4. Check the 5.0 V supply and ground reference circuit. Place the key switch ON.

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Use a multimeter to check for voltage from the wiring harness sensor connector X-026 pin 4 to pin 5. 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 an open or short to low source. Place the key switch OFF. Carefully disconnect the wiring harness from the ECU. Use a multimeter to check to perform the following checks. Connector Connector Connector Connector Connector Connector

From X-026 pin 2 X-026 pin 4 X-026 pin 5 X-026 pin 2 X-026 pin 4 X-026 pin 5

To Connector X-002A pin 37 Connector X-002B pin 22 Connector X-002A pin 10 Chassis ground Chassis ground Chassis ground

Result There should be continuity. There should be continuity. There should be continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If the engine harness test is good, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. B. If the engine 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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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3830-Intake valve position - Signal too high Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P2622. The Engine Control Unit (ECU) monitors the intake throttle position. The ECU supplies a reference voltage at ECU connector X-002A pin 24, and a ground reference at ECU connector X-002A pin 12. The intake throttle sensor sends a signal to the ECU connector X-002A at pin 63. Cause: The ECU is sensing the intake throttle position sensor voltage is greater than 4.75 V. Possible failure modes: 1. The intake throttle position sensor is faulty. 2. The intake throttle position wiring circuit is shorted to high source. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check for other fault codes present. A. If other fault codes are present, conduct that troubleshooting first. Then determine if fault code has been resolved. B. If no other fault codes are not present, continue with Step 2. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the intake position 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. Use Service Tool D to monitor "Intake throttle Position Sensor Output Voltage" with the intake throttle position fully closed. See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000). The voltage range should be 0.3 - 0.9 V. A. If the voltage is not in range, continue with Step 4. B. If the voltage is in range, continue with Step 7. 4. Check the voltage and ground reference circuit. Disconnect the wiring harness from the intake throttle valve. Place the key switch ON. Use a multimeter to check for voltage from the harness sensor connector pin 3 to pin 5. There should be approximately 4.5 - 5.5 V. A. If the voltage reading is correct, continue with Step 5. B. If the voltage reading is incorrect, continue with Step 6. 47711684 06/05/2014

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5. Check the signal circuit. Place the key switch OFF. Place a jumper wire between connector X-036 pin 3 and pin 6. Place the key switch ON. Monitor the diagnostic screen for fault code 3831 (P2621). A. If fault code 3831 is not present, continue with Step 6. B. If fault code 3831 is present, the sensor has failed. Replace the sensor. 6. Check the wiring harness. Place the key switch OFF. Disconnect the wiring harness from the ECU. Place the key switch ON. Use a multimeter to perform the following checks. From Sensor connector pin 3 Sensor connector pin 5 Sensor connector pin 6

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 the wiring harness test is good, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU is working properly. B. If the wiring harness test fails, locate and repair the damaged conductor. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05)

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3831-Intake valve position - Signal too low Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P2621. The Engine Control Unit (ECU) monitors the intake throttle position. The ECU supplies a reference voltage at ECU connector X-002A pin 24, and a ground reference at ECU connector X-002A pin 12. The intake throttle sensor sends a signal to the ECU connector X-002A at pin 63. Cause: The ECU is sensing the intake throttle position sensor voltage is less than 0.25 V. Possible failure modes: 1. The intake throttle position sensor is faulty. 2. The intake throttle position wiring circuit is shorted to low source or open. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check for other fault codes present. A. If other fault codes are present, conduct that troubleshooting first. Then determine if fault code has been resolved. B. If no other fault codes are not present, continue with Step 2. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the intake position 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. Use Service Tool D to monitor "Intake throttle Position Sensor Output Voltage" with the intake throttle position fully closed. See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000). The voltage range should be 0.3 - 0.9 V. A. If the voltage is not in range, continue with Step 4. B. If the voltage is in range, continue with Step 7. 4. Check the voltage and ground reference circuit. Disconnect the wiring harness from the intake throttle valve. Place the key switch ON. Use a multimeter to check for voltage from the harness sensor connector X-036 pin 3 to pin 5. There should be approximately 4.5 - 5.5 V. A. If the voltage reading is correct, continue with Step 5. B. If the voltage reading is incorrect, continue with Step 6. 47711684 06/05/2014

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5. Check the signal circuit. Place the key switch OFF. Place a jumper wire between connector X-036 pin 5 and pin 6. Place the key switch ON. Monitor the diagnostic screen for fault code 3830 (P2622). A. If fault code 3830 is not present, continue with Step 6. B. If fault code 3830 is present, the sensor has failed. Replace the sensor. 6. Check the wiring harness. Place the key switch OFF. Disconnect the wiring harness from the ECU. Use a multimeter to perform the following checks. Connector Connector Connector Connector

From X-036 pin 3 X-036 pin 5 X-036 pin 6 X-036 pin 3

To Connector X-002A pin 12 Connector X-002A pin 24 Connector X-002A pin 63 Chassis ground

Connector X-036 pin 5

Chassis ground

Connector X-036 pin 6

Chassis ground

Value There should be less than 1.0 Ω. There should be less than 1.0 Ω. There should be less than 1.0 Ω. There should be greater than 20,000 Ω. There should be greater than 20,000 Ω. There should be greater than 20,000 Ω.

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3948-Exhaust Gas Recirculation (EGR) lift sensor 1 - Signal too high Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0406. The Engine Control Unit (ECU) provides a sensor reference voltage to the Exhaust Gas Recirculation (EGR) sensor from the ECU connector X-002A pin 22 and a ground reference from the ECU connector X-002A pin 12. The ECU monitors the EGR sensor signal circuit at ECU connector X-002A pin 33, to monitor the valve movement. Cause: The ECU is sensing the EGR sensor signal is greater than 4.8 V. Possible failure modes: 1. The EGR valve has failed internally. 2. The EGR valve circuit wiring is shorted to a high source. 3. The ECU has failed internally. Solution: 1. Check for other fault codes present. Use the Service Tool D to check for fault code 1013 (P0653). A. If fault code 1013 is not present, continue with Step 2. B. If fault code 1013 is present, see that fault code diagnostic procedure. Then determine if this fault code has been resolved. 2. Verify that the fault is present and active. Use the Service Tool D to check the "EGR Position Sensor Output Voltage". See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000). The voltage range should be approximately 0.9 - 1.3 V when EGR valve is fully closed. A. If there is greater than 4.8 V, continue with Step 3. B. If the voltage is in range, the fault may be intermittent and not currently active. Continue with Step 7. 3. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the EGR valve 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 4. B. The connectors or the wiring harness has damage. Repair or replace the wiring harness or connectors as required. 4. Check the signal circuit. Disconnect the wiring harness from the EGR valve. Place a jumper wire between the wiring harness sensor connector X-035 pin 3 and pin 4. Place the key switch ON. Monitor the diagnostic screen for fault code 3949 (P0405). A. If fault code 3949 is present, remove the jumper wire. Continue with Step 5. 47711684 06/05/2014

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B. If fault code 3949 is not present, remove the jumper wire. Continue with Step 6. 5. Check the 5.0 V reference and ground reference circuit. Place the key switch ON. Use a multimeter to check for voltage from the wiring harness sensor connector X-035 between pin 2 and pin 3. There should be 4.5 - 5.5 V. A. If the voltage reading is not in range, continue with Step 6. B. If the voltage is in range, the sensor has failed. Replace the sensor. 6. Check the wiring harness for a short to high source. Place the key switch OFF. Carefully disconnect the wiring harness from the ECU. Place the key switch ON. Use a multimeter to check to perform the following checks. From Connector X-035 pin 4 Connector X-035 pin 2 Connector X-035 pin 3

To Chassis ground Chassis ground Chassis ground

Result There should be no voltage. There should be no voltage. There should be no voltage.

A. If the wiring harness test is good, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. B. If the wiring harness test fails, locate and repair the broken conductor. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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3949-Exhaust Gas Recirculation (EGR) lift sensor 1 - Signal too low Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0405. The Engine Control Unit (ECU) provides a sensor reference voltage to the Exhaust Gas Recirculation (EGR) sensor from the ECU connector X-002A pin 22 and a ground reference from the ECU connector X-002A pin 12. The ECU monitors the EGR sensor signal circuit at ECU connector X-002A pin 33, to monitor the valve movement. Cause: The ECU is sensing the EGR sensor signal is less than 0.2 V. Possible failure modes: 1. The EGR valve has failed internally. 2. The EGR valve circuit wiring is open or shorted to ground. 3. The ECU has failed internally. Solution: 1. Check for other fault codes present. Use the Service Tool D to check for fault code 1012 (P0652). A. If fault code1012 is not present, continue with Step 2. B. If fault code 1012 is present, see that fault code diagnostic procedure. Then determine if this fault code has been resolved. 2. Verify that the fault is present and active. Use the Service Tool D to check the "EGR Position Sensor Output Voltage". See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000). The voltage range should be approximately 0.9 - 1.3 V when EGR valve is fully closed. A. If there is less than 0.2 V, continue with Step 3. B. If the voltage is in range, the fault may be intermittent and not currently active. Continue with Step 7. 3. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the EGR valve 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 4. B. The connectors or the wiring harness has damage. Repair or replace the wiring harness or connectors as required. 4. Check the 5.0 V reference and ground reference circuit. Disconnect the wiring harness from the EGR valve. Place the key switch ON. Use a multimeter to check for voltage from the wiring harness sensor connector X-035 between pin 2 and pin 3. There should be 4.5 - 5.5 V. A. If the voltage reading is not in range, continue with Step 6. 47711684 06/05/2014

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B. If the voltage is in range, continue with Step 5. 5. Check the signal circuit. Place a jumper wire between the wiring harness sensor connector X-035 pin 2 and pin 4. Place the key switch ON. Monitor the diagnostic screen for fault code 3948 (P0406). A. If fault code 3948 is present, the sensor has failed. Replace the sensor. B. If fault code 3948 is not present, remove the jumper wire. Continue with Step 6. 6. Check the wiring harness for an open or short to low source. Place the key switch OFF. Carefully disconnect the wiring harness from the ECU. Use a multimeter to perform the following checks. Connector Connector Connector Connector Connector Connector

From X-035 pin 2 X-035 pin 4 X-035 pin 3 X-035 pin 2 X-035 pin 4 X-035 pin 3

To Connector X-002A pin 22 Connector X-002A pin 33 Connector X-002A pin 12 Chassis ground Chassis ground Chassis ground

Result There should be continuity. There should be continuity. There should be continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If the wiring harness test is good, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. B. If the wiring harness test fails, locate and repair the broken conductor. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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3950-Exhaust Gas Recirculation (EGR) valve stuck Open/Closed Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0403. The Engine Control Unit (ECU) monitors the Exhaust Gas Recirculation (EGR) motor at ECU connector X002B pin 58 and pin 45. Cause: The EGR valve is malfunctioning. Possible failure modes: 1. The EGR valve is faulty. 2. The wiring harness is faulty. 3. The ECU is faulty. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check for fault code 3974 - Exhaust Gas Recirculation (EGR) motor signal - Shorted to power or ground. A. If the fault code 3974 - Exhaust Gas Recirculation (EGR) motor signal - Shorted to power or ground is present, conduct that troubleshooting first. Then determine if this fault code has been resolved. B. If the fault code is not present, continue with Step 2. 2. Run the EGR status and active test. Use Service Tool D monitor the EGR status, see Exhaust Gas Recirculation (EGR) electrical system - Electrical test - EGR system (55.989). A. If the EGR valve test passes, continue with Step 6. B. If the EGR valve test fails, continue with Step 3. 3. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the EGR valve 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 4. B. The connectors or the wiring harness has damage. Repair or replace the wiring harness or connectors as required. 4. Inspect the EGR valve. See Exhaust Gas Recirculation (EGR) electrical system - Inspect (55.989) to inspect the EGR valve. A. If the EGR valve passes the inspection, continue with Step 5. B. If the EGR valve fails the inspection, see Exhaust Gas Recirculation (EGR) electrical system - Cleaning (55.989) . 5. Check the EGR valve harness. Place the key switch OFF. Disconnect the wiring harness from the EGR valve and the ECU.

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Use a multimeter to perform the following checks. From Connector X-035 pin 1 Connector X-035 pin 5 Connector X-035 pin 1

To Connector X-002B pin 45 Connector X-002B pin 58 Chassis ground

Connector X-035 pin 5

Chassis ground

Value There should be less than 1.0 Ω. There should be less than 1.0 Ω. There should be greater than 20,000 Ω. There should be greater than 20,000 Ω.

A. If the wiring harness test is good, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU is working properly. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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3951-Exhaust gas temperature 1 sensor - Signal too high Control Module : ECU NOTE: The exhaust gas temperature sensor 1 is also known as the Diesel Oxidation Catalyst (DOC) inlet temperature sensor. Context: When retrieving this fault code using Service Tool D, display code is P0428. The Engine Control Unit (ECU) provides a sensor reference voltage of 5.0 V from the ECU connector X-002A pin 34 and a ground reference from the ECU X-002A pin 15. The sensor resistance and signal level will vary with the exhaust gas temperature at the ECU connector X-002A pin 34. The higher the exhaust gas temperature is, the lower the resistance and signal level will be. The lower the exhaust gas temperature is, the higher the resistance and signal level will be. Cause: The ECU is sensing a signal level greater than 4.9 V in the exhaust gas temperature sensor circuit. Possible failure modes: 1. The exhaust gas temperature sensor has failed internally. 2. The exhaust gas temperature sensor circuit wiring is shorted to a high source. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the "Exhaust Gas Temperature" and "Exhaust Gas Temperature Sensor Output Voltage". See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000). 20 °C 40 °C 60 °C 80 °C

Exhaust gas temperature (68.0 °F) (104.0 °F) (140.0 °F) (176.0 °F)

Voltage output 2.2 1.3 0.7 0.4

2.5 V 1.7 V 1.0 V 0.7 V

A. If there is greater than 4.9 V, continue with Step 2. B. If the voltage is in range, the fault may be intermittent and not currently active. Continue with Step 6. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to DOC inlet temperature 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 sensor. Place the key switch OFF. Disconnect the wiring harness from the sensor. Measure the resistance from the DOC inlet temperature sensor connector from pin 1 to pin 2. Exhaust gas temperature 20 °C (68.0 °F) 40 °C (104.0 °F)

Resistance value 2.0 - 3.0 Ω 0.9 - 1.5 Ω 47711684 06/05/2014

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Exhaust gas temperature 60 °C (140.0 °F) 80 °C (176.0 °F)

Resistance value 0.4 - 0.8 Ω 0.2 - 0.4 Ω

A. If the measured resistance is within the specified range, leave the sensor connector disconnected and continue with Step 4. B. If the measured resistance is not within the specified range, the DOC inlet temperature sensor has failed internally. Replace the sensor. 4. Check the supply and ground reference circuit. Place the key switch ON. Use a multimeter to check for voltage from the wiring harness sensor connector X-016 between pin 1 to pin 2. There should be approximately 4.5 - 5.5 V. A. If the voltage reading is out of the range, continue with Step 5. B. If the voltage reading is in range, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. 5. Check the wiring harness for a short to high source. Place the key switch OFF. Carefully disconnect the wiring harness from the ECU. Place the key switch ON. Use a multimeter to check to perform the following checks. From Connector X-016 pin 1 Connector X-016 pin 2

To Chassis ground Chassis ground

Result There should be no voltage. There should be no voltage.

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3952-Exhaust gas temperature 1 sensor - Signal too low Control Module : ECU NOTE: The exhaust gas temperature sensor 1 is also known as the Diesel Oxidation Catalyst (DOC) inlet temperature sensor. Context: When retrieving this fault code using Service Tool D, display code is P0427. The Engine Control Unit (ECU) provides a sensor reference voltage of 5.0 V from the ECU connector X-002A pin 34 and a ground reference from the ECU X-002A pin 15. The sensor resistance and signal level will vary with the exhaust gas temperature at the ECU connector X-002A pin 34. The higher the exhaust gas temperature is, the lower the resistance and signal level will be. The lower the exhaust gas temperature is, the higher the resistance and signal level will be. Cause: The ECU is sensing a signal level less than 0.2 V in the Diesel Oxidation Catalyst (DOC) inlet temperature sensor circuit. Possible failure modes: 1. The DOC inlet temperature sensor has failed internally. 2. The DOC inlet temperature sensor circuit wiring is open or shorted to ground. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the "Exhaust Gas Temperature" and "Exhaust Gas Temperature Sensor Output Voltage". See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000). 20 °C 40 °C 60 °C 80 °C

Exhaust gas temperature (68.0 °F) (104.0 °F) (140.0 °F) (176.0 °F)

Voltage output 2.2 1.3 0.7 0.4

2.5 V 1.7 V 1.0 V 0.7 V

A. If there is less than 0.2 V, continue with Step 2. B. If the voltage is in range, the fault may be intermittent and not currently active. Continue with Step 6. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to DOC inlet temperature 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 sensor. Place the key switch OFF. Disconnect the wiring harness from the sensor. Measure the resistance from the DOC inlet temperature sensor connector from pin 1 to pin 2.

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20 °C 40 °C 60 °C 80 °C

Exhaust gas temperature (68.0 °F) (104.0 °F) (140.0 °F) (176.0 °F)

Resistance value 2.0 0.9 0.4 0.2

3.0 Ω 1.5 Ω 0.8 Ω 0.4 Ω

A. If the measured resistance is within the specified range, leave the sensor connector disconnected and continue with Step 4. B. If the measured resistance is not within the specified range, the DOC inlet temperature sensor has failed internally. Replace the sensor. 4. Check the supply and ground reference circuit. Place the key switch ON. Use a multimeter to check for voltage from the wiring harness sensor connector X-016 between pin 1 to pin 2. There should be approximately 4.5 - 5.5 V. A. If the voltage reading is out of the range, continue with Step 5. B. If the voltage reading is in range, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. 5. Check the wiring harness. Place the key switch OFF. Carefully disconnect the wiring harness from the ECU. Use a multimeter to check to perform the following checks. Connector Connector Connector Connector Connector

From X-016 pin 1 X-016 pin 2 X-016 pin 1 X-016 pin 2 X-016 pin 1

To Connector X-002A pin 34 Connector X-002A pin 15 Chassis ground Chassis ground Connector X-016 pin 2

Result There should be continuity. There should be continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If the wiring harness test fails, there is a short to low source in the wiring harness. Locate and repair the broken conductor. B. If the wiring harness test is good, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05)

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3953-Exhaust gas temperature 2 sensor - Signal too high Control Module : ECU NOTE: The exhaust gas temperature sensor 2 is also known as the Diesel Oxidation Catalyst (DOC) outlet temperature sensor. Context: When retrieving this fault code using Service Tool D, display code is P0438. The Engine Control Unit (ECU) provides a sensor reference voltage of 5.0 V from the ECU connector X-002A pin 35 and a ground reference from the ECU X-002A pin 15. The sensor resistance and signal level will vary with the exhaust gas temperature at the ECU connector X-002A pin 35. The higher the exhaust gas temperature is, the lower the resistance and signal level will be. The lower the exhaust gas temperature is, the higher the resistance and signal level will be. Cause: The ECU is sensing a signal level greater than 4.9 V in the exhaust gas temperature sensor circuit. Possible failure modes: 1. The DOC outlet temperature sensor has failed internally. 2. The DOC outlet temperature sensor circuit wiring is shorted to a high source. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the voltage range. 20 °C 40 °C 60 °C 80 °C

Exhaust gas temperature (68.0 °F) (104.0 °F) (140.0 °F) (176.0 °F)

Voltage output 2.2 1.3 0.7 0.4

2.5 V 1.7 V 1.0 V 0.7 V

A. If there is greater than 4.9 V, continue with Step 2. B. If the voltage is in range, the fault may be intermittent and not currently active. Continue with Step 6. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to DOC outlet temperature 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 sensor. Place the key switch OFF. Disconnect the wiring harness from the sensor. Measure the resistance from the DOC outlet temperature sensor connector from pin 1 to pin 2. Exhaust gas temperature 20 °C (68.0 °F) 40 °C (104.0 °F) 60 °C (140.0 °F)

Resistance value 2.0 - 3.0 Ω 0.9 - 1.5 Ω 0.4 - 0.8 Ω 47711684 06/05/2014

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Exhaust gas temperature 80 °C (176.0 °F)

Resistance value 0.2 - 0.4 Ω

A. If the measured resistance is within the specified range, leave the sensor connector disconnected and continue with Step 4. B. If the measured resistance is not within the specified range, the DOC outlet temperature sensor has failed internally. Replace the sensor. 4. Check the supply and ground reference circuit. Place the key switch ON. Use a multimeter to check for voltage from the wiring harness sensor connector X-017 between pin 1 to pin 2. There should be approximately 4.5 - 5.5 V. A. If the voltage reading is out of the range, continue with Step 5. B. If the voltage reading is in range, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. 5. Check the wiring harness for a short to high source. Place the key switch OFF. Carefully disconnect the wiring harness from the ECU. Place the key switch ON. Use a multimeter to perform the following checks. From Connector X-017 pin 1 Connector X-017 pin 2

To Chassis ground Chassis ground

Result There should be no voltage. There should be no voltage.

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3954-Exhaust gas temperature 2 sensor - Signal too low Control Module : ECU NOTE: The exhaust gas temperature sensor 2 is also known as the Diesel Oxidation Catalyst (DOC) outlet temperature sensor. Context: When retrieving this fault code using Service Tool D, display code is P0437. The Engine Control Unit (ECU) provides a sensor reference voltage of 5.0 V from the ECU connector X-002A pin 35 and a ground reference from the ECU X-002A pin 15. The sensor resistance and signal level will vary with the exhaust gas temperature at the ECU connector X-002A pin 35. The higher the exhaust gas temperature is, the lower the resistance and signal level will be. The lower the exhaust gas temperature is, the higher the resistance and signal level will be. Cause: The ECU is sensing a signal level less than 0.2 V in the DOC outlet temperature sensor circuit. Possible failure modes: 1. The DOC outlet temperature sensor has failed internally. 2. The DOC outlet temperature sensor circuit wiring damaged. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the voltage range. 20 °C 40 °C 60 °C 80 °C

Exhaust gas temperature (68.0 °F) (104.0 °F) (140.0 °F) (176.0 °F)

Voltage output 2.2 1.3 0.7 0.4

2.5 V 1.7 V 1.0 V 0.7 V

A. If there is less than 0.2 V, continue with Step 2. B. If the voltage is in range, the fault may be intermittent and not currently active. Continue with Step 6. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to DOC outlet temperature 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 sensor. Place the key switch OFF. Disconnect the wiring harness from the sensor. Measure the resistance from the DOC outlet temperature sensor connector from pin 1 to pin 2. Exhaust gas temperature 20 °C (68.0 °F) 40 °C (104.0 °F) 60 °C (140.0 °F)

Resistance value 2.0 - 3.0 Ω 0.9 - 1.5 Ω 0.4 - 0.8 Ω 47711684 06/05/2014

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Exhaust gas temperature 80 °C (176.0 °F)

Resistance value 0.2 - 0.4 Ω

A. If the measured resistance is within the specified range, leave the sensor connector disconnected and continue with Step 4. B. If the measured resistance is not within the specified range, the DOC outlet temperature sensor has failed internally. Replace the sensor. 4. Check the supply and ground reference circuit. Place the key switch ON. Use a multimeter to check for voltage from the wiring harness sensor connector X-017 between pin 1 to pin 2. There should be approximately 4.5 - 5.5 V. A. If the voltage reading is out of the range, continue with Step 5. B. If the voltage reading is in range, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. 5. Check the wiring harness. Place the key switch OFF. Carefully disconnect the wiring harness from the ECU. Use a multimeter to perform the following checks. Connector Connector Connector Connector Connector

From X-017 pin 1 X-017 pin 2 X-017 pin 1 X-017 pin 2 X-017 pin 1

To Connector X-002A pin 35 Connector X-002A pin 15 Chassis ground Chassis ground Connector X-017 pin 2

Result There should be continuity. There should be continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If the wiring harness test fails, locate and repair the broken conductor. B. If the wiring harness test passes, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05)

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3955-Camshaft sensor error - Invalid signal Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0341. The Engine Control Unit (ECU) receives a signal at the ECU connector X-002A pin 42, indicating the position of the camshaft sensor also known as G sensor. This signal is produced when a toothed wheel attached to the high pressure pump passes the camshaft sensor. The ECU provides a 5.0 V reference signal from the ECU connector X-002B at pin 9, and a ground reference signal from the ECU connector X-002A pin 18. Cause: The camshaft signal to the ECU is erratic. Possible failure modes: 1. The camshaft sensor has failed internally. 2. The camshaft sensor circuit wiring is damaged. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the "Cam Speed Active Flag" value. See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000).

NHIL13ENG0086AA

A. If the waveform does not compare to the graph, continue with Step 2. B. If the waveform is in range, the fault may be intermittent and not currently active. 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 camshaft 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 5.0 V and ground reference circuit. Disconnect the wiring harness from the camshaft sensor. Place the key switch ON. 47711684 06/05/2014

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From X-022 pin 1 X-022 pin 1 X-022 pin 1 X-022 pin 1

To Connector X-002A pin 42 Chassis ground Connector X-022 pin 2 Connector X-022pin 3

Result There should be continuity. There should be no continuity. There should be no continuity. There should be no continuity.

From X-022 pin 2 X-022 pin 3 X-022 pin 2 X-022 pin 3 X-022 pin 2

To Connector X-002B pin 9 Connector X-002A pin 18 Chassis ground Chassis ground Connector X-022 pin 3

Result There should be continuity. There should be continuity. There should be no continuity. There should be no continuity. There should be no continuity.

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3956-Injector 1and/or 4 - Shorted to high source Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P2148. The Engine Control Unit (ECU) has four injector driver circuits. Each of these circuits regulates an injector. Cause: The ECU has sensed the common power supply to injector 1 and injector 4 is shorted to a high source. Possible failure modes: 1. The wiring harness is faulty. 2. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the fault code is present. A. If the fault is present, continue with Step 2. B. If the fault is no longer present, the fault may be intermittent and not currently active. Continue with Step 4. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the injector 1 connector. Inspect the wiring harness from the ECU to the injector 4 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 harness or connectors as required. 3. Check the wiring harness for a short to high source. Place the key switch OFF. Disconnect the wiring harness from injector 1 connector. Disconnect the wiring harness from injector 4 connector. Disconnect the wiring harness from the ECU. Place the key switch ON. Use a multimeter to perform the following checks. From Connector X-002A pin 49 Connector X-002A pin 74 Connector X-002A pin 73 Connector X-002A pin 51

To Chassis Chassis Chassis Chassis

ground ground ground ground

Value There should be no voltage. There should be no voltage. There should be no voltage. There should be no voltage.

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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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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3957-Injector 1 and/or 4 - Shorted to low source Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P2147. The Engine Control Unit (ECU) has four injector driver circuits. Each of these circuits regulates an injector. Cause: The ECU has sensed the common power supply to injector 1 and injector 4 is shorted to a low source. Possible failure modes: 1. Injector 1 and/or 4 has failed. 2. The wiring harness is faulty. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the fault code is present. A. If the fault is present, continue with Step 2. B. If the fault is no longer present, the fault may be intermittent and not currently active. Continue with Step 5. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the injector 1 connector. Inspect the wiring harness from the ECU to the injector 4 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 harness or connectors as required. 3. Check the wiring harness for a short to low circuit. Place the key switch OFF. Disconnect the wiring harness from injector 1 connector. Disconnect the wiring harness from injector 4 connector. Disconnect the wiring harness from the ECU. Use a multimeter to check for a short to low circuit. From Connector X-002A pin 49

Chassis ground

Connector X-002A pin 74

Chassis ground

Connector X-002A pin 73

Chassis ground

Connector X-002A pin 51

Chassis ground

A. If the wiring harness test passes, continue with Step 4. 47711684 06/05/2014

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There should 20,000 Ω There should 20,000 Ω There should 20,000 Ω There should 20,000 Ω

Value be greater than be greater than be greater than be greater than

Electrical systems - FAULT CODES

B. If the wiring test fails, locate and repair the broken wiring. 4. Check the injectors. Place the key switch OFF. Disconnect the wiring harness from injector 1. Disconnect the wiring harness from injector 4. Use a multimeter to check the injectors. From Injector Injector Injector Injector

1 1 4 4

pin pin pin pin

1 2 1 2

To Chassis Chassis Chassis Chassis

ground ground ground ground

Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If injector 1 and injector 4 test passes, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU is working properly. B. If either injector test fails, locate and repair the failed injector. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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3958-Injector 1 and 4 - Open circuit Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P2146. The Engine Control Unit (ECU) has four injector driver circuits. Each of these circuits regulates an injector. Cause: The ECU has sensed the common power supply circuit to injector 1 and injector 4 is open. Possible failure modes: 1. The wiring harness is faulty. 2. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the fault code is present. A. If the fault is present, continue with Step 2. B. If the fault is no longer present, the fault may be intermittent and not currently active. Continue with Step 4. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the injector 1 connector. Inspect the wiring harness from the ECU to the injector 4 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 harness or connectors as required. 3. Check the wiring harness for an open circuit. Place the key switch OFF. Disconnect the wiring harness from the ECU. Disconnect the wiring harness from injector 1. Disconnect the wiring harness from injector 4. Use a multimeter to check for an open circuit. From Connector X-002A pin 49 Connector X-002A pin 74 Connector X-002A pin 73 Connector X-002A pin 51

Connector Connector Connector Connector

X-827 X-827 X-830 X-830

To pin pin pin pin

1 2 1 2

Value There should be less than 1.0 Ω There should be less than 1.0 Ω There should be less than 1.0 Ω There should be less than 1.0 Ω

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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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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3959-Injector 2 and/or 3 - Shorted to high source Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P2151. The Engine Control Unit (ECU) has four injector driver circuits. Each of these circuits regulates an injector. Cause: The ECU has sensed the common power supply to injector 2 and injector 3 is shorted to a high source. Possible failure modes: 1. The wiring harness is faulty. 2. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the fault code is present. A. If the fault is present, continue with Step 2. B. If the fault is no longer present, the fault may be intermittent and not currently active. Continue with Step 4. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the injector 2 connector. Inspect the wiring harness from the ECU to the injector 3 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 harness or connectors as required. 3. Check the wiring harness for a short to high source. Place the key switch OFF. Disconnect the wiring harness from injector 2. Disconnect the wiring harness from injector 3. Disconnect the wiring harness from the ECU. Use a multimeter to perform the following checks. From Connector X-002A pin 1 Connector X-002A pin 3 Connector X-002A pin 25 Connector X-002A pin 26

To Chassis Chassis Chassis Chassis

ground ground ground ground

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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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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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3960-Injector 2 and/or 3 - Shorted to low source Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P2150. The Engine Control Unit (ECU) has four injector driver circuits. Each of these circuits regulates an injector. Cause: The ECU has sensed the common power supply to injector 2 and injector 3 is shorted to a low source. Possible failure modes: 1. Injector 2 and/or 3 has failed. 2. The wiring harness is faulty. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the fault code is present. A. If the fault is present, continue with Step 2. B. If the fault is no longer present, the fault may be intermittent and not currently active. Continue with Step 5. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the injector 2 connector. Inspect the wiring harness from the ECU to the injector 3 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 harness or connectors as required. 3. Check the wiring harness for a short to low circuit. Place the key switch OFF. Disconnect the wiring harness from the ECU. Disconnect the wiring harness from injector 2. Disconnect the wiring harness from injector 3. Use a multimeter to check for a short to low circuit. From Connector X-002A pin 1 Connector X-002A pin 3 Connector X-002A pin 25 Connector X-002A pin 26

To Chassis Chassis Chassis Chassis

ground ground ground ground

A. If the wiring harness test passes, continue with Step 4. B. If the wiring test fails, locate and repair the broken wiring. 4. Check the injectors.

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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

Place the key switch OFF. Use a multimeter to check the injectors. From Injector Injector Injector Injector

2 2 3 3

pin pin pin pin

1 2 1 2

To Chassis Chassis Chassis Chassis

ground ground ground ground

Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If injector 2 and injector 3 test passes, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU is working properly. B. If either injector test fails, locate and repair the failed injector. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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3961-Injector 2 and 3 - Open circuit Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P2149. The Engine Control Unit (ECU) has four injector driver circuits. Each of these circuits regulates an injector. Cause: The ECU has sensed the common power supply circuit to injector 2 and injector 3 is open. Possible failure modes: 1. The wiring harness is faulty. 2. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the fault code is present. A. If the fault is present, continue with Step 2. B. If the fault is no longer present, the fault may be intermittent and not currently active. Continue with Step 4. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the injector 2 connector. Inspect the wiring harness from the ECU to the injector 3 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 harness or connectors as required. 3. Check the wiring harness for an open circuit. Place the key switch OFF. Disconnect the wiring harness from the ECU. Disconnect the wiring harness from injector 2. Disconnect the wiring harness from injector 3. Use a multimeter to check for an open circuit. From Connector X-002A pin 1 Connector X-002A pin 3 Connector X-002A pin 25 Connector X-002A pin 26

Connector Connector Connector Connector

X-828 X-828 X-829 X-829

To pin pin pin pin

1 2 1 2

Value There should be less than 1.0 Ω There should be less than 1.0 Ω There should be less than 1.0 Ω There should be less than 1.0 Ω

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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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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Electrical systems - FAULT CODES

3962-Supply pump control valve Suction Control Valve (SCV) stuck Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P1190. The Engine Control Unit (ECU) monitors the rail pressure signal to meter fuel to the injectors. Cause: The ECU is sensing actual pressure is excessive when compared to command pressure. Possible failure modes: 1. The pump supply is not installed correctly. 2. The pump supply has failed. 3. There is a fault in the fuel system. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the rail pressure. Rail pressure 250 - 350 bar (3625.0 - 5075.0 psi) 1400 - 2300 bar (20300.0 - 33350.0 psi)

Engine Condition Engine idling at 1,000 RPM. Accelerator to 100 %.

NHIL13ENG0089AA

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3963-Actual rail pressure above target Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P1089. The Engine Control Unit (ECU) monitors the rail pressure signal to meter fuel to the injectors. Cause: The ECU is sensing actual pressure is excessive when compared to command pressure. Possible failure modes: 1. The pump supply is not installed correctly. 2. The pump supply has failed. 3. There is a fault in the fuel system. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the rail pressure. See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000). Rail pressure 250 - 350 bar (3625.0 - 5075.0 psi) 1400 - 2300 bar (20300.0 - 33350.0 psi)

Engine Condition Engine idling at 1,000 RPM. Accelerator to 100 %.

NHIL13ENG0089AA

The signal graph should approximately match at idle, and at full acceleration. A. If the graph does not match during either check, continue with Step 2. B. If the graph is correct during the checks, the fault may be intermittent and not currently active. Continue with Step 6. 2. Check for air in the system. Replace fuel hose with a clear transparent hose. Check for air in the system. A. If air is in the system, bleed the air out of the system. B. If air is not in the system, continue with Step 3. 3. Check the fuel system. See Fuel injection system - Inspect (10.218). 47711684 06/05/2014

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Electrical systems - FAULT CODES

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3964-Actual rail pressure is excessive Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P1217. The Engine Control Unit (ECU) monitors the rail pressure signal to meter fuel to the injectors. Cause: The ECU is sensing actual pressure is excessive when compared to command pressure. Possible failure modes: 1. The pump supply is not installed correctly. 2. The pump supply has failed. 3. There is a fault in the fuel system. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the rail pressure. See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000). Rail pressure 250 - 350 bar (3625.0 - 5075.0 psi) 1400 - 2300 bar (20300.0 - 33350.0 psi)

Engine Condition Engine idling at 1,000 RPM. Accelerator to 100 %.

NHIL13ENG0089AA

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Electrical systems - FAULT CODES

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3965-Engine stop switch stuck closed Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P1530. Battery voltage is supplied to the Engine Control Unit (ECU) connector X-002A pin 81. When the engine stop signal is requested, the signal is interrupted to the ECU, and the engine will stop. Cause: The ECU is sensing the engine stop switch is ON. Possible failure modes: 1. The engine stop switch has failed. 2. The circuit wiring is faulty. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check the “Engine Stop Switch”, see Electrical system Computer support tools Overview Data Monitoring Screen (55.000). Turn the engine stop switch ON and OFF, and verify that the signals are correctly received. A. If the status is incorrect, continue with Step 2. B. If the status is correct, the fault may be intermittent and not currently active. Continue with Step 5. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the engine stop switch 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 wiring harness. Place the key switch OFF. Disconnect the wiring harness from the ECU. Place the key switch ON. Use a multimeter to perform the following checks. Switch position Normally Engine Stop Switch Request Signal

From Connector X-002A pin 81 Connector X-002A pin 81

To Chassis ground Chassis ground

Value 11.5 - 12.5 V 0 - 0.5 V

A. If the voltage reading is incorrect, continue with Step 4. B. If the voltage reading is correct, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU for proper operation. 4. Check the switch. 47711684 06/05/2014

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Use a multimeter to perform the following checks. Switch position Normally Engine Stop Switch Request Signal

From Pin 1 Pin 1

To Pin 2 Pin 2

Value Infinite resistance 0Ω

A. If the switch test is good, the wiring harness failed. Locate and repair the broken conductor. B. If the switch test fails, replace the switch. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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Electrical systems - FAULT CODES

3966-Water in fuel filter failure Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P3014. The water in fuel sensor indicates the presence of water in the fuel system. The sensor is located on the fuel filter. When the water level in the water separator reaches the warning level, the sensor sends an electrical signal to the Engine Control Unit (ECU). Cause: The ECU has sensed a high level of water in the fuel water separator. Possible failure modes: 1. The water in fuel sensor has failed. 2. The water in fuel sensor circuit is faulty. 3. The ECU has failed internally. Solution: 1. Check the fuel-water separator. A. If the water level is low, continue with Step 2. B. If the water level is high, drain out the water. Check to see if the fault code is no longer present. 2. Check the voltage to the switch. Disconnect the wiring harness from the water in fuel filter switch. Place the key switch ON. Use a multimeter to check for voltage from the sensor connector pin 1 to chassis ground. There should be approximately 11.5 - 12.5 V. A. If the voltage reading is incorrect, continue with Step 3. B. If the voltage reading is correct, replace the water in fuel sensor. 3. Check the ECU. Insert a back probe pin into ECU connector pin A80. Place the key switch ON. Use a multimeter to check for voltage from ECU connector pin A80 to chassis ground. There should be approximately 11.5 - 12.5 V. A. If the voltage is correct, there is an issue with the wiring harness. Locate and repair broken conductor. B. If the voltage is incorrect, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU is working properly. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) 47711684 06/05/2014

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Electrical systems - FAULT CODES

3967-Injector codes not written to Engine Control Unit (ECU) Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P1602. Each injector is marked with an individual code known as a Quick Response (QR) code. The QR code contains correction data for compensating for various tolerances. When an injector is replaced the QR code will need to be entered using the Service Tool D. Cause: QR code correction data not written. Possible failure modes: 1. The software could be faulty. 2. The ECU has failed internally. Solution: 1. Use the Service Tool D to verify the fault is active. Check the “QR Data” value with the “Injector Correction”. See Electrical system Computer support tools Overview — Utility (55.000). A. If the data is incorrect, continue with Step 2. B. If the data is correct, the fault may be intermittent and not currently active. Continue with Step 3. 2. Use the “Injector Correction” to write the "QR Data" value for each cylinder. A. If the data is still incorrect, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU is working properly. B. If the data is correct, the fault has been corrected. 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.

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3968-Incorrect injector codes Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P1601. Each injector is marked with an individual code known as a Quick Response (QR) code. The QR code contains correction data for compensating for various tolerances. When an injector is replaced the QR code will need to be entered using the Service Tool D. Cause: Incorrect entry of QR code data. Possible failure modes: 1. The software could be faulty. 2. The ECU has failed internally. Solution: 1. Use the Service Tool D to verify the fault is active. Read in the QR data with the "Injector Correction" utility. See Electrical system Computer support tools Overview — Utility (55.000). Verify that the data is correct by checking the QR code with the "Injector Correction." A. If the data is incorrect, continue with Step 2. B. If the data is correct, the fault may be intermittent and not currently active. Continue with Step 3. 2. Clear the fault. A. If the fault is still present, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU is working properly. B. If the fault is no longer present, the fault has been corrected. 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.

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Electrical systems - FAULT CODES

3969-Invalid injector codes Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0602. The Engine Control Unit (ECU) is an electronic device that monitors its ability to read and write memory. This allows the ECU to control, and monitor multiple sensors, actuators, and other parameters within the engine compartment. Cause: The ECU has detected the Quick Response (QR) code is faulty. Possible failure modes: 1. The software could be faulty. 2. The ECU has failed internally. Solution: 1. Use the Service Tool D to verify the fault is active. Place the key switch OFF, and then back ON. Clear the fault code. Place the key switch OFF, and then back ON. Start the engine. A. If the fault code is still active, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU is working properly. B. If the fault code 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 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

3970-Engine Control Unit (ECU) memory fault Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0606. The Engine Control Unit (ECU) is an electronic device that monitors its ability to read and write memory. This allows the ECU to control, and monitor multiple sensors, actuators, and other parameters within the engine compartment. Cause: The ECU has detected the Central Processing Unit (CPU) failed. Possible failure modes: 1. The software could be faulty. 2. The ECU has failed internally. Solution: 1. Use the Service Tool D to verify the fault is active. Place the key switch OFF, and then back ON. Clear the fault code. Place the key switch OFF, and then back ON. Start the engine. A. If the fault code is still active, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU is working properly. B. If the fault code 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 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

3971-Engine Control Unit (ECU) memory error - Verify engine dataset Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0601. The Engine Control Unit (ECU) is an electronic device that monitors its ability to read and write memory. This allows the ECU to control, and monitor multiple sensors, actuators, and other parameters within the engine compartment. Cause: The ECU has detected an internal failure. Possible failure modes: 1. The software could be faulty. 2. The ECU has failed internally. Solution: 1. Use the Service Tool D to verify the fault is active. Place the key switch OFF, and then back ON. Clear the fault code. Place the key switch OFF, and then back ON. Start the engine. A. If the fault code is still active, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU is working properly. B. If the fault code 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 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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3972-Intake throttle motor driver circuit invalid Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P2101. The Engine Control Unit (ECU) monitors the commanded and actual intake throttle position at ECU connector X-002B pin 57 and pin 44. Cause: The ECU has sensed the intake throttle motor drive circuit is not working correctly. Possible failure modes: 1. The intake throttle valve motor has failed. 2. The intake throttle valve circuit is faulty. 3. The ECU has failed internally. Solution: 1. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the intake throttle valve 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 2. B. The connectors or the wiring harness has damage. Repair or replace the wiring harness or connectors as required. 2. Check the intake throttle valve motor. Disconnect the wiring harness from the intake throttle valve. Use a multimeter to measure the resistance on the intake throttle valve motor pin 1 to pin 2. There should be approximately 0.3 - 100 Ω at 10 - 30 °C (50.0 - 86 °F). A. If the resistance is incorrect, replace the intake throttle valve body. See Electrical system Computer support tools - Overview — Utility (55.000) to initialize new throttle body. B. If the resistance is correct, continue with Step 3. 3. Check the wiring harness for a short to high source. Place the key switch OFF. Disconnect the wiring harness from the ECU. Place the key switch ON. Use a multimeter to perform the following checks. From Connector X-002B pin 44 Connector X-002B pin 57

To Chassis ground Chassis ground

A. If the wiring harness test passes, continue with Step 4. B. If the wiring test fails, locate and repair broken conductor. 4. Check the wiring harness.

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Value There should be no voltage. There should be no voltage.

Electrical systems - FAULT CODES

Place the key switch OFF. Use a multimeter to perform the following checks. From Connector X-036 pin 1 Connector X-036 pin 2 Connector X-002B pin 44 Connector X-002B pin 57 Connector X-002B pin 57

To Connector X-002B pin 44 Connector X-002B pin 57 Chassis ground Chassis ground Connector X-002B pin 44

Value There should be continuity. There should be continuity. There should be no continuity. There should be no continuity. There should be no continuity.

A. If the wiring test fails, locate and repair broken conductor. B. If the wiring harness test passes, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU is working properly. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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Electrical systems - FAULT CODES

3973-Exhaust Gas Recirculation (EGR) valve position does not match the target position Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P2413. The Engine Control Unit (ECU) monitors the Exhaust Gas Recirculation (EGR) motor at ECU connector X-002B pin 45 and pin 58. Cause: The ECU has sensed the EGR valve actual opening and target opening are off by +/- 50 %. Possible failure modes: 1. The EGR valve is faulty. 2. The wiring harness is faulty. 3. The ECU is faulty. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check for other EGR fault codes. A. If other fault codes are not present, continue with Step 2. B. If other EGR fault codes are present, conduct that troubleshooting first. Then determine if this fault code has been resolved. 2. Run the EGR status and active test. Use Service Tool D monitor the EGR status, see Exhaust Gas Recirculation (EGR) electrical system - Electrical test - EGR system (55.989). A. If the EGR valve test passes, continue with Step 5 B. If the EGR valve test fails, continue with Step 3. 3. Inspect the EGR valve. See Exhaust Gas Recirculation (EGR) electrical system - Inspect (55.989) to inspect the EGR valve. A. If the EGR valve passes the inspection, continue with Step 4. B. If the EGR valve fails the inspection, see Exhaust Gas Recirculation (EGR) electrical system - Cleaning (55.989). 4. Check the EGR valve harness. Place the key switch OFF. Disconnect the wiring harness from the EGR valve and the ECU. Use a multimeter to perform the following checks. From Connector X-035 pin 1 Connector X-035 pin 5 Connector X-035 pin 1

To Connector X-002B pin 45 Connector X-002B pin 58 Connector X-035 pin 5

Connector X-035 pin 1

Chassis ground

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Value There should be less than 1.0 Ω. There should be less than 1.0 Ω. There should be greater than 20,000 Ω. There should be greater than 20,000 Ω.

Electrical systems - FAULT CODES

From Connector X-035 pin 5

To Chassis ground

Value There should be greater than 20,000 Ω.

A. If the wiring harness test is good, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU is working properly. B. If the wiring harness test fails, locate and repair the damaged 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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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Electrical systems - FAULT CODES

3974-Exhaust Gas Recirculation (EGR) motor signal - Shorted to power or ground Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0404. The Engine Control Unit (ECU) monitors the Exhaust Gas Recirculation (EGR) motor at ECU connector X002B pin 58 and pin 45. Cause: The EGR valve is malfunctioning. Possible failure modes: 1. The EGR valve is faulty. 2. The wiring harness is faulty. 3. The ECU is faulty. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check for other fault codes related to the EGR valve. A. If other fault codes are present, conduct that troubleshooting first. Then determine if fault code P0403 - Exhaust Gas Recirculation (EGR) valve open/stuck has been resolved. B. If no other EGR valve fault codes are present, continue with Step 2. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the EGR valve 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 EGR valve harness for a short to high source. Place the key switch OFF. Disconnect the wiring harness from the EGR valve and the ECU. Place the key switch ON. Use a multimeter to perform the following checks. From Connector X-035 pin 1 Connector X-035 pin 5

To Chassis ground Chassis ground

Value There should be no voltage. There should be no voltage.

A. If the wiring harness test is good, continue with Step 4. B. If the wiring harness test fails, locate and repair the damaged conductor. 4. Check the EGR valve harness. Place the key switch OFF.

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Electrical systems - FAULT CODES

Use a multimeter to perform the following checks. From Connector X-035 pin 1 Connector X-035 pin 5 Connector X-035 pin 1

To Connector X-002B pin 45 Connector X-002B pin 58 Connector X-035 pin 2

Connector X-035 pin 5

Connector X-035 pin 4

Connector X-035 pin 1

Chassis ground

Connector X-035 pin 5

Chassis ground

Value There should be less than 1.0 Ω. There should be less than 1.0 Ω. There should be greater than 20,000 Ω. There should be greater than 20,000 Ω. There should be greater than 20,000 Ω. There should be greater than 20,000 Ω.

A. If the wiring harness test is good, continue with Step 5. B. If the wiring harness test fails, locate and repair the damaged conductor. 5. Check the EGR motor. Use a multimeter to measure the resistance of the EGR motor between pin 1 to pin 5. The resistance should be between 0.3 - 100 Ω at 10 - 30 °C (50.0 - 86 °F). A. If the resistance is correct, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU is working properly. B. If the resistance is incorrect, the motor has failed. Replace the EGR valve. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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Electrical systems - FAULT CODES

3975-Intake throttle valve stuck Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P0638. The Engine Control Unit (ECU) monitors the intake throttle position. The ECU supplies a reference voltage at ECU connector X-002A pin 24, and a ground reference at ECU connector X-002A pin 12. The intake throttle sensor sends a signal to the ECU connector X-002A pin 12. The ECU monitors the throttle valve opening and closing at connector X-002B pin 57 and pin 44. Cause: The ECU is sensing the intake throttle target angle and actual angle are out of range. Possible failure modes: 1. The intake throttle position sensor has failed. 2. The intake throttle position wiring circuit is faulty. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. Use the Service Tool D to check for other fault codes present. A. If other fault codes are present, conduct that troubleshooting first. Then determine if fault code has been resolved. B. If no other fault codes are not present, continue with Step 2. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the intake position 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. Run the intake status and active test. Use Service Tool D monitor the intake status, see Throttle Valve Actuator (TVA) - Electrical test - Intake throttle system (55.014). A. If the intake status test passes, continue with Step 9. B. If the intake status test fails, continue with Step 4. 4. Inspect the intake throttle valve. See Throttle Valve Actuator (TVA) - Inspect (55.014) to visually inspect the intake throttle valve. A. If the intake throttle valve passes the visual inspection, continue with Step 5. B. If the intake throttle valve fails the visual inspection, see Throttle Valve Actuator (TVA) - Cleaning (55.014) . 5. Check the supply and ground reference circuit. Disconnect the wiring harness from the intake throttle sensor. Place the key switch ON.

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Electrical systems - FAULT CODES

Use a multimeter to perform the following check. From Connector X-036 pin 3

To Connector X-036 pin 3

Value There should be approximately 4.5 - 5.5 V.

A. If the voltage reading is out of the range, continue with Step 7. B. If the voltage reading is in range, continue with Step 6. 6. Check the signal wire. Place a jumper wire between connector X-036 pin 3 to pin 6. Monitor the diagnostic screen for fault code 3831 (P2621). A. If fault code 3831 is not active, continue with Step 7. B. If fault code 3831 is active, continue with Step 8. 7. Check the wiring harness. Place the key switch OFF. Disconnect the wiring harness from the intake throttle valve and the ECU. Use a multimeter to perform the following checks. Connector Connector Connector Connector

From X-036 pin 3 X-036 pin 5 X-036 pin 6 X-036 pin 3

To Connector X-002A pin 12 Connector X-002A pin 24 Connector X-002A pin 63 Chassis ground

Connector X-036 pin 5

Chassis ground

Connector X-036 pin 6

Chassis ground

Connector X-036 pin 6

Connector X-036 pin 5

A. If the wiring harness test is good, see Electronic module - Electrical test Engine Control Unit (ECU) verification (55.640) to verify the ECU is working properly. B. If the wiring harness test fails, locate and repair the damaged conductor. 8. Check the wiring harness for the intake throttle valve motor. Place the key switch OFF. Disconnect the wiring harness from the ECU. Use a multimeter to perform the following checks. From Connector X-036 pin 1 Connector X-036 pin 2 Connector X-036 pin 1

To Connector X-002B pin 44 Connector X-002B pin 57 Connector X-036 pin 2

Connector X-036 pin 1

Chassis ground

Connector X-036 pin 2

Chassis ground

Value There should be less than 1.0 Ω. There should be less than 1.0 Ω. There should be greater than 20,000 Ω. There should be greater than 20,000 Ω. There should be greater than 20,000 Ω.

A. If the wiring harness test is good, the intake throttle valve sensor has failed. Replace the sensor. 47711684 06/05/2014

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B. If the wiring harness test fails, locate and repair the damaged conductor. 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. Mechanical Units Wire harnesses - Electrical schematic sheet 07 (55.100.DP-C.20.E.07) Mechanical Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06) EH Units Wire harnesses - Electrical schematic sheet 05 (55.100.DP-C.20.E.05) EH Units Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)

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Electrical systems - FAULT CODES

3976-Perform maintenance on Exhaust Gas Recirculation (EGR) timing 1-1 Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P1010. The Exhaust Gas Recirculation (EGR) system redirects the exhaust gas back into the cylinders. The exhaust gas displaces oxygen and fuel, lowering cylinder temperatures, which then lowers nitrogen oxide emissions. The Engine Control Unit (ECU) carefully meters this mixture into the cylinders (using the EGR valve) so as not to affect engine performance. Cause: The EGR valve is in need of servicing. Possible failure modes: 1. The EGR valve is dirty. Solution: 1. Use the Service Tool D to check for fault codes related to the EGR system. A. If no other fault codes are present, see Exhaust Gas Recirculation (EGR) electrical system - Cleaning (55.989). B. If other EGR valve fault codes are present, conduct that troubleshooting first. Then determine if fault code 3976 - Perform maintenance on Exhaust Gas Recirculation (EGR) timing 1-1 has been resolved.

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Electrical systems - FAULT CODES

3977-Perform maintenance on Exhaust Gas Recirculation (EGR) timing 1-2 Control Module : ECU Context: When retrieving this fault code using Service Tool D, display code is P1011. The Exhaust Gas Recirculation (EGR) system redirects the exhaust gas back into the cylinders. The exhaust gas displaces oxygen and fuel, lowering cylinder temperatures, which then lowers nitrogen oxide emissions. The Engine Control Unit (ECU) carefully meters this mixture into the cylinders (using the EGR valve) so as not to affect engine performance. Cause: The EGR valve is in need of servicing. Possible failure modes: 1. The EGR valve is dirty. Solution: 1. Use the Service Tool D to check for fault codes related to the EGR system. A. If no other fault codes are present, see Exhaust Gas Recirculation (EGR) electrical system - Cleaning (55.989). B. If other EGR valve fault codes are present, conduct that troubleshooting first. Then determine if fault code 3977 - Perform maintenance on Exhaust Gas Recirculation (EGR) timing 1-2 has been resolved.

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Index Electrical systems - 55 FAULT CODES - DTC 1004-Hydraulic Filter Restriction Switch - Hydraulic Filter Restricted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1009-Hydraulic Oil Temperature Sender - Over Temperature >210° F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1010-Battery 5V reference 1 circuit low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407 1011-Battery 5V reference 1 circuit high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409 1012-Battery 5V reference 2 circuit low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411 1013-Battery 5V reference 2 circuit high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414 1014-Vehicle system voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417 1015-Vehicle system voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419 1025-Throttle Sensor - Out Of Range Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1026-Hand Throttle Signal Out Of Range - Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 1030-Throttle Sensor - Out Of Range Short to Ground/ Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 1031-Hand Throttle Sensor - Short To Ground/ Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 1040-Engine overspeed warning, Engine speed greater than 2750 RPM for 5 seconds . . . . . . . . . . . . . . . . . . . . . 32 1041-Engine overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421 1044-Fuel level sensor below 2.0 ohm for 5 seconds, shorted low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 1045-Fuel Level Sensor Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 1051-Timeout of CAN message EEC1, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 1053-Timeout of CAN message CM1BC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 1054-Timeout of CAN message engine temperature, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . 42 1056-Timeout of CAN message DPFC1, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 1058-Timeout of CAN message EDC2BC, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 1059-Timeout of CAN message DM1, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 1201-Hydraulic oil filter switch open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 1205-Hydraulic Enable (EH Machines) - Hydraulic Enable Output, Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . 48 1212-Calibration Functions - Ground Drive Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 1213-Calibration Functions - Loader Valve Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 1214-Calibration Functions - Throttle Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 1221-Health Monitor Functions - UCM - UCM Temperature / Current Draw Over Limit (*) . . . . . . . . . . . . . . . . . . . 53 1222-Health Monitor Functions - UCM - UCM Sustained Over Temperature Limit (*) . . . . . . . . . . . . . . . . . . . . . . . 54 1223-Health Monitor Functions - UCM - UCM Sustained Over Current Limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 1224-Health Monitor Functions - UCM - Internal Memory or Core Monitoring Fault (*) . . . . . . . . . . . . . . . . . . . . . . 56 1225-Health Monitor Functions - UCM - EEPROM Memory Checksum Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 1350-Hyd Enable Switch - Implausible State (Hardwire vs CAN) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

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1532-Backup Alarm - Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 1533-Backup Alarm - Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 1816-Capacitor charge-up circuit malfunction (Insufficient charge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423 1817-Capacitor charge-up circuit malfunction (Excessive charge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425 1818-Engine Control Unit (ECU) watchdog fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427 1900-UCM - UCM Ground Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 1901-UCM - UCM Supply Voltage High (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 1902-UCM - UCM Supply Voltage Low (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 1903-UCM - UCM Supply Voltage Below Operational Limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 1904-UCM - Rail 12VB: 5V Regulators Supply Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 1905-UCM - 5VREF1 Sensor Supply Voltage Out of Range (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 1906-UCM - 5VREF3 Sensor Supply Voltage Out of Range (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 1907-UCM - Rail 12VF1: Aux Retract Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 1908-UCM - Rail 12VF2: Bucket Extend Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 1909-UCM - Rail 12VF3: Boom Raise/Lower Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 1910-UCM - Rail 12VH: Ldr Plt Interlk & Port Lock Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 1911-UCM - Rail 12VH1: Left & Right Pump Reverse Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 1912-UCM - Rail 12VM: Left & Right Brake Lights & Aux Extend Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . 88 1913-UCM - Rail 12VS1: Bucket Curl Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 1914-UCM - Rail 12VS2: Backup Alarm Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 1915-UCM - Rail 12VT1: Two Speed Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 1916-UCM - Rail 12VU1: Right & Left Pumps Forward Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 1917-UCM - Rail 12VU2: Park Brake Solenoid Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 3007-Coolant temperature sensor - Signal above range maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428 3008-Coolant temperature sensor - Signal below range minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431 3010-Intake manifold boost temperature sensor circuit - Signal above range maximum . . . . . . . . . . . . . . . . . . . . 433 3011-Intake manifold boost temperature sensor circuit - Signal below range minimum . . . . . . . . . . . . . . . . . . . . . 435 3015-Fuel temperature sensor - Signal above range maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437 3016-Fuel temperature sensor - Signal below range minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439 3019-Intake manifold boost pressure sensor circuit - Signal above range maximum . . . . . . . . . . . . . . . . . . . . . . . 442 3024-Atmospheric pressure sensor inside Engine Control Unit (ECU) - Signal above range maximum . . . . . . . 444 3025-Atmospheric pressure sensor inside Electronic Control Unit (ECU) - Signal below range minimum . . . . . 445 3037-Intake manifold boost pressure sensor circuit - Signal below range minimum . . . . . . . . . . . . . . . . . . . . . . . . 446 3088-Crank speed sensor - High voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448 3089-Crankshaft speed sensor - Invalid signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 3090-Camshaft speed sensor - No signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452 3102-Rail pressure sensor - Signal below range minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454 3112-Rail pressure sensor - Signal above range maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456 3210-Injector bank 1 circuit (Cylinder 1 and 4) - Short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458 3218-Injector bank 2 circuit (Cylinder 2 and 3) - Short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460

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3258-Starter relay circuit - Shorted to high source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462 3259-Starter relay circuit - Shorted to low source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464 3267-Engine Control Unit (ECU) fuel pump output - Shorted to high source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466 3268-Engine Control Unit (ECU) fuel pump output - Shorted to low source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468 3293-Common rail pressure exceeds hi upper limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470 3305-Common rail pressure below target pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472 3309-Common rail pressure exceeds upper limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474 3334-Controller Area Network (CAN) message not received from vehicle controller - TSC1-PE Active . . . . . . . 476 3390-Engine Air Filter Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 3691-Glow plug circuit - No load error for low voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478 3694-Glow plug circuit. - Short circuit to ground error for low voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480 3764-Engine controller main relay circuit (Terminal 30) - Early opening defect of main relay . . . . . . . . . . . . . . . . 482 3797-Differential pressure sensor - Signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484 3798-Differential pressure sensor - Signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486 3830-Intake valve position - Signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488 3831-Intake valve position - Signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 3948-Exhaust Gas Recirculation (EGR) lift sensor 1 - Signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492 3949-Exhaust Gas Recirculation (EGR) lift sensor 1 - Signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494 3950-Exhaust Gas Recirculation (EGR) valve stuck Open/Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496 3951-Exhaust gas temperature 1 sensor - Signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498 3952-Exhaust gas temperature 1 sensor - Signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 3953-Exhaust gas temperature 2 sensor - Signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502 3954-Exhaust gas temperature 2 sensor - Signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504 3955-Camshaft sensor error - Invalid signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506 3956-Injector 1and/or 4 - Shorted to high source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508 3957-Injector 1 and/or 4 - Shorted to low source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510 3958-Injector 1 and 4 - Open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512 3959-Injector 2 and/or 3 - Shorted to high source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514 3960-Injector 2 and/or 3 - Shorted to low source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516 3961-Injector 2 and 3 - Open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518 3962-Supply pump control valve Suction Control Valve (SCV) stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520 3963-Actual rail pressure above target . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522 3964-Actual rail pressure is excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524 3965-Engine stop switch stuck closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526 3966-Water in fuel filter failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528 3967-Injector codes not written to Engine Control Unit (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529 3968-Incorrect injector codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530 3969-Invalid injector codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531 3970-Engine Control Unit (ECU) memory fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532 3971-Engine Control Unit (ECU) memory error - Verify engine dataset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533 3972-Intake throttle motor driver circuit invalid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534 3973-Exhaust Gas Recirculation (EGR) valve position does not match the target position . . . . . . . . . . . . . . . . . . 536 47711684 06/05/2014

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3974-Exhaust Gas Recirculation (EGR) motor signal - Shorted to power or ground . . . . . . . . . . . . . . . . . . . . . . . 538 3975-Intake throttle valve stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540 3976-Perform maintenance on Exhaust Gas Recirculation (EGR) timing 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543 3977-Perform maintenance on Exhaust Gas Recirculation (EGR) timing 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544 4043-Hydraulic Oil Temperature Sender Short To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 4044-Hydraulic Oil Temperature Sender Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 4055-Park Brake Valve (On/Off) - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 4056-Park Brake Valve (On/Off) - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 4057-Park Brake Valve (On/Off) - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 4061-Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit (*) . . . . . . . . . . . . . . 113 4062-Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground (*) . . . . . . . . . . . 115 4071-Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit (*) . . . . . . . . . . . . . . . 117 4072-Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground (*) . . . . . . . . . . . . 119 4081-Forward Pump Control Valves (Directional) - Common Solenoid Return Short to Power (*) . . . . . . . . . . . . 121 4082-Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground (*) . . . . . . . . . . 123 4083-Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit (*) . . . . . . . . . . . . . . 125 4309-Park Brake Button - Park Brake Button Timeout (30 sec) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 4309-Park Brake Button - Park Brake Button Timeout (30 sec) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 4361-Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit (*) . . . . . . . . . . . . . . 130 4362-Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground (*) . . . . . . . . . . . 132 4371-Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit (*) . . . . . . . . . . . . . . . 134 4372-Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground (*) . . . . . . . . . . . . 136 4381-Reverse Pump Control Valves (Directional) - Common Solenoid Return Short to Power (*) . . . . . . . . . . . . 138 4382-Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground (*) . . . . . . . . . . 140 4383-Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit (*) . . . . . . . . . . . . . . 143 4401-Park Brake (Mechanical Machines) - Park Brake Solenoid - Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . 145 4402-Park Brake (Mechanical Machines) - Park Brake Solenoid - Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . 148 4431-Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) (*) . . . . . . . . . . . 150 4731-Right Swash Plate Sensor - Pin A Short to Ground/ Open Circuit Right Hand Pump Angle #1 (*) . . . . . . . 153 4732-Right Swash Plate Sensor - Pin A Short to Power Right Hand Pump Angle #1 (*) . . . . . . . . . . . . . . . . . . . . 155 4734-Right Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit Right Hand Pump Angle #2 (*) . 157 4735-Right Swash Plate Angle Sensor - Pin B Short to Power Right Hand Pump Angle #2 (*) . . . . . . . . . . . . . . 160 4737-Right Swash Plate Angle Sensor - In Range Fault Right Hand Pump Angle #1 and Right Hand Pump Angle #2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 4741-Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit Left Hand Angle #1 (*) . . . . . . . . . 165 4742-Left Swash Plate Angle Sensor - Pin A Short to Power Left Hand Angle #1 (*) . . . . . . . . . . . . . . . . . . . . . . . 167 4744-Left Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit Left Hand Pump Angle #2 (*) . . . . 169 4745-Left Swash Plate Angle Sensor - Pin B Short to Power Left Hand Pump Angle #2 (*) . . . . . . . . . . . . . . . . . 172 4747-Left Swash Plate Angle Sensor - In Range Fault Left Hand Pump Angle #1 and Left Hand Pump Angle #2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

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4752-Left Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle Left Hand Pump Angle #1 and Left Hand Pump Angle #2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 4754-Right Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle Right Hand Pump Angle #1 and Right Hand Pump Angle #2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 4781-Solenoid Valve - Solenoid Supply Open Circuit Two Speed Solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 4782-Solenoid Valve - Solenoid Supply Short to Ground Two Speed Solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . 183 4783-Solenoid Valve - Solenoid Supply Short to Power Two Speed Solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 185 4951-Hydraulic Enable (Mechanical Machines) - Hydraulic Interlock Solenoid, Short to Power (*) . . . . . . . . . . . 187 4952-Hydraulic Enable (Mechanical Machines) - Hydraulic Interlock Solenoid Open Circuit (*) . . . . . . . . . . . . . . 189 5051-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 5052-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . 193 5053-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 195 5061-Port Lock Valve (On/Off) - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 5062-Port Lock Valve (On/Off) - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 5063-Port Lock Valve (On/Off) - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 5121-Right Joystick F-B Axis - Pin A Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . 203 5122-Right Joystick F-B Axis - Pin B Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . 207 5124-Right Joystick F-B Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211 5131-Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . 216 5132-Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 5134-Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . 224 5135-Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 5137-Right Joystick R-L Axis (ISO/H Pattern) - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 5141-Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 5142-Aux Thumbwheel Axis - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 5144-Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242 5145-Aux Thumbwheel Axis - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 5147-Aux Thumbwheel Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247 5201-Left Joystick L-R Axis - Pin A Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . 250 5202-Left Joystick L-R Axis - Pin B Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . 254 5204-Left Joystick L-R Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 5211-Left Joystick F-B Axis - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 5212-Left Joystick F-B Axis - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 5214-Left Joystick F-B Axis - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 5215-Left Joystick F-B Axis - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 5217-Left Joystick F-B Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 5221-Loader Arm Valve (Directional) - Solenoid Raise A Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 284 5222-Loader Arm Valve (Directional) - Solenoid Raise A Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . 286 5231-Loader Arm Valve (Directional) - Solenoid Lower B Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . 288 5232-Loader Arm Valve (Directional) - Solenoid Lower B Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . 290 5241-Boom Valve (Directional) - Common Solenoid (C) Return Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . 292

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5242-Loader Arm Valve (Directional) - Loader Arm Solenoids Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . 294 5243-Boom Valve (Directional) - Common Solenoid (C) Return Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 296 5251-Loader Bucket Valve (Directional) - Solenoid Rollback (A) Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . 298 5252-Loader Bucket Valve (Directional) - Solenoid Rollback (A) Supply Short to Ground (*) . . . . . . . . . . . . . . . . 300 5261-Bucket Valve (Directional) - Solenoid Dump (B) Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302 5262-Bucket Valve (Directional) - Solenoid Dump (B) Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . 304 5271-Bucket Valve (Directional) - Common Solenoid (C) Return Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . 306 5272-Loader Bucket Valve (Directional) - Loader Bucket Solenoids Short to Ground (*) . . . . . . . . . . . . . . . . . . . . 308 5273-Bucket Valve (Directional) - Common Solenoid (C) Return Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 310 5281-Aux Valve (Directional) - Solenoid Forward (A) Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 5282-Aux Valve (Directional) - Solenoid Forward (A) Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 314 5291-Aux Valve (Directional) - Solenoid Reverse (B) Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316 5292-Aux Valve (Directional) - Solenoid Reverse (B) Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 318 5309-Float Button - Float Button Timeout (30 sec) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 5371-EHF Pump Control PRV's (Directional) - Forward Solenoid (A) Supply Open Circuit (*) . . . . . . . . . . . . . . . 322 5372-EHF Pump Control PRV's (Directional) - Forward Solenoid (A) Supply Short to Ground (*) . . . . . . . . . . . . 324 5381-EHF Pump Control PRV's (Directional) - Reverse Solenoid (B) Supply Open Circuit (*) . . . . . . . . . . . . . . . 326 5382-EHF Pump Control PRV's (Directional) - Reverse Solenoid (B) Supply Short to Ground (*) . . . . . . . . . . . . 328 5391-EHF Pump Control PRV's (Directional) - Solenoids Return Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . 330 5392-EHF Pump Control PRV's (Directional) - EHF Pumps Solenoids Short to Ground (*) . . . . . . . . . . . . . . . . . 333 5393-EHF Pump Control PRV's (Directional) - EHF Pumps Solenoids Short to Power (*) . . . . . . . . . . . . . . . . . . 335 5409-CAN Message Error - Aux Override Disabled Due To Aux Override Button Timeout (30 sec) (*) . . . . . . . . 338 5501-Loader Arm Spool Sensor - Sensor Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339 5502-Loader Arm Spool Sensor - Sensor Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341 5503-Hydraulic Enable (Mechanical Machines) - EH AUX Output, Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . 343 5504-Bucket Valve Spool Sensor - Sensor Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345 5505-Bucket Valve Spool Sensor - Sensor Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347 5507-Auxiliary Valve Spool Sensor - Sensor Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 5508-Auxiliary Valve Spool Sensor - Sensor Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353 5511-Loader Arm Spool Sensor - Implausible State Sensor vs. Loader Arm Command, Stuck Spool/ PRV (*) 356 5512-Bucket Valve Spool Sensor - Implausible State Sensor vs. Loader Bucket Command (*) . . . . . . . . . . . . . . 359 5513-Auxiliary Valve Spool Sensor - Implausible State Sensor vs. Auxiliary Command (*) . . . . . . . . . . . . . . . . . 361 5601-Aux Valve (Directional) - Common Solenoid Return Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364 5602-Loader Auxiliary Valve (Directional) - Loader Auxiliary Solenoids Short to Ground (*) . . . . . . . . . . . . . . . . . 367 5603-Loader Auxiliary Valve Solenoid Return Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369 5701-Pattern Switch - Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371 5703-Pattern Switch - Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374 5811-Loader Lockout Switch - Implausible State (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377 9004-Memory Error - Triple Redundant: Hour Meter - Location 1 Corrupt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380 9005-Memory Error - Triple Redundant: Hour Meter - Location 2 Corrupt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381

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9006-Memory Error - Triple Redundant: Hour Meter - Location 3 Corrupt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382 9151-CAN Connection: CAN Communication Timed Out After 5 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383 9152-CAN Connection - CAN Communication Timed Out After 5 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384 9153-CAN Connection - EEC1 Message Timed Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385 9154-CAN Connection - TSC1 Message Timed Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386 9156-Hyd Enable Switch - Hyd Enable Button Error from AIC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387 9158-H-Pattern Indicator Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388 9159-ISO-Pattern Indicator Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390 9160-H-Pattern Indicator Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392 9161-ISO-Pattern Indicator Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395 9401-Memory Error - Double Redundant: Memory Corruption Detected and Repaired . . . . . . . . . . . . . . . . . . . . . 398 9403-Memory Error - Double Redundant: Unrecoverable Memory Corruption Operable . . . . . . . . . . . . . . . . . . . 399 9404-Memory Error - Triple Redundant: Hour Meter - Hour Meter Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401 9405-CAN - DM1 (EH Machines): Loss Of DM1 Message From UCM (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402 9406-CAN - Can Communication Lost (EH Machines): Loss Of All CAN Communication From UCM (*) . . . . . 403 9407-Memory Error - ID Errors: Unrecoverable Hardware ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404 9408-Memory Error - ID Errors: Unrecoverable Panel ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405 9410-Loss of EGR inducement status message from EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406

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

47711684 06/05/2014 EN

SERVICE MANUAL Front loader and bucket L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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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

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Front loader and bucket - 82 Arm - 100

SERVICE Arm Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Front loader and bucket - Arm

Arm - Remove L218 L220

WE WE

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. Lower the loader arm down on the pins. 2. Remove the engine area body panels (1).

RAPH12SSL0312AA

RAPH12SSL0326AA

RAPH12SSL0325AA

3. Remove the auxiliary hoses hold-down clamp (1) located on the loader arm link.

4. Remove the bucket cylinder hoses hold-down clamp (1) located on the loader arm link.

5. Raise the loader arm, and release loader arm lock pins. Carefully lower the loader arms. 47711684 06/05/2014

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Front loader and bucket - Arm

6. Place a suitable lifting device on the bucket end of the loader arm.

RAPH12SSL0314AA

RAPH12SSL0323AA

RAPH12SSL0316AA

7. Disconnect, label, and cap off the auxiliary hoses (2). 8. Remove the horn (1). 9. Disconnect and cap off the hydraulic coupler hoses (3) (if applicable).

10. Pull the hydraulic coupler hoses through the loader arm (if applicable).

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Front loader and bucket - Arm

11. Disconnect, label, and cap off the bucket cylinder hoses (1).

RAPH12SSL0313AA

RAPH12SSL0320AA

RAPH12SSL0315AA

12. Remove the loader arm cylinder hardware (1), and disconnect the loader arm cylinders from the loader arm.

13. Support the loader arm link with a suitable lifting device.

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Front loader and bucket - Arm

14. Support the loader arm with a suitable lifting device , and remove the loader arm link hardware (1).

RAPH12SSL0324AA

RAPH12SSL0322AA

RAPH12SSL0321AA

15. Remove the loader arm link hardware (1).

16. Carefully remove the loader arm link.

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Front loader and bucket - Arm

17. Support the loader arm with a suitable lifting device.

RAPH12SSL0319AA

RAPH12SSL0318AA

RAPH12SSL0317AA

18. Remove the loader arm hardware (1) , and lower the loader arm links (2).

19. Carefully remove the loader arm.

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Front loader and bucket - Arm

Arm - Install L218 L220

WE WE

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 installation position.

RAPH12SSL0317AA

RAPH12SSL0318AA

RAPH12SSL0321AA

2. Apply LOCTITE® SILVER GRADE ANTI-SEIZE 767 to the tapered area of the pins and bosses. Carefully place the loader arm link into installation position. Install the loader arm link hardware (1).

3. Carefully place the loader arm link into installation position.

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Front loader and bucket - Arm

4. Apply LOCTITE® SILVER GRADE ANTI-SEIZE 767 to the tapered area of the pins and bosses. Install the loader arm hardware (1). Tighten the link bolt (1) to a torque of 645 - 873 N·m (476 - 644 lb ft).

RAPH12SSL0324AA

RAPH12SSL0322AA

RAPH12SSL0320AA

5. Install the loader arm link hardware (1).

6. Connect the loader arm cylinders to the loader arm. Install the loader arm cylinder hardware (1).

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Front loader and bucket - Arm

7. Push the hydraulic coupler hoses through the loader arm (if applicable).

RAPH12SSL0316AA

RAPH12SSL0323AA

RAPH12SSL0313AA

8. Connect the auxiliary hoses (2). 9. Install the horn (1). 10. Connect the hydraulic coupler hoses (3) (if applicable).

11. Connect the bucket cylinder hoses (1).

12. Remove the lifting device. 13. Raise the loader arm, and engage the loader arm lock pins.

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Front loader and bucket - Arm

14. Install the bucket cylinder hoses hold-down clamp (1) located on the loader arm link.

RAPH12SSL0325AA

RAPH12SSL0326AA

RAPH12SSL0312AA

15. Install the auxiliary hoses hold-down clamp (1) located on the loader arm link.

16. Install the engine area body panels (1).

17. Raise the loader arm, and release loader arm lock pins. Carefully lower the loader arms. 18. Grease all grease points on the loader arm.

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Index Front loader and bucket - 82 Arm - 100 Arm - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Arm - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Front loader and bucket - 82 Bucket - 300

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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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 Cutting edge - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Bucket release device Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Quick coupler Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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Front loader and bucket - Bucket

Bucket - General specification L218 L220

WE WE

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 L218 L220

WE WE

BS04E150

Mechanical coupling mounting plate assembly (1) Mounting Plate (2) Left Hand Handle (3) Dust Cap

(7) Latch Pin (8) Plug (9) Clip

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(13) Pin (14) Bolt (15) Right Hand Handle

Front loader and bucket - Bucket

(4) Grease Zerk (5) Plate (6) Spring Pin

(10) Pin (11) Compression Spring (12) Guide

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(16) Pin (17) Bushing

Front loader and bucket - Bucket

Bucket Cutting edge - Replace L218 L220

WE WE

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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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). 47711684 06/05/2014

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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 L218 L220

WE WE

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. At this point you can relieve the pressure in the system. See Hydraulic systems - Depressurising (35.000). 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 three and four for 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 six for the left hand side. 8. Coupler is now unattached from the machine.

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Front loader and bucket - Bucket

Bucket release device - Disassemble L218 L220

WE WE

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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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 L218 L220

WE WE

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

931001788

2. Install the assembled unit (1) through the inside of the coupler (2).

3. While supporting the coupler handle in place, install pivot pin (1).

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4. Install clip (1) on backside of pivot pin.

931001790

86092922

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 L218 L220

WE WE

NOTE: The images in these instructions may not be the actual model being worked on. All models have the same concept. 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. Tighten hardware. 3. Repeat step two 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, securing the pin to the coupler. 7. Repeat steps five and six 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 L218 L220

WE WE

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

NOTE: The images in these instructions may not be the actual model being worked on. All models have the same concept. 1. 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. At this point you can relieve the pressure in the system. See Hydraulic systems - Depressurising (35.000).

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Front loader and bucket - Bucket

3. On the right 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 couple. This will remove the tilt cylinder from the coupler.

20111348

20111349

931002057

5. Repeat steps three and four for the left hand side. 6. Mark the hoses and ports on the valve accordingly. This will help in reinstalling the hoses to the proper ports. Remove the two hoses (1) from the hydraulic valve (2). Plug or cap the valve ports and the hose ends. This will keep the hydraulic system from getting contaminated.

7. Remove the hardware (1) from the pivot pin (2) securing the coupler to the machine. Remove the pivot pin from the machine. 8. Repeat step seven for the left hand side. 9. Coupler is now unattached from the machine.

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Front loader and bucket - Bucket

Quick coupler - Install L218 L220

WE WE

931002057

20111348

20111349

4. Extend the tilt cylinders until they align with the top holes of the coupler. 5. 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. 6. Install the hardware (1) to the pin locking plate, securing the pin to the coupler. 7. Repeat steps five and six for the left hand side of the machine.

8. 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.

9. Start the machine and cycle through the positions of the coupler to bleed the system of air.

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Index Front loader and bucket - 82 Bucket - 300 Bucket - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Bucket Cutting edge - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Bucket release device - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Bucket release device - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Bucket release device - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Bucket release device - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Bucket release device - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Quick coupler - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Quick coupler - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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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 Platform, cab, bodywork, and decals L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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Contents Platform, cab, bodywork, and decals - 90

[90.154] Cab doors and hatches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1

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Platform, cab, bodywork, and decals - 90 Cab doors and hatches - 154

L218 TIER 4 [NEM476231 - ] L220 TIER 4 [NEM475087 - ]

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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 L218 L220

WE WE

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 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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SPECIAL TOOL INDEX Genuine CAS10162A [Portable Filter Caddy] CAS1871 [Seal Press] CAS10192 [Vacuum Pump] CAS1871 [Seal Press] CAS10508 [Fitting Kit For Unions] CAS1871 [Seal Press] CAS1871 [Seal Press] CAS10193 [ Kit For Vacuum Pump]

Kit

Reference

PAGE

Hydraulic systems - Cleaning

35.1 / 19

Hydraulic Hydraulic Hydraulic Hydraulic

35.1 35.1 35.1 35.1

systems systems systems systems

Cleaning Cleaning Cleaning Cleaning

Hydraulic systems - Cleaning Oil reservoir - Apply vacuum Oil reservoir - Apply vacuum

Reference

CAS10899 [Nitrogen Charging Accumulator - Discharging Kit Complete]

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19 19 19 20

35.1 / 20 35.4 / 3 35.4 / 3

PAGE 35.8 / 30

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