48050419D Linked PDF

Service Manual
845B VHP
845B VHP 865B VHP
865B VHP 885B VHP
885B VHP
865B AWD
865B AWD
885B AWD 885B AWD
Motor Graders Motor Graders
1/1
Part Number
48050419D
Service Manual
4th Edition
English 10/2017
Part Number
Printed in Brazil 48050419D
Copyright © 2017 – CNH Industrial Brasil Ltda. 4th Edition
All Rights Reserved. English 10/2017
SERVICE MANUAL
845B Direct drive transmission, Tier 3, made in Brazil [HBZN0845VBAF00184

- ], 845B Torque converter transmission, Tier 3, made in Brazil
[HBZN0845VCAF01093 - ], 865B Direct drive transmission, Tier 3, made in
Brazil [NBAF15000 - ], 865B Torque converter transmission, Tier 3,made in
Brazil [NBAF14004 - ], 865B AWD Direct drive transmission, All wheel drive
(AWD), Tier 3, made in Brazil [HBZN0865TBAF00840 - ], 885B Direct drive
transmission, Tier 3, made in Brazil [HBZN0885LBAF00098 - ], 885B Torque
converter transmission, Tier 3, made in Brazil [HBZN0885PCAF00871 - ],
885B AWD Direct drive transmission, All wheel drive (AWD), Tier 3, made
in Brazil [HBZN0885TBAF00558 - ]
48050419D 06/10/2017
EN
Link Product / Engine
Product Market Product Engine

845B Transmissão de acionamento Australia New Zealand F4HE9687W*J101
direto, Tier 3, produzido no Brasil
[HBZN0845VBAF00184 - ]
845B Transmissão de acionamento Latin America F4HE9687W*J101
[HBZN0845VBAF00184 - ]
845B Transmissão de acionamento Asia Pacific F4HE9687W*J101
[HBZN0845VBAF00184 - ]
845B Transmissão de acionamento Middle East Africa F4HE9687W*J101
[HBZN0845VBAF00184 - ]
845B Transmissão de acionamento North America F4HE9687W*J101
[HBZN0845VBAF00184 - ]
845B Transmissão do conversor Australia New Zealand F4HE9687W*J101
de torque, Tier 3, produzido no
Brasil [HBZN0845VCAF01093 - ]
845B Transmissão do conversor North America F4HE9687W*J101
845B Transmissão do conversor Latin America F4HE9687W*J101
845B Transmissão do conversor Asia Pacific F4HE9687W*J101
845B Transmissão do conversor Middle East Africa F4HE9687W*J101
865B Transmissão de acionamento Latin America F4HE9687C*J100
[NBAF15000 - ]
865B Transmissão de acionamento Australia New Zealand F4HE9687C*J100
[NBAF15000 - ]
865B Transmissão de acionamento Asia Pacific F4HE9687C*J100
[NBAF15000 - ]
865B Transmissão de acionamento Middle East Africa F4HE9687C*J100
[NBAF15000 - ]
865B Transmissão de acionamento North America F4HE9687C*J100
[NBAF15000 - ]
865B Transmissão do conversor Asia Pacific F4HE9687C*J100
Brasil [NBAF14004 - ]
48050419D 06/10/2017
Product Market Product Engine
865B Transmissão do conversor North America F4HE9687C*J100
865B Transmissão do conversor Australia New Zealand F4HE9687C*J100
865B Transmissão do conversor Middle East Africa F4HE9687C*J100
865B Transmissão do conversor Latin America F4HE9687C*J100
865B AWD Transmissão de North America F4HE9687C*J100
acionamento direto, tração
em todas as rodas (AWD),
Tier 3, produzido no Brasil
[HBZN0865TBAF00840 - ]
885B Transmissão de acionamento Middle East Africa F4HE9684L*J100
[HBZN0885LBAF00098 - ]
885B Transmissão de acionamento Latin America F4HE9684L*J100
[HBZN0885LBAF00098 - ]
885B Transmissão de acionamento North America F4HE9684L*J100
[HBZN0885LBAF00098 - ]
885B Transmissão de acionamento Asia Pacific F4HE9684L*J100
[HBZN0885LBAF00098 - ]
885B Transmissão de acionamento Australia New Zealand F4HE9684L*J100
[HBZN0885LBAF00098 - ]
885B Transmissão do conversor Australia New Zealand F4HE9687K*J105
Brasil [HBZN0885PCAF00871 - ]
885B Transmissão do conversor Middle East Africa F4HE9687K*J105
885B Transmissão do conversor Latin America F4HE9687K*J105
885B Transmissão do conversor North America F4HE9687K*J105
885B Transmissão do conversor Asia Pacific F4HE9687K*J105
885B AWD Transmissão de North America F4HE9684L*J100
acionamento direto, tração
em todas as rodas (AWD),
Tier 3, produzido no Brasil
[HBZN0885TBAF00558 - ]
48050419D 06/10/2017
Contents
INTRODUCTION
Transmission.............................................................................. 21
[21.113] Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
[21.135] Powershift transmission external controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2
[21.105] Powershift transmission hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3
[21.155] Powershift transmission internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4
[21.700] Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5
[21.900] Hydraulic pump drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.6
Front axle system ....................................................................... 25

[25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1
[25.400] Non-powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2
Rear axle system........................................................................ 27

[27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1
[27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2
[27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3
Brakes and controls .................................................................... 33

[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1
Hydraulic systems....................................................................... 35
[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1
Frames and ballasting ................................................................. 39

[39.100] Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1
[39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.2
Steering..................................................................................... 41
[41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1
Cab climate control ..................................................................... 50

[50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1
48050419D 06/10/2017
[50.104] Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2
[50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.3
Electrical systems ....................................................................... 55

[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1
[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
[55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5
[55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
[55.024] Transmission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7
[55.051] Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls. . . . . . . . . . . . . . . . . . . 55.8
[55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . . . 55.9
[55.020] Transmission speed sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10
[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11
Dozer blade and arm................................................................... 86

[86.110] Dozer blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.1
Tools ......................................................................................... 89
[89.128] Ripper assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.1
48050419D 06/10/2017
48050419D 06/10/2017
INTRODUCTION
48050419D 06/10/2017
1
Contents
INTRODUCTION
Safety rules - Batteries (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Variable displacement pump - Safety rules (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Torque - Minimum tightening torques for normal assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Maintenance chart and Lubrication (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Consumables (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Consumables (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Consumables (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Conversion factors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
(*) See content for specific models

48050419D 06/10/2017
2
INTRODUCTION
Safety rules - Batteries

845B
865B
885B
WARNING
Improper operation or service of this machine can result in an accident.
Before working on any component(s) of the electrical circuit, put the starter switch key in the off (shut
down) position. When disconnecting batteries, always disconnect the negative (-) cable first. When
reconnecting batteries, always connect the negative (-) cable last.
Failure to comply could result in death or serious injury.
W0264A
WARNING
Electrical shock hazard!
Before working on any part of the electrical system, disconnect the battery ground cable. Complete
all electrical work before connecting the cable.
W0129A
WARNING
Battery gas can explode!
To prevent an explosion: 1. Always disconnect the negative (-) battery cable first. 2. Always connect
the negative (-) battery cable last. 3. Do not short circuit the battery posts with metal objects. 4. Do
not weld, grind, or smoke near a battery.
W0011A
WARNING
Explosion hazard!
When jump-starting the machine, connect and disconnect the jumper cables exactly as indicated in
this manual. DO NOT connect the jumper cables to the machine battery terminals. Make sure no
persons are near the connecting points before starting the engine. Start the engine from the operator’s
seat.
W0342A
WARNING
Explosive gas!
Batteries emit explosive hydrogen gas and other fumes while charging. Ventilate the charging area.
Keep the battery away from sparks, open flames, and other ignition sources. Never charge a frozen
battery.
W0005A
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.
W0006A
48050419D 06/10/2017
3
INTRODUCTION
WARNING
Battery gas can explode!
To prevent an explosion: 1. Always disconnect the negative (-) battery cable first. 2. Always connect
the negative (-) battery cable last. 3. Do not short circuit the battery posts with metal objects. 4. Do
not weld, grind, or smoke near a battery.
W0011A
WARNING
Explosion hazard!
If battery electrolyte is frozen, attempting to charge the battery or jump-start the engine can cause the
battery to explode. Always keep batteries at full charge to prevent frozen battery electrolyte. Never
charge a frozen battery.
W0203A
WARNING
Improper operation or service of this machine can result in an accident.
An error connecting auxiliary starting cables or short-circuiting battery terminals can cause an acci-
dent. Connect auxiliary starting cables as instructed in this manual.
W0263A
WARNING
Explosion hazard!
Batteries emit explosive gases. Always ventilate when using in an enclosed area or when charging.
Keep the battery away from sparks, open flames, and other ignition sources.
W0369A
WARNING
Eye injury hazard!
Wear eye protection when jump-starting the machine and when charging the battery.
W0382A
WARNING
Chemical hazard!
Battery acid can cause severe burns. Some batteries have a ventilation tube. If there is battery acid
in the tube, this acid can be released when the battery is turned upside down. If you turn the battery
upside down, point the ventilation tube away from you and any other people in the area.
W1084A
48050419D 06/10/2017
4
INTRODUCTION
Variable displacement pump - Safety rules

845B ANZ --- APAC --- LA --- MEA --- NA
865B AWD Direct drive transmission, All wheel drive (AWD), Tier 3, made NA
Personal safety
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible death or injury.
Throughout this manual and on machine safety signs, you will find the signal words DANGER, WARNING, and CAU-
TION 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. The color
associated with DANGER is RED.
WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury. The color
associated with WARNING is ORANGE.
CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury. The
color associated with CAUTION is YELLOW.
FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT

IN DEATH OR SERIOUS INJURY.
Machine safety
NOTICE: Notice indicates a situation that, if not avoided, could result in machine damage or property damage. The
color associated with Notice is BLUE.
Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine dam-
age 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.
48050419D 06/10/2017
5
INTRODUCTION
Torque - Minimum tightening torques for normal assembly

METRIC NON-FLANGED HARDWARE

NOM. LOCKNUT LOCKNUT
SIZE CL.8 CL.10
CLASS 8.8 BOLT and CLASS 10.9 BOLT and W/CL8.8 W/CL10.9
CLASS 8 NUT CLASS 10 NUT BOLT BOLT
PLATED PLATED
UNPLATED UNPLATED
W/ZnCr W/ZnCr
2.2 N·m (19 lb 2.9 N·m (26 lb 3.2 N·m (28 lb 4.2 N·m (37 lb 2.9 N·m (26 lb
M4 2 N·m (18 lb in)
in) in) in) in) in)
4.5 N·m (40 lb 5.9 N·m (52 lb 6.4 N·m (57 lb 8.5 N·m (75 lb 5.8 N·m (51 lb
M5 4 N·m (36 lb in)
in) in) in) in) in)
7.5 N·m (66 lb 10 N·m (89 lb 11 N·m (96 lb 15 N·m (128 lb 6.8 N·m (60 lb 10 N·m (89 lb
M6
in) in) in) in) in) in)
18 N·m (163 lb 25 N·m (217 lb 26 N·m (234 lb 35 N·m (311 lb 17 N·m (151 lb 24 N·m (212 lb
M8
49 N·m (36 lb 70 N·m (51 lb 33 N·m (25 lb 48 N·m (35 lb
M10 37 N·m (27 lb ft) 52 N·m (38 lb ft)
ft) ft) ft) ft)
M12 64 N·m (47 lb ft) 91 N·m (67 lb ft)
ft) ft) ft) ft)
158 N·m (116 lb 210 N·m 225 N·m (166 lb 301 N·m (222 lb 143 N·m (106 lb 205 N·m (151 lb
M16
ft) (155 lb ft) ft) ft) ft) ft)
319 N·m (235 lb 425 N·m 440 N·m (325 lb 587 N·m (433 lb 290 N·m (214 lb 400 N·m (295 lb
M20
ft) (313 lb ft) ft) ft) ft) ft)
551 N·m (410 lb 735 N·m 762 N·m (560 lb 1016 N·m 501 N·m (370 lb 693 N·m (510 lb
M24
ft) (500 lb ft) ft) (750 lb ft) ft) ft)
NOTE: M4 through M8 hardware torque specifications are shown in pound-inches. M10 through M24 hardware torque
specifications are shown in pound-feet.
48050419D 06/10/2017
6
INTRODUCTION
METRIC FLANGED HARDWARE

NOM. CLASS 8.8 BOLT and CLASS 10.9 BOLT and LOCKNUT LOCKNUT
SIZE CLASS 8 NUT CLASS 10 NUT CL.8 CL.10
W/CL8.8 W/CL10.9
BOLT BOLT
PLATED PLATED
UNPLATED UNPLATED
W/ZnCr W/ZnCr
2.4 N·m (21 lb 3.2 N·m (28 lb 3.5 N·m (31 lb 4.6 N·m (41 lb 2.2 N·m (19 lb 3.1 N·m (27 lb
M4
4.9 N·m (43 lb 6.5 N·m (58 lb 7.0 N·m (62 lb 9.4 N·m (83 lb 4.4 N·m (39 lb 6.4 N·m (57 lb
M5
8.3 N·m (73 lb 11 N·m (96 lb 12 N·m (105 lb 16 N·m (141 lb 7.5 N·m (66 lb 11 N·m (96 lb
M6
M8
54 N·m (40 lb 77 N·m (56 lb
M10 40 N·m (30 lb ft) 57 N·m (42 lb ft) 37 N·m (27 lb ft) 53 N·m (39 lb ft)
ft) ft)
93 N·m (69 lb 100 N·m (74 lb 134 N·m (98 lb
M12 70 N·m (52 lb ft) 63 N·m (47 lb ft) 91 N·m (67 lb ft)
ft) ft) ft)
M16
ft) ft) ft) ft) ft) ft)
M20
ft) ft) ft) ft) ft) ft)
607 N·m (447 lb 809 N·m (597 lb 838 N·m (618 lb 1118 N·m 552 N·m (407 lb
M24
ft) ft) ft) (824 lb ft) ft)
IDENTIFICATION
Metric Hex head and carriage bolts, classes 5.6 and up
20083680 1
1. Manufacturer's Identification
2. Property Class
Metric Hex nuts and locknuts, classes 05 and up
20083681 2
48050419D 06/10/2017
7
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

LOCKNUT LOCKNUT
NOMINAL SAE GRADE 5 BOLT SAE GRADE 8 BOLT
GrB W/ Gr5 GrC W/ Gr8
SIZE and NUT and NUT
BOLT BOLT
UN-
UN-
PLATED PLATED PLATED
PLATED
or W/ZnCr W/ZnCr
or PLATED
PLATED GOLD GOLD
SILVER
SILVER
8 N·m (71 lb 11 N·m (97 lb 12 N·m 16 N·m 12.2 N·m (109 lb
1/4 8.5 N·m (75 lb in)
in) in) (106 lb in) (142 lb in) in)
17 N·m 23 N·m 24 N·m 32 N·m 17.5 N·m (155 lb 25 N·m (220 lb
5/16
(150 lb in) (204 lb in) (212 lb in) (283 lb in) in) in)
30 N·m (22 lb 40 N·m 43 N·m (31 lb 57 N·m (42 lb
3/8 31 N·m (23 lb ft) 44 N·m (33 lb ft)
ft) (30 lb ft) ft) ft)
48 N·m (36 lb 65 N·m 68 N·m (50 lb 91 N·m (67 lb
7/16 50 N·m (37 lb ft) 71 N·m (53 lb ft)
ft) (48 lb ft) ft) ft)
74 N·m (54 lb 98 N·m 104 N·m 139 N·m 108 N·m (80 lb
1/2 76 N·m (56 lb ft)
ft) (73 lb ft) (77 lb ft) (103 lb ft) ft)
107 N·m 142 N·m 150 N·m 201 N·m 156 N·m (115 lb
9/16 111 N·m (82 lb ft)
(79 lb ft) (105 lb ft) (111 lb ft) (148 lb ft) ft)
147 N·m 196 N·m 208 N·m 277 N·m 153 N·m (113 lb 215 N·m (159 lb
5/8
(108 lb ft) (145 lb ft) (153 lb ft) (204 lb ft) ft) ft)
3/4
7/8
1
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.
48050419D 06/10/2017
8
INTRODUCTION
INCH FLANGED HARDWARE

NOM- LOCKNUT LOCKNUT
SAE GRADE 5 BOLT and SAE GRADE 8 BOLT and
INAL GrF W/ Gr5 GrG W/ Gr8
NUT NUT
SIZE BOLT BOLT
UNPLATED PLATED UNPLATED PLATED
or PLATED W/ZnCr or PLATED W/ZnCr
SILVER GOLD SILVER GOLD
1/4 9 N·m (80 lb in) 8 N·m (71 lb in)
in) in) in) in)
5/16
3/8 30 N·m (22 lb ft) 43 N·m (32 lb ft)
ft) ft) ft) ft)
7/16 48 N·m (35 lb ft) 68 N·m (50 lb ft)
ft) ft) ft) ft)
81 N·m (60 lb 108 N·m (80 lb 115 N·m (85 lb 153 N·m 104 N·m (77 lb
1/2 74 N·m (55 lb ft)
ft) ft) ft) (113 lb ft) ft)
117 N·m (86 lb 156 N·m 165 N·m 221 N·m 157 N·m (116 lb
9/16 106 N·m (78 lb ft)
ft) (115 lb ft) (122 lb ft) (163 lb ft) ft)
162 N·m (119 lb 216 N·m 228 N·m 304 N·m 147 N·m (108 lb 207 N·m (153 lb
5/8
ft) (159 lb ft) (168 lb ft) (225 lb ft) ft) ft)
3/4
7/8
1
IDENTIFICATION
Inch Bolts and free-spinning nuts
20083682 3
Grade Marking Examples
SAE Grade Identification

1 Grade 2 - No Marks 4 Grade 2 Nut - No Marks
2 Grade 5 - Three Marks 5 Grade 5 Nut - Marks 120° Apart
3 Grade 8 - Five Marks 6 Grade 8 Nut - Marks 60° Apart
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INTRODUCTION
Inch Lock Nuts, All Metal (Three optional methods)
20090268 4
Grade Identification
Grade Corner Marking Method (1) Flats Marking Method (2) Clock Marking Method (3)
Grade A No Notches No Mark No Marks
Grade B One Circumferential Notch Letter B Three Marks
Grade C Two Circumferential Notches Letter C Six Marks
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INTRODUCTION
Maintenance chart and Lubrication

845B ANZ (6 x 3 torque converter) OR (Tier 1) --- APAC (6 x 3 torque converter)
OR (Tier 1) --- LA (6 x 3 torque converter) OR (Tier 1) --- MEA (6 x 3 torque
converter) OR (Tier 1)
865B ANZ (6 x 3 torque converter) OR (Tier 2) OR (Tier 0) --- APAC (6 x 3 torque
converter) OR (Tier 2) OR (Tier 0) --- LA (6 x 3 torque converter) OR (Tier 2)
OR (Tier 0) --- MEA (6 x 3 torque converter) OR (Tier 2) OR (Tier 0)
885B ANZ (8 x 8 direct drive) OR (Tier 2) OR (Tier 0) --- APAC (8 x 8 direct drive)
OR (Tier 2) OR (Tier 0) --- LA (8 x 8 direct drive) OR (Tier 2) OR (Tier 0) ---
MEA (8 x 8 direct drive) OR (Tier 2) OR (Tier 0)
SERVICE POINTS A B C D E F
Air cleaner (Note 1) 1 AR
As Required Hydraulic filter (Note 2) 1 AR
(AR) Cab Air Filter (if equipped) 1 AR
Batteries (See Electrical System) 2 AR
Engine oil level (including filters) 1 10
Radiator (coolant level) (Note 3) 1 10
10 hours
or daily Transmission Oil Level (warm, engine running)
1 10
(Transmission )
Differential Lock Oil Filter (if equipped) 1 10
50 hours Fuel Reservoir Filter (wash screen) 1 50
or every Fuel Water Separator (drain water) 2 50
week Hydraulic tank (complete system) 1 50
Moldboard Lift Cylinder Pivots 4 100
Moldboard Lift Cylinders Balls 2 100
Moldboard Side Shift Cylinders Balls 2 100
100 hours
Articulation of Tilt Cylinders 2 100
or every
15 days Moldboard Tilt Pivots 2 100
Articulation Cylinders Pivots 4 100
Articulation Bearings 2 100
Drawbar Ball and Socket 1 100
Alternator and Air Conditioner Belt 2 250
Universal Joints and Drive Shaft 2 250
Circle Turn Gearbox Oil Level 1 250
Front Axle Articulation Pin 2 250
Front Wheel Lean Bar Pivots 2 250
Front Wheel Lean Cylinder Pivots 2 250
250 hours Front Wheel Knuckle Lean Pivots 4 250
or every Knuckle King Pin Bearings 4 250
1 month Moldboard Lift Cylinder Articulation Bearings 2 250
Tandem Swing Bearing 2 250
Tires Condition and Pressure 6 250
Cab Air Filter (if equipped) 1 250
Steering Bar Ball Joints 4 250
Moldboard Articulation Pivots 4 250
Moldboard Side Shift Terminal Pivots 2 250
Engine Oil and Oil Filter 2 250
A – Points / B – Check / C – Change / D – Lubricate / E – Adjust / F – Clean / Drain
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INTRODUCTION
Fuel Filters and Water Separator 2 500
Fuel Tank Drain Plug (drain sediment) 1 500
Hydraulic System Oil Filter 1 500
Transmission Oil Filter (Note 4) (Transmission ) 1 500
500 hours Transmission Oil Filter (Transmission ) 2 500
or every Front Wheel Bearing Grease 2 500
3 months Tandem Wheel Shafts Bearings (Graziano) 8 500
Tandem Case Oil Level 2 500
Rear Axle Differential and Planetary Gear Oil Level (Graziano) 1 500
ROPS Fixing Bolts Torque 16 500
Seat Belts Fixing Bolts Torque 2 500
Transmission Screen (Transmission ) 1 1000
Transmission Oil (Note 4) (Transmission ) 1 1000
Transmission Oil (Transmission ) 1 1000
1000 hours
Engine Valves Clearance 12 1000
or every
6 months Circle Turn Gear Housing Oil 1 1000
Alternator and Air Conditioning Belts 2 1000
Air Cleaner Elements (See Air Cleaner System) 2 1000
Tandem Case Oil 2 1000
Rear Axle Differential and Planetary Gear Oil (Graziano) 1 2000
2000 hours
Hydraulic System Oil (Note 5) 1 2000
or every
year Engine Coolant 2 2000
Turbocharger Fixing Bolts Torque 4 2000
ATTENTION: See Consumables for specifications and detailed capacities about Fluids and Lubricants.
NOTE: (1) – Carry out maintenance on the air filter element if the main warning display (Non-Critical Warnings –
YELLOW) shows "AIR FILTER".
NOTE: (2) – Carry out maintenance on the hydraulic filter element if the main warning display (Non-Critical Warnings
– YELLOW) shows "HYDRAULIC FILTER".
NOTE: (3) – Check the coolant level in the expansion tank if the main stop display (Critical Warnings – RED) shows
"COOLANT LEVEL".
NOTE: (4)- Change the transmission fluid and replace the filter after the first 100 hours of operation.
NOTE: (5)- Change every 2000 hours or once a year, whichever comes first.
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INTRODUCTION

845B (8 x 8 direct drive) OR (6 x 3 torque converter) OR (Tier 3-VHP)
SERVICE POINTS A B C D AND F

Radiator (coolant level) (Note 3) 1 10
10 hours
Transmission Oil Level (warm, engine running)
or daily 1 10
(Transmission 6X3 Torque Converter 8X4 Direct Drive)
100 hours
or every
or every
Knuckle King Pin Bearings 4 250
1 month
Moldboard Lift Cylinder Articulation Bearings 2 250
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INTRODUCTION
SERVICE POINTS A B C D AND F

Transmission Oil Filter (Note 4) (Transmission 6X3 Torque
Converter – Models 845B 6X3 Torque Converter – Models 1 500
865B 6X3 Torque Converter – Models 885B )
500 hours
Transmission Oil Filter (Transmission 8X4 Direct Drive –
or every
Models 845B 8X4 Direct Drive – Models 865B 8X4 Direct 2 500
3 months
Drive – Models 885B )
Front Wheel Bearing Grease 2 500
Tandem Wheel Shafts Bearings (Graziano) 8 500
Transmission Screen (Transmission 8X4 Direct Drive –
Models 845B 8X4 Direct Drive – Models 865B 8X4 Direct 1 1000
Drive – Models 885B )
Transmission Oil (Note 4) (Transmission 6X3 Torque
Converter – Models 845B 6X3 Torque Converter – Models 1 1000
865B 6X3 Torque Converter – Models 885B )
1000 hours Transmission Oil (Transmission 8X4 Direct Drive – Models
or every 845B 8X4 Direct Drive – Models 865B 8X4 Direct Drive – 1 1000
6 months Models 885B )
Circle Turn Gear Housing Oil 1 1000
2000 hours
or every
"COOLANT LEVEL".
NOTE: (4)- Change the transmission fluid and replace the filter after the first 100 hours of operation.
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INTRODUCTION

865B (8 x 8 direct drive) OR (Tier 3-VHP) OR (AWD)
885B (8 x 8 direct drive) OR (Tier 3-VHP) OR (AWD)
10 hours Radiator (coolant level) (Note 3) 1 10
or daily Transmission oil level (warm, engine running) 1 10
100 hours
or every
or every
Knuckle King Pin Bearings 4 250
1 month
Moldboard Lift Cylinder Articulation Bearings 2 250
Front Wheel Drive (AWD) Pump Filter (Note 6) 1 500
500 hours
Transmission Oil and Oil Filter 1 500
or every
Front Wheel Bearing Grease 2 500
3 months
Tandem Wheel Shafts Bearings (Graziano) 8 500
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INTRODUCTION
Transmission Screen 1 1000
Transmission Oil 1 1000
1000 hours Circle Turn Gear Housing Oil 1 1000
or every
6 months
Front Wheel Drive (AWD) Gear Housing Oil (Note 5) 2 1000
2000 hours
or every
"COOLANT LEVEL".
NOTE: (5) – Change the oil in the front wheel drive gear housings after the first 100 hours of operation.
NOTE: (6) – Replace the front wheel drive pump hydraulic filter after the first 100 hours.
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INTRODUCTION
Consumables
Fuel Reservoir
Specifications No. 2 DIESEL
Total capacity 341 l (90 US gal)
Engine Oil
Specifications CASE AKCELA ENGINE OIL 15W-40
Capacity with a filter change
Capacity without a filter change
Engine Cooling System

50% Water + 50% CASE AKCELA PREMIUM
Specifications
ANTI-FREEZE
Total capacity 32 l (8.5 US gal)
Hydraulic System
CASE AKCELA HY-TRAN® ULTRA™ HYDRAULIC
Specifications
TRANSMISSION OIL
Tank with a filter 90 l (23.8 US gal)
Transmission
Specifications
Refill capacity (with filter change)
Refill capacity (without filter change)
Power Rear Axle

Specifications CASE AKCELA LIMITED SLIP ADDITIVE
845B Models – 40 l (10.6 US gal)
Central compartment (differential) 865B Models – 44 l (11.6 US gal)
Tandem and Brakes

Specifications CASE AKCELA TRANSAXLE FLUID 20W-40
Refill capacity 69 l (18.2 US gal)
Circle Turn Gear Reducer

Specifications CASE AKCELA GEAR 135 H EP 80W-90
Refill 2.8 l (0.7 US gal)
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INTRODUCTION
Grease fitings
Specifications CASE AKCELA 251H EP MULTI-PURPOSE GREASE
Rear Ripper/Scarifier/Blade –
Front Axle Wheel Hubs/Bearings –
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INTRODUCTION
Consumables
845B ANZ (8 x 8 direct drive) OR (6 x 3 torque converter) OR (Tier 3-VHP) ---
APAC (8 x 8 direct drive) OR (6 x 3 torque converter) OR (Tier 3-VHP) --- LA
(8 x 8 direct drive) OR (6 x 3 torque converter) OR (Tier 3-VHP) --- MEA (8 x
8 direct drive) OR (6 x 3 torque converter) OR (Tier 3-VHP) --- NA (8 x 8
direct drive) OR (6 x 3 torque converter) OR (Tier 3-VHP)
Fuel Reservoir
Engine Oil
Capacity with a filter change 16 l (4.2 US gal)
Capacity without a filter change 15 l (4.0 US gal)

Specifications
ANTI-FREEZE
Hydraulic System
For a Cold Climate – CASE AKCELA HY-TRAN®
ULTRA™ HYDRAULIC TRANSMISSION OIL
Specifications
For a Tropical Climate – CASE AKCELA AW
HYDRAULIC FLUID 68 HV
Transmission
Specifications
Power Rear Axle

Central compartment (differential) 865B Models – 44 l (11.6 US gal)
Tandem and Brakes

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INTRODUCTION

Grease fitings
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INTRODUCTION
Consumables
865B ANZ (8 x 8 direct drive) OR (Tier 3-VHP) OR (AWD) --- APAC (8 x 8 direct
drive) OR (Tier 3-VHP) OR (AWD) --- LA (8 x 8 direct drive) OR (Tier 3-VHP)
OR (AWD) --- MEA (8 x 8 direct drive) OR (Tier 3-VHP) OR (AWD) --- NA
(8 x 8 direct drive) OR (Tier 3-VHP) OR (AWD)
885B ANZ (8 x 8 direct drive) OR (Tier 3-VHP) OR (AWD) --- APAC (8 x 8 direct
drive) OR (Tier 3-VHP) OR (AWD) --- LA (8 x 8 direct drive) OR (Tier 3-VHP)
OR (AWD) --- MEA (8 x 8 direct drive) OR (Tier 3-VHP) OR (AWD) --- NA
(8 x 8 direct drive) OR (Tier 3-VHP) OR (AWD)
Fuel Reservoir
Engine Oil
Capacity with a filter change 16 l (4.2 US gal)
Capacity without a filter change 15 l (4.0 US gal)

Specifications
ANTI-FREEZE
Hydraulic System
For a Cold Climate – CASE AKCELA HY-TRAN®
ULTRA™ HYDRAULIC TRANSMISSION OIL
Specifications
For a Tropical Climate – CASE AKCELA AW
HYDRAULIC FLUID 68 HV
Transmission
Specifications
Power Rear Axle

Central compartment (differential) 44 l (11.6 US gal)
Tandem and Brakes


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INTRODUCTION
Front Wheel Reducer

Refill capacity 4.1 l (1.1 US gal)
Grease fitings
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INTRODUCTION
Conversion factors
845B
865B
885B
Area
Metric System to U.S. System U.S. System to Metric System
1 m² = 10.76391 ft² 1 ft² = 0.09290 m²
1 ha = 2.47105 ac 1 ac = 0.40469 ft²
m² – Square meter / ft² – Square foot / ha – Hectare / ac – Acre
Force
1 N = 3.59694 oz 1 oz = 0,27801 N
1 N = 0.22481 lb 1 lb = 4.44822 N
Length
1 mm = 0.03937 in 1 in = 25.4 mm
1m = 3.28084 ft 1 ft = 0.30480 m
1 km = 0.62137 miles 1 miles = 1.60934 km
Mass
1 kg = 2.20462 lb 1 lb = 0.45359 kg
1 g = 0.03527 oz 1 oz = 28.34952 g
Mass/Area
1 kg/ha = 0.89300 lbs/ac 1 lbs/ac = 1.11982 kg/ha
Mass/Energy
1 g/kWh = 0,00164 lb/(HP/h) 1 lb/(HP/h) = 608,277 g/kWh
Mass/Volume
1 kg/m³ = 1.68556 lb/yd³ 1 lb/yd³ = 0.59328 kg/m³
Horse Power
1 kW = 1.35962 Hp 1 Hp = 0.73550 kW
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INTRODUCTION
Pressure
1 bar = 14.50377 lbf/in² 1 lbf/in² = 0.06894 bar
1 kPa = 0,14503 lbf/in² 1 lbf/in² = 6,89475 kPa
Engine coolant
1 °C = ((1.8 x ° C) + 32) °F 1 °F = (0.56 x (° F - 32)) °C
Torque
1 N·m = 0.73756 lb ft 1 lb ft = 1.35582 N·m
1 N·m = 8.85075 lb in 1 lb in = 0.11298 N·m
Velocity
1 km/h = 0.62137 mph 1 mph = 1.60934 km/h
Volume
1 cm³ = 0.06102 in³ 1 in³ = 16.38706 in³
1 m³ = 35.31467 ft³ 1 ft³ = 0.02832 m³
1 m³ = 1.30795 yd³ 1 yd³ = 0.76455 m³
1 ml = 0.03381 US fl oz 1 US fl oz = 29.57353 ml
1 litre = 1.05669 US qt 1 US qt = 0.94635 litre
1 litre = 0.87988 l 1l = 1.13652 litre
1 litre = 0.26417 l 1l = 3.78541 litre
1 litre = 0.21997 l 1l = 4.54610 litre
Volume/Time
1 l/min = 0.26417 US gpm 1 US gpm = 3.78541 l/min
1 l/min = 0.21997 UK gpm 1 UK gpm = 4.54610 l/min
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SERVICE MANUAL
Transmission

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Contents
Transmission - 21
[21.113] Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
[21.135] Powershift transmission external controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2
[21.105] Powershift transmission hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3
[21.155] Powershift transmission internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4
[21.700] Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5
[21.900] Hydraulic pump drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.6
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Transmission - 21
Powershift transmission - 113

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Contents
Transmission - 21
TECHNICAL DATA
Powershift transmission
General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Rear housing
Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Front housing
Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Input housing
Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
FUNCTIONAL DATA
Identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Input shaft
Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Drive oil dipstick line
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Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Rear housing
Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Front housing
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Input shaft coupling
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Transmission/Converter oil pump
Transmission/Converter oil pump - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Input housing
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
SERVICE
Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Calibrate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Input shaft
- Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Drive oil dipstick line
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Rear housing
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
- Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
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Front housing
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Input shaft coupling
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Transmission/Converter oil pump
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Input housing
Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
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Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
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Transmission - Powershift transmission
Powershift transmission - General specification

845B Torque converter transmission, Tier 3, made in Brazil (6 x 3 torque converter) OR (Tier 1) OR (Tier 3-VHP)
[HBZN0845VCAF01093 - ]
865B Torque converter transmission, Tier 3,made in Brazil [NBAF14004 - ] (6 x 3 torque converter) OR (Tier 2) OR (Tier 3-VHP) OR (Tier 0)
Denomination of standard dimensions

NOTE: Linear density in kg/m. Area density in t/m2.
“Units” Symbol New Old Turn Note

The decals indicate
the approximate
speeds and all of the
speeds at the three
different engine
speeds: , (engine
speed at which of
the Power Take-Off m Kg (kilogram) kg
(PTO) is reached,
marked by a white
spot on the center
of each black bar on
the decals) and , the
maximum engine
speed.
Torque F N (Newton) kp 1 kp = 9.81 N
Service A J (Joule) kpm 0.102 kpm = 1J = 1 N·m
Horse Power P kW (kilowatt) HP (DIN) 1 Hp = 0.7355 kW
1 kW = 1.36 Hp
Nm (Newton
Torque T kpm 1 kpm = 9.81 N·m T (Nm) = F (N). r (m)
meter)
Nm (Newton
Moment (Force) M kpm 1 kpm = 9.81 N·m M (Nm) = F (N). r (m)
meter)
1.02 atü = 1.02 kp/cm2
Pressure (over-) pü Bar atü
= 1 bar = 750 torr
Min -1
Speed n RPM
tr / min
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[HBZN0845VCAF01093 - ]
Conversion table
25.40 mm = 1 in
1 kg = 2.205 lb
9.81 N·m (1 kpm) = 7.233 lb ft x ft (pound force per foot)
1.356 N·m (0.138 kpm) = 1 lb ft x ft (pound force per foot)
1 Kg/cm = 5.560 lb in (pound per inch)
1 bar (1.02 kp/cm2) = 14.233 psi
0.070 bar (0.071 kp/cm2) = 1 psi
1l = 0.264 US gal (Imp.)
4.456 l = 1 US gal (Imp.)
1l = 0.220 US gal (USA)
3.785 l = 1 US gal (USA)
1609.344 m = 1 Mile (land mile)
0 °C = + 32 °F
0 °C = 273.15 Kelvin
Powershift transmission - Torque

[HBZN0845VCAF01093 - ]
Tightening torques for the bolts

Friction coefficient: µ tot.= 0.12 for the plugs and nuts without reworking, as well as for the phosphated nuts. Leave
finger tight.
Take tightening torques from the following chart, unless otherwise specified:
Metric ISO standard thread DIN 13.
Dimension 8.8 10.9 12.9

M4 2.8 4.1 4.8
M5 5.5 8.1 9.5
M6 9.5 14 16.5
M7 15 23 28
M8 23 34 40
M10 46 68 79
M12 79 115 135
M14 125 185 215
M16 195 280 330
M18 280 390 460
M20 390 560 650
M22 530 750 880
M24 670 960 1100
M27 1000 1400 1650
M30 1350 1900 2250
M33 1850 2600 3000
M36 2350 3300 3900
M39 3000 4300 5100
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Metric ISO fine thread DIN 13.
Dimension 8.8 10.9 12.9

M8 x 1 24 36 43
M9 x 1 36 53 62
M10 x 1 52 76 89
M10 X 1.25 49 72 84
M12 x 1.25 87 125 150
M12 x 1.5 83 120 145
M14 x 1.5 135 200 235
M16 x 1.5 205 300 360
M18 x 1.5 310 440 520
M18 x 2 290 420 490
M20 x 1.5 430 620 720
M22 x 1.5 580 820 960
M24 x 1.5 760 1100 1250
M24 x 2 730 1050 1200
M27 x 1.5 1100 1600 1850
M27 x 2 1050 1500 1800
M30 x 1.5 1550 2200 2550
M30 x 2 1500 2100 2500
M33 x 1.5 2050 2900 3400
M33 x 2 2000 2800 3300
M36 x 1.5 2700 3800 4450
M36 x 3 2500 3500 4100
M39 x 1.5 3450 4900 5700
M39 x 3 3200 4600 5300
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Powershift transmission - Special tools

[HBZN0845VCAF01093 - ]
5870 350 000

Mounting stand assembly with a tilting device.
LAIL11MG2026A0A 1
5870 350 063

Fasteners.
LAIL11MG1758A0A 2
5870 350 090

Clamping profile.
LAIL11MG1759A0A 3
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5870 105 005

Belt spanner.
LAIL11MG1882A0A 4
5873 042 004

Socket TX 40.
LAIL11MG1883A0A 5
5873 042 002

Socket TX 27.
LAIL11MG1883A0A 6
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5870 204 063

M6 adjusting screws.
LAIL11MG1762A0A 7
5870 204 002

Assortment of eyelets.
LAIL11MG1763A0A 8
5870 204 036

Adjusting screws.
LAIL11MG1764A0A 9
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5870 345 107

Mounting Device.
LAIL11MG1765A0A 10
5870 287 007

HP hand operated pump
LAIL11MG1766A0A 11
5870 950 101

Minimess fitting ( M12 X 1.5).
LAIL11MG1767A0A 12
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0636 804 003

M20 eyelet.
LAIL11MG1768A0A 13
0664 462 774

M12 eyelet.
LAIL11MG1769A0A 14
5870 260 010

Cable.
LAIL11MG1770A0A 15
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5870 600 003

Special tool.
LAIL11MG1884A0A 16
5870 026 100

Puller insert.
LAIL11MG1771A0A 17
5873 001 057

Grab sleeve.
LAIL11MG1772A0A 18
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5873 011 011

Quick grip.
LAIL11MG1885A0A 19
5870 300 028

Cutting device.
LAIL11MG1773A0A 20
5870 345 088

Mounting Device.
LAIL11MG1774A0A 21
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5873 001 000

Basic tool.
LAIL11MG1775A0A 22
5873 001 058

Grab sleeve.
LAIL11MG1776A0A 23
5873 011 014

Quick grip.
LAIL11MG1885A0A 24
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5870 600 005

Special tool.
LAIL11MG1887A0A 25
5870 451 006

Lubricant.
LAIL11MG1922A0A 26
5870 600 006

Special Tool
LAIL11MG1888A0A 27
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5870 345 089

Installer.
LAIL11MG1777A0A 28
5870 280 007

Crank handle
LAIL11MG1778A0A 29
5870 048 057

Driver tool
LAIL11MG1779A0A 30
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5870 057 011

Driver tool.
LAIL11MG1780A0A 31
5870 260 002

Cable.
LAIL11MG1781A0A 32
5870 204 011

Setscrews M8
LAIL11MG1782A0A 33
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5870 204 007

M10 adjusting screws
LAIL11MG1782A0A 34
5870 055 070

Driver tool.
LAIL11MG1783A0A 35
5870 057 010

Driver tool.
LAIL11MG1780A0A 36
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5870 048 080

Driver tool.
LAIL11MG1784A0A 37
5870 656 056

Reducer adapter.
LAIL11MG1785A0A 38
Powershift transmission - Special tools

[HBZN0845VCAF01093 - ]
Commercial tools for disassembly and reassembly
5870 200 055

Magnetic stand
LAIL11MG2027A0A 1
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5870 200 057

Dial indicator.
LAIL11MG1540A0A 2
5870 200 066 ( 70 mm) / 5870 200 067 ( 100 mm)

Gauge blocks.
LAIL11MG1541A0A 3
5870 200 072 ( 200 mm) / 5870 200 114 ( 300 mm)
Digital depth micrometer.
LAIL11MG1542A0A 4
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5870 200 109 ( 150 mm)

Digital micrometer.
LAIL11MG1543A0A 5
5870 203 030( 0.6 – 6.0 N·m) / 5870 203 031 ( 1.0 – 12 N·m)
5870 203 032 ( 3.0 – 23 N·m) / 5870 203 033 ( 5.0 – 45 N·m)
5870 203 034 ( 10 – 90 N·m) / 5870 203 039 ( 80 – 400 N·m)
5870 203 016 ( 140 – 750 N·m) / 5870 203 011 ( 750 – 2000 N·m)
Torque wrench.
LAIL11MG1923A0A 6
5870 221 500 ( 230 V) / 5870 221 501 ( 115 V)

Hot air blower.
LAIL11MG1544A0A 7
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5870 280 004 (Ø 600 mm) / 5870 280 006

5870 280 004(Ø 600 mm)
Plastic hammer.
5870 280 006
Replacement nylon insert.
LAIL11MG1482A0A 8
5870 281 026

Lifting strap.
LAIL11MG1545A0A 9
5870 281 047

Lifting chain.
LAIL11MG1924A0A 10
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5870 345 071

Pry bar (crowbar).
LAIL11MG1547A0A 11
5870 650 004

Puller.
LAIL11MG1548A0A 12
5870 900 013

Set of internal pliers.
I1 - I2 - I3 - I4.
LAIL11MG1549A0A 13
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5870 900 014

Set of internal pliers.
I11 - I21 - I31 - I41 90°.
LAIL11MG1550A0A 14
5870 900 015

Set of external pliers.
A1 - A2 - A3 - A4.
LAIL11MG1551A0A 15
5870 900 016

Set of external pliers.
A01 - A02 - A03 - A04 90°.
LAIL11MG1552A0A 16
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5870 970 001/ 5870 970 002 / 5870 970 003 / 5870 970 004 /
5870 970 006 / 5870 970 007 / 5870 970 026 / 5870 970 028
Two-arm puller.
5870 970 001
Width between the jaws 80 mm.
Depth of the throat 100 mm.
5870 970 002
5870 970 003
5870 970 004
5870 970 006 LAIL11MG1553A0A 17
5870 970 007
Depth of the throat 300 – 500 mm.
5870 970 026
5870 970 028
5870 971 001

Three-arm puller.
5870 971 002
5870 971 003
5870 971 004
5870 971 005
Width between the jaws 390 mm. LAIL11MG1554A0A 18
5870 971 006

845B Direct drive transmission, Tier 3, made in Brazil (8 x 8 direct drive) OR (Tier 1) OR (Tier 3-VHP)
[HBZN0845VBAF00184 - ]
865B Direct drive transmission, Tier 3, made in Brazil [NBAF15000 - ] (8 x 8 direct drive) OR (Tier 2) OR (Tier 3-VHP) OR (Tier 0) OR (AWD)
885B Direct drive transmission, Tier 3, made in Brazil [HBZN0885LBAF00098 (8 x 8 direct drive) OR (Tier 2) OR (Tier 3-VHP) OR (Tier 0) OR (AWD)
-]
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Direct Drive Transmission (Lubrication)

Name Usage
Transmission Oil All moving parts and O-rings

[HBZN0845VBAF00184 - ]
Direct Drive Transmission

Charge pump-to-input housing screws
100 N·m (74 lb ft)
Suction manifold-to-input housing screws
25 N·m (18 lb ft)
Suction tube-to-charge pump
190 N·m (140 lb ft)
Suction tube-to-suction manifold
190 N·m (140 lb ft)
Wiring harness bracket-to-rear housing screw
87 N·m (64 lb ft)
Wiring harness connector-to-wiring harness bracket
18 – 27 N·m (13 – 20 lb ft)

-]
Charge pump-to-input housing screws

115 N·m (85 lb ft)
Suction manifold-to-input housing screws
25 N·m (18 lb ft)
Suction tube-to-charge pump
190 N·m (140 lb ft)
Suction tube-to-suction manifold
190 N·m (140 lb ft)
Wiring harness bracket-to-rear housing screw
87 N·m (64 lb ft)
Wiring harness connector-to-wiring harness bracket
18 – 27 N·m (13 – 20 lb ft)
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Rear housing - General specification

[HBZN0845VBAF00184 - ]
-]
Axial play (Main Rear Gearbox Case)

Description Specification
Output Shaft 0 – 0.051 mm (0 – 0.002 in)
Rear housing - Torque

[HBZN0845VBAF00184 - ]
Main Case Rear Housing

Lift hanger support and cover-to-rear housing screw
87 N·m (64 lb ft)
Bearing retainer-to-rear housing screws
25 N·m (18 lb ft)
Dipstick tube assembly-to-front housing screws
25 N·m (18 lb ft)
Yoke-to-output shaft screw.
215 N·m (159 lb ft)
Rear housing - Torque

-]
Main case rear housing

Lift Hanger and Cover-to-Main Case Rear Housing Cap screw.
87 N·m (64 lb ft)
Direct Drive Input Bearing Retainer-to-Main Case Front Housing Cap Screws.
37 N·m (27 lb ft)
Dipstick tube assembly-to-front housing cap screws.
25 N·m (18 lb ft)
Yoke-to-output shaft cap screw.
215 N·m (159 lb ft)
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Front housing - General specification

[HBZN0845VBAF00184 - ]
-]
Lube
Name Usage
LOCTITE® 242® Oil seal
Weight
Name Specification
Front housing 120 kg (265 lb)
Front housing - Torque

[HBZN0845VBAF00184 - ]
-]
Main Case Front Housing

Front housing-to-rear housing screws
87 N·m (64 lb ft)
Plug 1-5/8 in
190 N·m (140 lb ft)
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Input housing - General specification

[HBZN0845VBAF00184 - ]
-]
Direct Drive Input Assembly (Lubrication)

Name Usage
LOCTITE® 620™ Oil seal
Grease O-Ring
Input housing - Torque

[HBZN0845VBAF00184 - ]
Magnetic pickup-to-input housing screws

10 N·m (7 lb ft)
Input housing assembly-to-front housing screws
87 N·m (64 lb ft)
Hex head socket head-to-input housing plug
102 N·m (75 lb ft)
Lift bracket-to-input housing
87 N·m (64 lb ft)
Bearing retainer-to-front housing screw
37 N·m (27 lb ft)
Direct drive input housing assembly
50 kg (110 lb)
Input housing - Torque

-]
Magnetic pickup-to-input housing sensor screws

10 N·m (7 lb ft)
Input Housing Assembly-to-Main Case Front Housing Screws
87 N·m (64 lb ft)
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Powershift transmission - Identification

[HBZN0845VCAF01093 - ]
Identification plate label
LAIL11MG0507F0A 1
1. Transmission type 5. Oil filling (oil specification)

2. Transmission number 6. ZF lubricant list
3. ZF parts list number 7. Oil amount
4. Overall transmission ratio 8. Customer number
Notes on ordering spare parts

Provide the following information when ordering original spare parts. Complete the details to avoid errors in the de-
livery of the parts.
1. Transmission type
(this information is on the identification plate)
2. Unit number
3. Part list number
4. Make and type of spare part
5. Denomination of spare part
6. Spare part number
7. Shipping mode
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Powershift transmission - Sectional view

[HBZN0845VCAF01093 - ]
BRCE12GRCCM028A 1
Configuration 6 WG-160
1. Transmission Schematics K2 2st gear clutch

2. Gear Schematics K3 3rd gear clutch
KV Forward clutch K4 4th gear clutch
KR Reverse clutch AN Input
K1 1st gear clutch AB Outlet
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LAIL11MG1491G0A 2
1. Input flange (driven via the prop shaft) 9. Clutch shaft “K3”
2. Torque converter 10. Output flange – Rear side
3. Inductive sensor for engine speed 11. Output flange
4. Transmission pump 12. Output flange – Converter side
5. Clutch shaft “KR” 13. Clutch shaft ”K1”
6. P.T.O, Coaxial, depending on the engine 14. Converter safety valve
7. Clutch shaft “KV” 15. Clutch shaft “K4”
8. Clutch shaft “K2”
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Powershift transmission - Overview

[HBZN0845VCAF01093 - ]
LAIL11MG0512G0A 1
Direct drive transmission
A. Input Shaft K. Magnetic sensor

B. Front seal L. Suction screen assembly
C. Charge pump group M. Output yoke fitting
D. Main case front housing N. Control valve group
E. Main case rear housing O. Auxiliary pump drive
F. Dipstick gauge P. First stage output shaft
G. Dipstick tube assembly Q. Suction tube
H. Disc brake caliper assembly R. Auxiliary drive pump
(Depending on each application)
I. Yoke flange R. Magnetic sensor
J. Brake Disc
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Powershift transmission - Overview

-]
LAIL11MG0219G0A 1
Direct drive transmission DF250
A. Input Shaft K. Magnetic sensor

B. Front seal L. Suction screen assembly
C. Charge pump group M. Output yoke fitting
D. Main case front housing N. Control valve group
E. Main case rear housing O. Magnetic pickup sensor
F. Dipstick gauge P. First stage output shaft
G. Dipstick tube assembly Q. Auxiliary pump drive
R. Suction tube
H. Disc brake caliper assembly R. Ground drive pump
I. Yoke flange (Depending on each application)
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J. Brake Disc T. Magnetic pickup sensor
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Input shaft - Overview

[HBZN0845VBAF00184 - ]
LAIL11MG1337F0A 1
A. Input shaft assembly B. Driveline assembly
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Input shaft - Overview

-]
LAIL11MG1829G0A 1
A. Input shaft assembly E. Thrust race

B. Driveline assembly F. Snap ring
C. Input Shaft G. Bearing
D. 43T pulse gear H. Sealing ring
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Drive oil dipstick line - Overview

-]
LAIL11MG2114G0A 1
Dipstick assembly
A. 1/4 inch hose D Bolt (2)

B. Dipstick gauge AND Dipstick gasket
C. Dipstick tube assembly
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Rear housing - Overview

[HBZN0845VBAF00184 - ]
LAIL11MG0218G0A 1
Rear housing component identification (DF150)
A. Join I. Tap
B. Rear Housing (DF150) J. Washer (2)
C. Elbow K. Lock washer (2)
D. Identification Plate L. Bolt, M6 x 20 Class 8.8 (2)
E. Bolt (2) M. Snap ring
F. Bearing cup N. Pressure washer
G. O-ring (2) O. Plug
H. Magnetic pickup sensor (If Magnetic Pickup Sensor Not Used)
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Rear housing - Overview

-]
BRCE12GRCCM033A 1
Rear housing component identification
A. Join J. Washer (2)

B. Rear housing K. Lock washer (2)
C. Elbow L. Bolt, M6 x 20 Class 8.8 (2)
D. Identification Plate M. Snap ring
E. Bolt (2) N. Pressure washer
F. Bearing cup O. Magnetic pickup sensor
G. O-ring (2) P. Plug
H. Magnetic pickup sensor (If no magnetic pickup sensor is used)
I. Tap
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Front housing - Exploded view

[HBZN0845VBAF00184 - ]
LAIL11MG1593G0A 1
Front housing component identification
A. E. Bore sleeve
Hex bolt12 x 120 mm (18 used) F. Bearing cup
B. Front Housing (DF250) G. Plug with an O-ring (2 used)
C. Guide pin (2 used) H. Lube Relief Valve Assembly
D. Input Bushing I. Support
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Front housing - Overview

[HBZN0845VBAF00184 - ]
LAIL11MG1662F0A 1
Front housing assembly
A. Lube relief valve D. Input Bushing

B. Bore sleeve (4 used) E. Plug with an O-ring (2 used)
C. Bearing cup
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Front housing - Exploded view

-]
BRCE12GRCCM032A 1
Front housing component identification
A. E. Bore sleeve
Hex bolt12 x 120 mm (18 used) F. Bearing cup
B. Front Housing (DF250) G. Plug with an O-ring (2 used)
C. Guide pin (2 used) H. Lube Relief Valve Assembly
D. Input Bushing I. Support
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Front housing - Overview

-]
LAIL11MG2015A0A 1
Front housing assembly
A. Lube relief valve

B. Bore sleeve
C. Bearing cup
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Input shaft coupling - Exploded view

-]
LAIL11MG1830G0A 1
A. Bolt M8 x 50 mm x 10.9 (7)

B. Direct Drive input bearing retainer
C. O-Ring
D. Coupling shaft
E. Driveline assembly
F. Deflector
G. Inset drawing
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Transmission/Converter oil pump - Overview

[HBZN0845VBAF00184 - ]
-]
LAIL11MG0816G0A 1
Charge pump group
A. Oil pump E. Sleeve (SAE C)

B. Cup plug F. Snap ring
C. Set screw G. O-Ring
D. Bolt M16 X 65 8.8 mm (3)
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Input housing - Exploded view

[HBZN0845VBAF00184 - ]
-]
LAIL11MG1590G0A 1
Input Housing Assembly
A. Hex head bolt, 12 x 280 mm (4)

B. Oil seal
C. Input housing (SAE 3)
D. Driveline assembly
E. Locating pin
F. Hex head bolt, 12 x 110 mm (3)
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Input housing - Exploded view

[HBZN0845VBAF00184 - ]
-]
LAIL11MG1828G0A 1
Input assembly
A. Input housing I. Snap ring

B. Hex socket plug J. Bolt M6 X 20 8.8 mm (2)
C. Lift hanger K. Lock washer (2)
D. Bolt M12 X 20 8.8 mm (2) L. Washer (2)
E. Bearing (3) M. Magnetic pickup cover
F. Driven gear 36T N. Magnetic pickup sensor
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G. Bearing (with snap ring) O. O-Ring

H. Bearing spacer
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Input housing - Overview

-]
LAIL11MG1831G0A 1
Direct drive input housing and bearing
A. Input housing B. Ball bearing
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Powershift transmission - Pressure test

[HBZN0845VCAF01093 - ]
Measuring points
NOTE: Carry out measurements when the transmission has reached operating temperature(approx. 80 – 90 °C) can
be varied.
LAIL11MG1492F0A 1
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LAIL11MG1493F0A 2
Designation at
No. Denomination of item Connection
valve block
Measuring points for oil pressure and temperature
51 Before the converter (opening pressure) – 11 – 13 bar M10 X 1.0 H
52 Before the converter (opening pressure) – 4.3 – 7.3 bar M10 X 1.0
53 Front clutch (KV) – 16 – 18 bar M10 X 1.0 B
55 Reverse clutch (KR) – 16 – 18 bar M10 X 1.0 AND
56 Clutch (K1) – 16 – 18 bar M10 X 1.0 D
57 Clutch (K2) – 16 – 18 bar M10 X 1.0 A
58 Clutch (K3) – 16 – 18 bar M10 X 1.0 C
60 Clutch (K4) – 16 – 18 bar M10 X 1.0 F
63 After the converter, Temperature 100 °C, short-term 120 °C M14 X 1.5
65 System pressure – 16 – 18.5 bar M10 X 1.0 K
Measuring points for flow rates
15 Connection to heat exchanger 1–5/16 in - 12 UN-2B
16 Connection from heat exchanger 1–5/16 in - 12 UN-2B
Inductive sensor, impulse sensor, speed sensor and switch
21 Inductive sensor – Turbine rotation M18 X 1.5
34 Speed sensor – Output
47 Inductive sensor – Central gear chain M18 X 1.5
48 Inductive sensor – Engine speed M18 X 1.5
54 Differential pressure switch for pressure filter M14 X 1.5
Connecting
10 Vent M10 x 1
49 Plug connection at electro-hydraulic control unit
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Powershift transmission - Service instruction

[HBZN0845VBAF00184 - ]
Transmission lifting procedure

1. Use a lift sling similar to (A).
2. It should hold the transmission level without bending
the lift hangers (B).
LAIL11MG2000A0A 1
Repair stand
NOTE: The repair stand (A) used in this manual is an OTC
DIVISION product, part number 1735, and its capacity is
907 kg (2000 lb).
When any other stand is used, consult the Manufac-

turer’s instructions for mounting.
The approximate empty weight is 545 kg (1202 lb).
NOTE: The exact weights depend on the options included.
LAIL11MG1372A0A 2
Fixing the transmission to the repair stand

NOTE: See “Special Tools” for the Assembly Stand Plate
drawings.
LAIL11MG1654A0A 3
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Powershift transmission - Service instruction

-]
Transmission lifting procedure

1. Use a lift sling similar to (A).
2. It should hold the transmission level without bending
the lift hangers (B).
LAIL11MG2012A0A 1
Repair stand
NOTE: The repair stand (A) used in this manual is an OTC
DIVISION product, part number 1735, and its capacity is
907 kg (2000 lb).
When any other stand is used, consult the Manufac-

turer’s instructions for mounting.
The approximate empty weight is 703 kg (1550 lb).
NOTE: The exact weights depend on the options included.
LAIL11MG2013A0A 2
Fixing the transmission (DF series) to the repair stand

NOTE: See “Special Tools” for the Assembly Stand Plate
drawings.
LAIL11MG1916A0A 3
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Powershift transmission - Disassemble

[HBZN0845VCAF01093 - ]
P.T.O.
1. Loosen the hexagonal headed bolts (1) and remove the
cover (2).
LAIL11MG0137A0A 1
2. Remove the O-ring (1) from the cover and loosen the
Allen screws (2).
LAIL11MG0138A0A 2
3. Remove the flange (1) and the O-ring (2).

4. Loosen the hex nuts and remove both covers (3) with
the O-rings.
5. Remove circlip (4).
LAIL11MG0139A0A 3
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6. Pull the pump shaft (1) out of the housing bore.

7. Remove the rectangular ring (2).
LAIL11MG0140A0A 4
8. Press the ball bearing (1) off the pump shaft.
LAIL11MG0141A0A 5
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Powershift transmission - Assemble

[HBZN0845VCAF01093 - ]
P.T.O.
1. For a shaft pump without a “Lock-up” clutch, press the
ball bearing (1) into the pump bearing (2) until contact
is made.
LAIL11MG0161A0A 1
2. For a shaft pump with a “Lock-up” clutch, install the

four-point bearing (1) in the pump shaft.
3. Press the lower bearing inner ring to the contact posi-
tion.
4. Position the ball bearing.
5. Press the upper bearing inner ring to the contact posi-
tion.
6. Adjust the axial play of 0.0 – 0.05 mm using a retaining
ring (2), with a thickness of between 2.2 – 2.5 mm (in
steps of 0.05 mm.
LAIL11MG0162A0A 2
7. Install the rectangular ring (1).

50 x 2.5 without a Lock-up clutch
60 x 3 with a Lock-up clutch
8. Grease and centrically align rectangular ring.
9. Install the pump shaft (2) until contact is obtained.
LAIL11MG0163A0A 3
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10. Fix the pump shaft by means of an 85 x 3 retaining

ring (1).
11. Install the O-ring 104 x 3 (2) onto the flange (3) and
then grease it and bring it into the contact position on
the rear part of the housing.
LAIL11MG0164A0A 4
12. Fix the flange with Allen screws (1).

13. Insert the O-ring 130 x 3 (2) into the hole of the flange
and grease it.
Tightening torque (M16/8.8 x 30) MA = 195 N·m
LAIL11MG0165A0A 5
14. Place the cover sheet (1) on the flange and fix it with
hex screws (2).
LAIL11MG0166A0A 6
15. For the lubrication line for the version with a “Lock-up”
clutch, install the PTO for the lubrication line
(1) Lubrication line PTO.
(2) Banjo bolt (6 – DIN 7643) seal ring (A-10 CU).
(3) Screw neck (SDS-L6 10 X 1) O-ring (10 X 1).
LAIL11MG0167A0A 7
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Powershift transmission - Calibrate

[HBZN0845VBAF00184 - ]
-]
Transmission Calibration
Reasons to calibrate the transmission:
1. To make the Transmission Control Unit (TCU) work with the transmission.
2. To reduce the impact of manufacturing tolerances.
3. To provide consistency between machines. The calibration process ensures that each transmission clutch is
activated from the same point, before the clutch coupling.
When to calibrate:
1. If the solenoid valve assembly has been replaced.
2. After repairs that involve the transmission gears.
3. If the Transmission Control Unit (TCU) has been replaced.
4. If shifting quality deteriorates.
Calibration of the Transmission Clutches

1. Start the engine on a flat, level, firm surface away from
any obstacles. Move the machine back and forth to
warm up the transmission oil.
NOTE: The transmission oil temperature should be be-
tween 60 – 71 °C (140 – 160 °F) for the calibration to be
effective.
2. Bring the machine to a stop.
3. Support the implements on the ground.
4. Set the parking brake. Put the ignition switch in the
“OFF” position.
5. Clear the area of unauthorized personnel. COIL15GRD0040AA 1
6. The fuse compartment is located on the bottom of the

right-hand console in the operator's cab. Open the
compartment to access connectors (X36) and (X37).
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7. Remove the seal from connector (X37).

8. Connect a connector (X37) that makes a bridge [con-
nects pin (A) to pin (B)] on the calibration connector of
the machine's wiring harness (X36).
ATTENTION: Any error that appears during calibration will
cause the process to terminate. You must re-start the cali-
bration process from the beginning.
COIL15GRD0059BA 2
COIL15GRD0039BA 3
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9. Turn the ignition switch to the “ON” position to power

the Transmission Control Unit (TCU). The liquid crystal
display should indicate “Calibration” to start the calibra-
tion process.
10. Run the engine. Keep the engine at a speed of
1600 RPM. The engine governor should keep the
speed stabilized within a range of ± 50 RPM.
COIL15GRD0041AB 4
11. Put the gear shift lever in the “Forward” position (for-
ward gear).
COIL15GRD0042AB 5
12. During the first seconds of the calibration process,

the actuation and response speeds of the clutch drive
cylinders are tested.
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13. Then the clutch calibration process starts.
A. Pressure hold time of the gear and steering clutches.

NOTE: The liquid-crystal display will show C1H, C2H, C3H, CAH, CBH, CCH, and CDH during acquisition of the
respective pressure hold time of each clutch.
COIL15GRD0043FA 6
B. Fill time of the gear and steering clutches.

NOTE: The liquid-crystal display will show C1F, C2F, C3F, CAF, CBF, CCF, and CDF during acquisition of the
respective fill time of each clutch.
COIL15GRD0049FA 7
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14. The liquid crystal display will indicate “END” (end)

when the calibration routine is finished.
COIL15GRD0056AB 8
15. Turn the ignition switch to the “OFF” position to power

down the Transmission Control Unit (TCU). Put the
transmission selector lever in the "Neutral" position.
COIL15GRD0057AA 9
COIL15GRD0058AA 10
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16. Remove the plug from the connector that makes the
bridge between the calibration connector (X36) and
the connector (X37).
COIL15GRD0039BA 11
17. Reinstall the seal of the connector (X37).

18. The transmission clutches calibration process is com-
plete.
COIL15GRD0059BA 12
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Electronic Service Tool

The Electronic Service Tool can be used to check the following transmission parameters.
• Current TCU errors
• Stored TCU errors
• Gear selector data
• Inching pedal data
• Information about the application
• Data input and output states
• Calibration of the clutch valves
• Gear and temperature information
Diagnostic connector and troubleshooting (X38)
COIL15GRD0059BA 13
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The Additional Tools screen is used to view the state of the transmission controller and the transmission system
components. The transmission diagnostic tool provides:
• Information about programming, application, and specification of the Transmission Control Unit (TCU)
• Transmission controller error information
• Testing resources for the input component of the transmission controller
• Information about gears, temperature, and calibration of the transmission clutches
• Application search resources
The Tool Bar can be used to view the Additional Tools screen.
Place the cursor over the Additional Tools button on the Tool Bar. Use the mouse to left click on the
Additional Tools button.
COIL15GRD0062EB 14
Left click on the “Start the Transmission Diagnostic Tool” button to start the Transmission Diagnostics Tool.
The Electronic Service Tool will connect the Transmission Diagnostics Tool Application. As soon as the Diagnostics
Tool is connected, the following screen will be displayed.
COIL15GRD0063FA 15
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Transmission Diagnostics Application

The Electronic Service Tool connects the Transmission Diagnostics Tool Application. As soon as the Electronic
Service Tool is connected, the following screen will be displayed.
(1) Application title
Identifies the Electronic Service Tool application installed
(2) Drop-down menus
Drop-down menus allow the user to activate the functions of the Electronic Service Tool
(3) Transmission controller specification
Specification for the transmission controller and the part number of the application that is installed on the
Transmission Control Unit. This number will be requested if you need assistance. Write this number down
before you request technical assistance.
(4) Serial number of the transmission controller
(5) “Exit” button (Exit)
Used to close the screen of the Transmission Diagnostics Tool application and return to the main screen
of the Electronic Service Tool
(6) Connection path of the Transmission Control Unit
Used to identify the connection of the Transmission Diagnostics Tool to the Transmission Controller.
COIL15GRD0064FA 16
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The drop-down menus allow the user to:

• Connect the Transmission Diagnostics Tool application
• View Transmission Controller error information
• View and monitor information about components and the transmission controller input
• View information about the application and specification of the Transmission Control Unit (TCU)
• View information about gears, temperature, and calibration of the transmission clutches
• Search for transmission controller programming information
• View information related to error codes, data logging files, and the boot code of the controller
• Verify the version of the Transmission Diagnostics Tool
• Exit the Transmission Diagnostics Tool application
COIL15GRD0065FA 17
The drop-down menus are used to:
• View Transmission Controller (TCU) error information
• Monitor information about components and input of the Transmission Controller
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TCU errors
TCU errors are displayed in two categories:
• Current Errors – A failure in the transmission system that is affecting the system's operation.
• Stored Errors – A failure in the transmission system that is not affecting the system's operation.
Information about components and the Transmission Controller input

This information is used to:
(1) Monitor components and input values of the Transmission Controller
(2) View information about the TCU application
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“Display” menu (Display)

"TCU errors" sub-menu (Transmission Controller Unit Errors) –
"Current Errors"
To see the Transmission Controller Unit errors, place the cursor over the “Display” menu (Display). Left click.
Another menu will appear to the right. Left click on “Current Errors” (Current errors).
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The current errors are only shown when the issue is present/active. Only one error code may be displayed at a
time. If there are multiple errors, the next error can only be displayed once the previous error is corrected. The
transmission gear selector lever must be placed in the “N” position to clear the error on the display.
Use the details button to view detailed information about the current error. Left click on the “Details” button (Details).
COIL15GRD0069FA 21
This indicator changes color to indicate that the information from the TCU is being updated. This indicator is
shown for TCU inputs that vary. If the system locks up, the indicator will show a red light. This information is not
related to the severity of the error codes.
A screen with the TCU (“TCU Error description”) error description will be shown. The error description identifies
the component and the action of the component that caused the error listed. To close the TCU error description
screen, place the cursor over the “OK” button. Left click.
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"TCU errors" sub-menu (Transmission Controller Unit Errors) –

"Stored Errors" (Stored errors)
To see the errors stored in the Transmission Controller Unit, place the cursor over the “Display” menu (Display).
Left click. Another menu will appear to the right. Left click on “Stored Errors” (Stored errors).
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TCU stored errors will be shown. Stored errors are historical errors that are used to diagnose the TCU at
the factory. The TCU can store up to eight errors at a time. #1 is the most recent and #8 is the oldest. Errors
displayed more than once (intermittent or recurrent) may indicate a connection issue or an operating condition
that is not displayed as an error.
Use the details buttons to view detailed information about the stored errors. Left click on a “Details” button (Details).
A screen with the TCU error description will be shown.
COIL15GRD0072FA 25
The error description identifies the component and the action of the component that caused the error listed. To
close the TCU error description screen, place the cursor over the “OK” button. Left click.
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"Gear Selector Data" sub-menu (Monitoring of the gear selector function)

To monitor the input values from the transmission gear selector lever to the TCU, place the cursor over the
“Display” menu. Left click. Select “Gear Selector Data”.
COIL15GRD0074FA 27
A screen with TCU gear and selection information will be shown. The content of the screen indicates the following:
• The position of the gear selector lever
• The activated input of the gear selector lever (1)
• The non-activated input of the gear selector lever (0)
• The transmission gear engaged
To close the screen with information about TCU gear and selection, place the cursor over the “Close” button.
Left click.
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"Inching Pedal Data" sub-menu

Monitoring the functions of the inching pedal
To monitor the input values of the inching pedal for the Transmission Control Unit, place the cursor over the
“Display” menu. Left click. Select “Inching Pedal Data”.
COIL15GRD0076FA 29
A screen with the Inching Pedal status will be shown. This screen indicates:
• The position of the Inching Pedal as a bar graph
• The position of the Inching Pedal as a percentage of its total stroke
• The input state of the clutch switch
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To close the Inching Pedal status screen, place the cursor over the “Close” button. Left click.
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"Application Information" (Application Information) sub-menu

Checking the Transmission Control Unit application information
To check the TCU application information, place the cursor over the “Display” menu. Left click. Select “Application
Information”.
COIL15GRD0080FA 32
A screen with TCU information will be shown.

To close the TCU information screen, place the cursor over the "Close" button. Left click.
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"Input and Output States" sub-menu

Viewing the input and output states
To view information about the Transmission Control Unit (TCU) input and output states, place the cursor over the
“Display” menu. Left click. Select “Input and Output States”.
COIL15GRD0082FA 34
The TCU input and output states screen will be shown. Left click on the “Binary” button to show the values in binary.
The TCU input and output states screen indicates the state/condition (ON/OFF) of important switches, such as
the parking brake switch, neutral switch, etc. This screen is used to diagnose the error codes. The state of
each switch can be monitored to check if its state/condition changes during operation. This may indicate which
component is the cause of an error.
To close the TCU input and output states screen, place the cursor over the “Close” button. Left click.
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"Clutch Calibration Values" sub-menu

Checking the calibration temperature of the clutches
To check clutch calibration information from the Transmission Control Unit (TCU), place the cursor over the
“Display” menu. Left click. Select “Clutch Calibration Values”.
COIL15GRD0083FA 36
The clutch calibration values screen will be shown.

• If the Transmission Control Unit (TCU) is new and therefore not yet calibrated, the values shown will be the
default values. The default values will allow the transmission to function without damaging the clutches, but
will not provide a gear shift quality that is optimal.
• Once the TCU is calibrated for the transmission, the values shown represent the current required to fill each
clutch and the current required to start the “lock up” of each clutch.
• The TCU uses information about the clutch calibration values to control the gear shift quality.
To close the clutch calibration values screen, place the cursor over the “Close” button. Left click.
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"Speed and Temperature" sub-menu

Viewing information about transmission rotations and temperature
To check the information about the Transmission Control Unit (TCU) rotations and temperature, place the cursor
over the “Display” menu. Left click. Select “Speed and Temperature”.
COIL15GRD0086FA 38
The TCU rotations and temperature screen will be shown.

To close the TCU rotations and temperature screen, place the cursor over the “Close” button. Left click.
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“Read” (Read) menu

The “Read” menu is used to look for information related to the transmission controller programming.
NOTE: Use the “Read” menu transmission diagnostic tool only with support of a dealer.
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“Bytes” sub-menu
Looking for information by “Bytes”
To read information by “Bytes”, place the cursor over the “Read” menu. Left click. Select “Byte”.
COIL15GRD0088FA 41
The “Read a BYTE” screen will be shown. Enter the “Byte” address on the screen in HEX. Place the cursor over the
“OK” button. Left click. To close the “Read a BYTE” screen, place the cursor over the “Cancel” button. Left click.
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“Word” (Word) sub-menu

Looking for information by words (Word)
To read information by words (Word), place the cursor over the “Read” menu. Left click. Select “Word”.
COIL15GRD0090FA 43
The “Read a WORD” screen will be shown. Enter the word (Word) address on the screen in HEX. Place the
cursor over the “OK” button. Left click. To close the “Read a WORD” screen, place the cursor over the “Cancel”
button. Left click.
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“View” (View) menu

• View information related to the transmission controller error codes list
• View a data logging file created by the user
• View information related to Initialization/TCU Codes
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“Error Code List” (Error Code List) sub-menu

Viewing Error Code Files (Error Code List).
To view the Error Code Files, place the cursor over the “View” menu. Left click. Select “Error Code List”.
COIL15GRD0102FA 46
An Error Code Files viewing screen will be displayed.

Place the cursor over the name of the file. Left click. Once the file name is selected, it is highlighted (darkened).
To open the file saved on the hard drive of the Electronic Service Tool, left click on the “Open” button.
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A screen with the Error Code List will be displayed.

Place the cursor over one of the arrows, or on the scroll bar, to view information for additional codes.
To close the screen with the Error Code List, place the cursor over the “Close” button. Left click.
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“Data Log File” (Data Log File) sub-menu

Viewing Data Log Files (Data Log File)
To view the Data Log Files, place the cursor over the “View” menu. Left click. Select “Data Log File”.
COIL15GRD0095FA 49
A Data Log Files viewing screen will be displayed.

Place the cursor over the name of the file. Left click. Once the file name is selected, it is highlighted (darkened).
To open the file saved on the hard drive of the Electronic Service Tool, left click on the “Open” button.
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“Boot/Code Information” (Boot/Code Information) sub-menu

Viewing the Boot/Code Information (Boot/Code Information)
To view the Boot/Code Information, place the cursor over the “View” menu. Left click. Select “Boot/Code
Information”.
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“Help” (Help) menu

The “Help” menu allows you to view information related to the version of the Transmission Diagnostics Application.
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“About” (Application Version) sub-menu

Viewing the Version of the Transmission Diagnostics Application (About)
To view information about the Version of the Transmission Diagnostics Application, place the cursor over the
“Help” menu and select. Left click. Select “About”.
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A screen with information about the Transmission Diagnostics Application will be shown.
To close this screen, place the cursor over the “OK” button. Right click.
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Closing the Transmission Diagnostics Tool

To close the Transmission Diagnostics Tool application, place the cursor over the “Exit” button. Left click.
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Input shaft - Disassemble

[HBZN0845VCAF01093 - ]
1. Remove the piston ring (1).

2. The torque converter turbine shaft (2) and intermediary
gear (3) are fixed by a snap ring.
NOTE: When separated, the components will be de-
stroyed.
LAIL11MG0147A0A 1
3. Pull tapered roller bearing (inner ring) off the drive gear.
(S) Basic tool 5873 001 000
(S) Grab sleeve or 5873 001 058
or
(S) Rapid grip 5873 011 014
LAIL11MG0148A0A 2
4. Pull tapered roller bearing (inner ring) off the drive gear.
(S) Grab sleeve 5873 001 058
(S) Compression device or 5870 026 100
or
(S) Rapid grip 5873 011 011
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Input shaft - Assemble

[HBZN0845VCAF01093 - ]
1. Undercool shaft (1) (approx. -80 °C), heat the drive

gear (2) (approx. +120 °C) and mount until contact is
obtained.
ATTENTION: Wear protective gloves!
LAIL11MG0153A0A 1
2. Secure the drive gear by means of a 90 x 3 retaining

ring (1)
LAIL11MG0154A0A 2
3. Press the conical bearing (inner ring) (1) onto the input
shaft until contact is obtained.
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4. Press the conical bearing (inner ring) (1) onto the input
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Version with a clutch of “Lock-up”

1. Place the 35 x 2 O-ring (1) into the lower annular groove
of the input shaft and grease it.
LAIL11MG0157A0A 5
2. Install the lock washer SB 38 (1) on the annular groove

(2) of the turbine shaft.
LAIL11MG0158A0A 6
3. Mount the turbine shaft (1) until the snap ring engages
into the input shaft groove. Turbine shaft is axially fixed.
4. Snap in and interlock the 60 x 3 rectangular ring (2).
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Version with a clutch of “Lock-up”

1. Mount the turbine shaft (1) until the snap ring engages
into the input shaft groove. Turbine shaft is axially fixed.
2. Snap in and interlock rectangular ring.
(2) 60 x 3
(3) 36 X 2.5
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Input shaft - Remove

[HBZN0845VBAF00184 - ]
NOTE: Before starting removal, see Input shaft -

Overview (21.113).
NOTICE: Make sure that the input shaft assembly (B) does
not move up with the input housing assembly (A). It could
fall and cause damage or personal injury.
NOTICE: The input bearing will usually come up with the
input housing assembly. Do not let it fall out before it can
be safely removed.
LAIL11MG1387A0A 1
1. Remove the input housing assembly (A).

NOTICE: If the coupling shaft (D) comes up with the input
shaft assembly, do not let it fall.
2. Lift the input shaft assembly (B) from the bearing re-
tainer (C).
LAIL11MG1388A0A 2
3. Place the input assembly (E) with the snap ring facing
upwards.
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4. Remove and discard the seal ring (F).
LAIL11MG1390A0A 4
NOTICE: Wear safety glasses when removing or installing

snap rings.
5. Remove the snap ring (G).
6. Remove the thrust race (H).
LAIL11MG1391A0A 5
7. Mark the input shaft (I) and gear (J) for reassembly.
LAIL11MG1392A0A 6
8. Remove gear from input shaft.

9. Inspect all parts for wear and damage.
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Input shaft - Install

[HBZN0845VBAF00184 - ]
NOTE: Before starting installation, see Input shaft -

Overview (21.113).
1. Align the marks made on the input shaft (A) and gear
(B).
LAIL11MG2049A0A 1
2. Install gear on input shaft.
LAIL11MG2048A0A 2
3. Install the thrust washer (C).

snap rings.
4. Install the snap ring (D).
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NOTICE: Always use new seal rings. The seal rings must
be sized to fit the shaft groove tightly to prevent damage
during installation. Check that seal ring is in place and
sized immediately before assembly.
5. Size the seal ring (E) by twisting it in a circle with a
diameter of approximately 25 mm (1 in).
6. Apply grease to the seal ring and seal surfaces.
7. Install ring seal (E).
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[HBZN0845VBAF00184 - ]
Coupling Shaft and Retainer

NOTE: Before starting removal, see Input shaft -
Overview (21.113).
1. Remove the coupling shaft (A).
2. Remove the O-ring (B).
LAIL11MG1394A0A 1
NOTICE: Note the position of the oil baffle (E). This part
must be installed correctly for the transmission to function
and lubricate properly.
3. Remove seven screws (C) and the oil baffle from the
bearing retainer assembly (D).
LAIL11MG1395A0A 2
NOTICE: Be careful not to scratch or damage the inside

diameter of the bearing retainer. The input shaft seal ring
surface will be damaged.
4. Remove the bearing retainer (D).
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5. Use a soft mandril to remove the bearing (G). Take care

not to damage the retainer (H).
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[HBZN0845VBAF00184 - ]
Bearing Retainer
Overview (21.113).
NOTICE: This bearing is installed flush. Firmly seated on
the bottom of the bearing bore.
1. Install the new bearing (A).
LAIL11MG1175A0A 1
2. Install the retainer with the bearing (C). Use one of the
fixing screws (D) to help align through the holes in the
retainer with the threaded holes in the front housing of
the transmission (E).
LAIL11MG1655A0A 2
NOTE: There are two holes (H) in the retainer that are oil
passages, not fixing holes.
3. Install the baffle (G) and seven cap screws (F).
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NOTICE: Pay attention to the position of the oil baffle (G).

4. Install the oil baffle (G) as illustrated.
5. Lubricate bearing with clean transmission fluid.
LAIL11MG1396A0A 4
6. Tighten the bolts (F) with a torque of 37 N·m (27 lb ft).

Make sure that the oil baffle stays in its proper position.
LAIL11MG1942A0A 5
7. Lubricate the O-ring (J) with grease.

NOTE: The O-ring must sit flush against the front housing.
8. Install O-ring on bearing retainer.
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[HBZN0845VBAF00184 - ]
Coupling Shaft
Overview (21.113).
1. Lubricate the coupling shaft (A) with clean transmission
fluid.
2. Install coupling shaft into transmission first stage shaft.
NOTE: The two ends of the shaft are identical.
LAIL11MG1657A0A 1
Input Shaft Assembly and Input Ball Bearing

NOTICE: Before installing the input shaft assembly, check
that the seal ring is in place and is lubricated.
NOTE: Refer to ASSEMBLE THE INPUT SHAFT in Shaft
assemblies - Assemble (21.155) of this group for more
information about the sizing of the seal rings.
1. Check that the seal ring (A) is in place and is lubricated
with grease.
2. Grease the seal area (B) and the shaft splines (C).
3. Install the input shaft assembly (D).
LAIL11MG1658A0A 2
4. Lubricate the input ball bearing (E) with clean transmis-

sion fluid.
5. Install a new ball bearing (E).
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-]
1. Lift input housing carefully from transmission. The di-

rect drive input assembly should stay with transmis-
sion.
LAIL11MG1864A0A 1
LAIL11MG1865A0A 2
2. Remove the input assembly (A).
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3. Remove seal ring (H).

4. Remove bearing (G), inspect it, and discard it.
5. Remove the snap ring (F).
6. Remove the thrust race (E).
7. Remove the 43-tooth pulse gear (D).
8. Inspect for wear and damage.
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-]
1. Place the 43-tooth pulse gear (D) in the input shaft (C).
2. Place the thrust race (E) onto the pulse gear.
3. Install the snap ring (F) onto the input shaft.
4. Press the new bearing (G) onto the input shaft.
5. Lubricate the bearing (G) with transmission fluid.
6. Install ring seal (H).
LAIL11MG1817A0A 1
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Drive oil dipstick line - Remove

-]
1. Remove the 1/4 inch hose (A) (A) from the valve and
dipstick tube assembly (C).
2. Remove two screws (D) from the dipstick tube assem-
bly.
3. Remove dipstick tube assembly.
4. Remove the gasket (E).
BRCE12GRCCM034A 1
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Drive oil dipstick line - Install

-]
1. Install the gasket (E).

2. Remove the two screws (D) from the dipstick tube as-
sembly.
3. Install a 1/4 inch hose (A) from the dipstick tube assem-
bly to the valve (C).
4. Tighten the bolts (D) with a torque of 25 N·m (18 lb ft).
BRCE12GRCCM034A 1
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Rear housing - Remove

[HBZN0845VBAF00184 - ]
NOTE: See Input housing - Remove (21.113), Front

housing - Disassemble (21.113), Transmission con-
trol valve - Remove (21.135) and Shaft assemblies -
Remove (21.155), before removing the rear housing.
1. Position the rear housing (A) as illustrated.
LAIL11MG1439A0A 1
2. Remove the three cap screws (A) and the lift bracket
(B).
3. Inspect lift bracket for damage.
LAIL11MG1440A0A 2
4. Roller bearings.
NOTICE: If bearings (A) and (B) were removed from the
rear housing, they must be replaced with new bearings.
NOTICE: Use new inner races for these bearings on the
fourth stage clutch assembly and the sixth stage shaft as-
sembly.
5. Remove the fourth stage bearing (A).
6. Remove the sixth stage bearing (B).
LAIL11MG1674A0A 3
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Rear housing - Install

[HBZN0845VBAF00184 - ]
1. Position the rear housing (A) as illustrated.
LAIL11MG1439A0A 1
2. Install the three bolts (A) and the lifting support (B).
3. Torque screws to 87 N·m (64 lb ft).
LAIL11MG1441A0A 2
4. Roller bearings.
NOTICE: Use a tool that only applies force to the outer race
to install the bearings.
NOTICE: Push the bearings (A) firmly against the bottom
of their bores. Do not damage the bearing cages and races
during installation.
5. Lubricate bearings with clean transmission fluid.
6. Install the two new bearings (A).
7. Seat bearings against the bottom of the bearings bores.
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Front housing - Remove

[HBZN0845VBAF00184 - ]
Wiring Connector Screws and Support

1. Loosen the bolts (A).
2. Remove the bolts (B).
3. Remove the wiring connector support (C).
LAIL11MG1961A0A 1
4. Remove the remaining bolts (D).
LAIL11MG1404A0A 2
5. Remove the guide pins (E), if loose.
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Front housing - Disassemble

[HBZN0845VBAF00184 - ]
Fixing the Lifting Tool

1. Remove cap screws from front housing.
LAIL11MG2014A0A 1
2. Use the four threaded holes (A) located in the front

housing to attach the lifting tool.
LAIL11MG1406A0A 2
NOTICE: Use four high grade bolts (C) of the correct length
to attach the lifting tool to the front housing.
3. Position the lifting tool (B).
4. Install the four bolts (C).
LAIL11MG1660A0A 3
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NOTICE: The rear housing assembly weighs approxi-

mately 120 kg (265 lb).
LAIL11MG1407A0A 4
5. Use a hoist with a safety hook (D) to lift and remove the
front housing.
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Remove Front Housing

NOTICE: Lever the housings to loosen the gasket seal,
using the lugs on the front and rear housings.
LAIL11MG1408A0A 5

mately 120 kg (265 lb). Do not allow any part of your body
under the front housing assembly.
1. Remove front housing.
LAIL11MG1661A0A 6
2. Remove and discard the joint (C).
LAIL11MG2005A0A 7
3. Check for the two guide pins (D).
LAIL11MG2006A0A 8
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Front housing - Disassemble

-]
Fixing the Lifting Tool

1. Remove cap screws from front housing.
LAIL11MG2014A0A 1
2. Use the four threaded holes (A) located in the front

housing to attach the lifting tool.
LAIL11MG1486A0A 2
NOTICE: Use high grade bolts of the correct length to at-

tach the lifting tool to the front housing.
4. Install the four bolts (C).
LAIL11MG1487A0A 3
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6. Use a hoist with a safety hook (D) to lift and remove the
front housing.
LAIL11MG1869A0A 4
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Remove Front Housing

NOTICE: Lever the housings to loosen the gasket seal,
using the lugs on the front and rear housings.
LAIL11MG1408A0A 5
NOTICE: The front housing must be level when removing

to prevent damage to the oil seals on the stage assemblies.
Use guide pins to lift the front housing.
mately 120 kg (265 lb). Do not allow any part of your body
under the front housing assembly.
7. Lift the front housing (A) away from the rear housing
(B) .
8. Remove front housing.
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[HBZN0845VBAF00184 - ]
Remove the plug with an O-Ring

NOTE: Before starting removal, see Front housing -
Overview (21.113).
1. Remove the two plugs (A) with O-rings.
2. Remove and discard the O-rings (B).
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Front housing - Install

[HBZN0845VBAF00184 - ]
Install a plug with an O-Ring

NOTE: Before starting installation, see Front housing -
Overview (21.113).
1. Lubricate and install the new O-rings (B).
2. Install the plugs (A) with the O-rings.
3. Torque them to 190 N·m (140 lb ft).
LAIL11MG1409A0A 1
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[HBZN0845VBAF00184 - ]
[HBZN0845VCAF01093 - ]
-]
NOTE: Before starting removal, see Front housing -

Overview (21.113). Front housing - Overview (21.113)
Front housing - Overview (21.113) .
Removal of the bore sleeves

1. Inspect the bore sleeves (A) for wear or damage.
LAIL11MG1180A0A 1
2. Remove bore sleeves from front side of front housing.
LAIL11MG1181A0A 2
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Removal of the lubrication relief valve

1. Position front housing with bearing bore side up.
2. Remove the lubrication relief valve (A).
LAIL11MG1185A0A 3
Removal of the bearing cup

1. Remove bearing cup.
LAIL11MG1187A0A 4
Removal of the oil seal

1. Remove the oil seal (A).
LAIL11MG1189A0A 5
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[HBZN0845VBAF00184 - ]
[HBZN0845VCAF01093 - ]
-]
NOTE: Before starting installation, see Front housing -

Overview (21.113). Front housing - Overview (21.113)
Front housing - Overview (21.113) .
Installation of the oil seal

NOTE: Apply LOCTITE® 242® or equivalent to the outside
diameter of the oil seal before installation.
1. Install new oil seal flush with shoulder.
LAIL11MG1190A0A 1
Install the bearing cup

1. Remove bearing cup.
LAIL11MG1188A0A 2
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Install the lubrication relief valve

1. Position front housing with bearing bore side down.
2. Install a new lubrication relief valve (A).
LAIL11MG1186A0A 3
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Install the bore sleeves

1. Position the front housing with the bearing bore facing
upwards.
NOTICE: Install the bore sleeves with the internal chamfer
facing upwards.
LAIL11MG1182A0A 4
2. Place the bore sleeve (A) onto the guide tool (B) with
the outside diameter chamfer of the bore sleeve at the
end of the tool.
LAIL11MG1183A0A 5
3. Install bore sleeve flush with shoulder.
LAIL11MG1184A0A 6
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[HBZN0845VBAF00184 - ]
Preparing the rear housing and gear group for assembly with the front housing
1. Clean gasket surfaces on front and rear housings.
NOTICE: Check for both guide pins (D). If they are not in
place, they must be installed before joining the front and
rear housings.
LAIL11MG1410A0A 1
2. Install the guide pins (D).

3. Install the new joint (C).
LAIL11MG1411A0A 2
NOTICE: Use the guide pins (D) to align the front and rear
housings. Failure to install guide pins will cause damage
to seal rings.
NOTE: The guide pins (D) must be long enough to reach
through the front housing and be removed after the front
housing is in place.
4. Install the two guide pins (D).
LAIL11MG1663A0A 3
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Installation and lubrication of the seal rings

NOTICE: The seal ring ends overlap and must fit together.
LAIL11MG1191A0A 4
NOTICE: Use new seal rings.

NOTE: For the shaft assemblies, torque the seal rings
19 mm (0.75 in). For the first stage shafts, torque the seal
ring 25 mm (0.98 in).
1. Turn the seal ring in a circle of approximately 25 mm
(0.98 in).
LAIL11MG1192A0A 5
2. Install a seal ring (A) on the first stage shaft (B).
LAIL11MG1664A0A 6
3. Install, as required, two or three seal rings (C) on the

clutch shaft assemblies.
LAIL11MG1665A0A 7
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4. Lubricate all seal rings.

5. Check seal rings for proper fit in the grooves, in clutch
shaft assemblies.
6. Rotate the seal rings so that the end gaps are approx-
imately 120 degrees apart.
LAIL11MG1412A0A 8
7. Lubricate all bearings with clean transmission fluid.
LAIL11MG1666A0A 9
8. Apply grease to the yoke splines (E) on the output stage

shaft.
LAIL11MG1413A0A 10
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Front housing - Assemble

[HBZN0845VBAF00184 - ]

NOTICE: Use four high grade bolts (C) of the correct length
to attach the lifting tool to the front housing.
LAIL11MG1660A0A 1
1. Attach the lifting tool (B).

NOTICE: Do not allow any part of your body under the front
cover assembly. Personal injury is possible.
NOTICE: Use guide pins to prevent damage to the seal
rings.
2. Install the guide pins (C).
3. Check that the guide pins (D) and the gasket (E) are
flush with the surface of the rear housing.
4. Lower the front housing assembly (F) onto the clutch
shaft assemblies and onto the rear housing.
LAIL11MG2061A0A 2
NOTICE: Do not attempt to mate the front and rear housing

together using the screws. If the housings do not close up
completely without being forced, there is a problem that
must be corrected.
5. Check that the front housing is level with the rear hous-
ing (H).
LAIL11MG1193A0A 3
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6. Install the cap screws (J) and the wiring harness

bracket (K).
LAIL11MG1414A0A 4
LAIL11MG1194A0A 5
8. Remove the lifting tool (L).
LAIL11MG1195A0A 6
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Front housing - Assemble

-]
NOTICE: When installing the front housing to the rear

housing, use two guide pins to help align the housings and
to protect the seal rings during this operation. Check the
guide pins before installing (refer to the disassemble and
assemble front housing instructions for the guide pin hole
location).
1. Attach lift tool to front housing.
LAIL11MG1869A0A 1
NOTE: Refer to the information about removing the front

housing on attaching the lifting tool.
2. Install new gasket onto rear housing.
3. Install the front housing (A) to the rear housing (B).
LAIL11MG1870A0A 2
4. Install bolts.
LAIL11MG2014A0A 3
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Input shaft coupling - Remove

-]
Remove the Coupling Shaft and the Input Bearing Retainer

1. Remove the coupling shaft (B).
2. Remove the bolts (C).
3. Remove the bolt and deflector (D).
4. Remove the O-ring.
5. Remove the direct drive input bearing retainer (F).
LAIL11MG1465A0A 1
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Input shaft coupling - Install

-]
Direct Drive Input Assembly

1. Align the oil passage and bolt holes in the direct drive
input bearing retainer with oil passage and bolt holes in
the front housing.
NOTICE: The baffle (B) must be in place and installed cor-
rectly to properly direct the oil flow. It also must not interfere
with installing the input housing.
2. Install the bolts (A) and the baffle (B).
3. Lubricate and install a new O-ring (C).
LAIL11MG1467A0A 1
5. Install coupling shaft (D).
LAIL11MG2120A0A 2
6. Install the input assembly (E).
LAIL11MG2121A0A 3
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Transmission/Converter oil pump - Install

[HBZN0845VCAF01093 - ]
1. Insert the pressure relief valve (1) into the housing hole
until contact is obtained.
2. Mount two adjusting screws (S) and position the gasket
(2) and oil feed housing (3).
NOTE: Use assembly grease.
(S) Adjusting screws (M8) 5870 204 011
LAIL11MG0411A0A 1
3. Install two adjusting screws (S) and mount the stator

shaft (1).
NOTE: Pay attention to radial installation position.
(S) Adjusting screws (M10) 5870 204 007
LAIL11MG0412A0A 2
NOTE: In case of wear marks in the pump housing or on

the control disk, the pump assy must be replaced.
4. Items 1 through 6 may be exchanged.
(1) Pump housing with rotor
(2) Pressure ring
(3) Shaft seal (75 x 90 x 10)
(4) Support shim (95 x 76 x 84 x3)
(5) Needle bearing assembly (bearing outer ring and
needle bearing)
(6) Ring (75 x 84 x 4.6) LAIL11MG0413A0A 3
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5. Install the following parts into the pump housing (1).

(6) Ring
(5A) Bearing external ring
(5B) Needle cage
(4) Support shim
LAIL11MG0414A0A 4
6. With the sealing lip facing downwards, carefully insert

the shaft seal (3) into the pump housing (1) until contact
is obtained and fix it with a snap ring (2).
7. Wet outer diameter of shaft seal with spirit.
(S) Installer 5870 055 070
(S) Cable 5870 260 002
LAIL11MG0415A0A 5
8. Install outer rotor.

9. Chamfer (arrow) to show downwards.
LAIL11MG1481A0A 6
10. Install inner rotor.

11. Teeth (arrow) to show upwards.
LAIL11MG1881A0A 7
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12. Position the control disc and fix it radially with two
Allen screws (1).
NOTE: Do not tighten the Allen screws – just turn them until
contact is obtained and then turn them back approx 1/2 a
turn.
NOTE: Pay attention to the installation position of the con-
trol disc, see diagram.
13. Place an 182 x 3 O-ring (2) into the annular groove
and oil it.
LAIL11MG0416A0A 8
14. Mount the pre-assembled pump (1) and, as a first

step, insert it evenly using Allen screws (3 parts) until
contact is obtained.
NOTE: Pay attention to radial installation position.
NOTE: Then remove the Allen screws.
LAIL11MG0417A0A 9
15. Fit new 9.5x1.6 O-rings to the Allen screws.

NOTE: Grease the O-rings.
16. Fix the transmission pump (2) with Allen screws (1).
Tightening torque (10/8.8 x 75) MA = 4 6 N·m
LAIL11MG0418A0A 10
17. Fix the oil feed housing (1) with Torx screws (2).
18. Fasten the fixing plate (3) with Allen screws (4).
NOTE: Pay attention to the installation position of the fixing
plate.
LAIL11MG0419A0A 11
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19. Fix the torque converter housing (1) with hexagonal

screws (2).
LAIL11MG0420A0A 12
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Transmission/Converter oil pump - Remove

[HBZN0845VBAF00184 - ]
-]
NOTICE: The charge pump cannot be repaired. The pump

assembly must be replaced if any defect is found.
NOTE: The transmission is shown with the input housing
engine facing downwards.
1. Remove the three bolts (A).
LAIL11MG1377A0A 1
NOTICE: The driven gear and support bearings may es-

cape from the input housing during removal of the charge
pump assembly. These assemblies are a slip fit. Do not
allow gear and bearing assembly to fall. Personal injury or
damage to the components could occur.
LAIL11MG1378A0A 2
NOTICE: The driven gear and bearing assembly stays in

the input housing and if additional disassembly of the trans-
mission is necessary, remove the driven gear and bearing
assembly to avoid it falling out when the transmission is
turned over.
NOTE: Refer to the "Direct Drive Input Assembly" sec-
tion for information on disassembling and assembling the
driven gear assembly.
2. Remove the charge pump (B) and bearing assembly
(D) from the input housing.
3. Remove the O-ring (C).
LAIL11MG2060A0A 3
4. Discard the O-ring (C).
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Transmission/Converter oil pump - Install

-]
NOTE: The driven gear on the charge pump must mesh

with the idler gear. Refer to "Direct Drive input assembly
(install driven gear assemblies)". The idler gear assembly
can be installed immediately before the charge pump or as
part of the charge pump.
ATTENTION: Never install the idler gear assembly without
installing the charge pump. The idler gear assembly is a
slip fit and can fall out causing personal injury.
LAIL11MG1379A0A 1
1. Lubricate a new O-ring (C) and install it on the charge

pump (B).
NOTE: “OPTIMOLY PASTE WHITE T” is used for storage
and lubrication for extended periods, prevention against
gripping from corrosion, and noise prevention.
NOTICE: “OPTIMOLY PASTE WHITE T” is only appropri-
ate for specific paste applications and cannot replace the
oil or lubricating grease. Do not mix with other greases,
pastes or oils.
LAIL11MG1380A0A 2
2. Apply “OPTIMOLY PASTE WHITE T” to the charge

pump splines.
3. Install charge pump (B) into front cover.
4. Install three screws (A) through the charge pump into
the front cover.
NOTE: “OPTIMOL” is a registered trademark.
LAIL11MG1938A0A 3
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Input housing - Service instruction

-]
Theory of Operation Direct Drive Transmission

The engine is directly connected to the input shaft of the
transmission. When the transmission is engaged into
gear the engine power is connected to the output shaft
of the transmission at different speed ratios depending
on which directional and speed clutches are engaged.
Each clutch is engaged hydraulically and controlled by
an individual proportional valve. The rate of the pres-
sure rise behind each clutch piston is determined by the
Transmission Control Unit (TCU) providing the current
to each valve. The engine power may be disconnected
from the transmission output shaft by depressing the
clutch pedal or by shifting the transmission to the neu-
tral or park position.
The transmission charge pump and vehicle pumps are
always connected to the engine power via a constant
mesh gear train.
A torsional damper may be installed between the en-
gine and transmission input shaft to detune the system
from harmful resonant frequencies.
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Input housing - Remove

[HBZN0845VBAF00184 - ]

NOTE: Before starting removal, see Input housing - Ex-
ploded view (21.113).
1. Remove wiring harness.
2. Remove charge pump.
3. Position transmission with input housing assembly up.
LAIL11MG1142A0A 1
4. Remove the seven bolts (A).
LAIL11MG1381A0A 2
NOTICE: Check that the lifting device will lift the entire input
housing assembly. This component weighs approximately
50 kg (110 lb).
NOTICE: The lifting device must be arranged so that it lifts
the input housing assembly straight up without twisting or
tilting.
5. Install the lifting device (A).
LAIL11MG2046A0A 3
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NOTICE: Make sure that the input shaft assembly (B) does
not move up with the input housing assembly (A). It might
fall causing damage or personal injury. The input bearing
(C) will sometimes come up with the input housing, so be
careful that it does not drop out.
NOTE: If the input bearing (C) stays with the input housing
(A), make sure that it does not fall out. It can be removed
later.
6. Carefully lift the input housing assembly (A) from the
transmission (E). The input shaft assembly (B), input
bearing (C), and O-ring (D) should stay with the trans-
mission (see CAUTION and NOTE above).
LAIL11MG1144A0A 4
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[HBZN0845VBAF00184 - ]
Idler Shafts
1. Position the input housing assembly (A) engine side up.
LAIL11MG1145A0A 1
2. Install a bolt (A) on the threaded side of the idler shaft

(B). Use this bolt to pull idler shafts out of input housing.
The shafts are a slip fit.
3. Remove the O-rings (C) from the grooves in each idler
shaft.
4. Remove two O-rings from bottom of each idler shaft
bores.
5. Discard O-rings and inspect idler shaft for wear or dam-
age..
LAIL11MG1146A0A 2
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[HBZN0845VBAF00184 - ]
Input Oil Seal and Ball Bearing

NOTE: If the input ball bearing has stayed in the input hous-
ing, remove it with the oil seal.
1. Remove the oil seal (A) by pushing it down on top of
the input ball bearing.
LAIL11MG1147A0A 1
2. Remove the oil seal (A) and input ball bearing (B).
LAIL11MG1148A0A 2
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Auxiliary Pump Drive Gear Assembly

1. Install two cap screws (A) in the threaded holes in the
bearing spacer (B).
NOTICE: The bearing spacer (B) is not a tight fit on the
bearing so do not allow the auxiliary pump drive driven gear
and bearing assembly to fall as it could cause damage or
personal injury.
LAIL11MG1149A0A 1
2. Remove the bearing spacer together with the auxiliary

pump drive driven gear and bearing assembly (C).
LAIL11MG1150A0A 2
3. Remove the bearing spacer.

4. During reassembly, remember to install the lock ring
in the bearing (A). Remove the driven gear (C), the
bearings (A), and (B), using a puller.
LAIL11MG1151A0A 3
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Input housing - Install

Auxiliary Pump Drive Driven Gear Assembly

NOTE: Before starting installation, see Input housing -
Exploded view (21.113).
NOTICE: Only press on the inner race of bearings.
1. Use a press bearing installation tool to install a new
lower bearing (A) on the auxiliary pump drive driven
gear (B).
LAIL11MG1152A0A 1
2. Turn over the driven gear (C) and press the new upper
bearing with the snap ring (D) onto the gear.
NOTE: Install a new bearing with a snap ring until it is flush
with the gear.
3. Set the assembly aside.
LAIL11MG1153A0A 2
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[HBZN0845VBAF00184 - ]
Idler Gears and Bearings

1. Remove the idler gear assembly (A) from the charge
pump through the opening in the charge pump.
LAIL11MG1154A0A 1
2. Remove the idler gear assembly from the auxiliary

pump drive (A) through the opening in the auxiliary
pump.
LAIL11MG1155A0A 2
NOTE: Both the left and right side idler gears and the bear-
ing assemblies are removed in the same way.
snap rings.
3. Remove the snap ring (A).
LAIL11MG1156A0A 3
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4. Push both bearings (A) out from the side from which
the snap ring was removed.
LAIL11MG1157A0A 4
(A) Bearing (2 used)

(B) Gear
(C) Snap ring (2 used)
LAIL11MG1158A0A 5
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[HBZN0845VBAF00184 - ]
Idler Gears and Bearings

NOTE: Both idler gears are fitted in the same way. Install
the bearing into the idler gear correctly. The snap ring side
of the bearing must be on the outside of the gear.
1. Install the snap ring mounting side of the new bearing
(A) on the outside of the gear.
LAIL11MG1159A0A 1
2. Turn the idler gear and install the second bearing.

3. Set both assemblies aside.
LAIL11MG1160A0A 2
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[HBZN0845VBAF00184 - ]
Lift Hanger
1. Remove the two screws (A).
2. Remove the lift hanger (B).
LAIL11MG1161A0A 1
Hex Socket Plug

1. Remove the socket head hex plug (A) and O-ring (B).
2. Discard O-ring.
3. Inspect socket head plug for damage.
LAIL11MG1163A0A 2
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[HBZN0845VBAF00184 - ]
Hex Socket Plug

1. Lubricate a new O-ring (A) and install it on the plug (B).
2. Install plug assembly.
LAIL11MG1164A0A 1
Lift Hanger
NOTICE: Replace the removed screws with new ones of
the same length and grade as the original ones.
1. Install the two bolts (A).
LAIL11MG1162A0A 2
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[HBZN0845VBAF00184 - ]
Oil Seal
1. Position the input housing (A) with the engine facing
upwards.
NOTICE: If the new oil seal is not coated on the outside
diameter with a sealant, apply LOCTITE® 620™.
2. Install a new oil seal (B) flush with the machined sur-
face on the input housing.
LAIL11MG1165A0A 1
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[HBZN0845VBAF00184 - ]
Idler Gear Assemblies and Bearings

1. Lubricate all of the bearings with clean transmission
fluid.
2. Place the idler gear assembly (A) into the auxiliary
pump port of the input housing.
LAIL11MG1166A0A 1
3. Slide the idler group assembly (A) into its position be-
tween the auxiliary pump opening and the input shaft
hole.
LAIL11MG1167A0A 2
4. Place the other idler group assembly (B) into its position
between the auxiliary pump opening and the input shaft
hole.
LAIL11MG1168A0A 3
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Auxiliary pump drive dear

1. Lubricate both bearings with clean transmission fluid.
2. Install the auxiliary pump drive gear assembly snap ring
up (A) in the pump drive port.
LAIL11MG1384A0A 4
3. Align the teeth of gear (B) and (C).

4. Push the auxiliary pump drive gear assembly (B) into
the bore in the front cover.
LAIL11MG1385A0A 5
5. Install the bearing spacer (E).
LAIL11MG1386A0A 6

snap rings. Wear safety glasses when removing or in-
stalling snap rings. Personal injury to self or bystanders
could result.
6. Install the snap ring (F) into the groove.
LAIL11MG1172A0A 7
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[HBZN0845VBAF00184 - ]
Idler Shafts
NOTE: The hole through the idler gear shafts (D) must be
aligned with the hole through the input housing (B). Use
one of the long input housing cap screws (F) to guide the
alignment of the shaft.
1. Align the hole in the bearing in the idler gear assembly
(A) with the hole in the idler gear shaft in the input
housing (B).
2. Lubricate the O-ring (C) with grease and install it in the
cavity in the idler gear shaft (D).
3. Use grease to hold the O-ring (E) to the bottom of the
idler gear shaft during installation (see the alternative
installation procedure as well). LAIL11MG1169A0A 1
Alternative O-Ring installation procedure

4. Lubricate the O-ring (E) with grease and position it at
the bottom of the hole in the idler gear shaft in the input
housing.
5. Align the hole in the idler gear shaft with the input hous-
ing hole, inserting one of the long bolts (F) from the in-
put housing via both parts.
6. Push the idler gear shaft through the idler gear assem-
bly into the input housing. Be sure both O-ring stay in
place.
LAIL11MG1170A0A 2
7. Install the other idler shaft (G) in the same way.

NOTICE: Both the idler gears should turn.
8. Remove the cap screws that were used as alignment
guides.
LAIL11MG1171A0A 3
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[HBZN0845VBAF00184 - ]
Auxiliary Pump Drive Gear

1. Lubricate both bearings with clean transmission fluid.
2. Install the auxiliary pump drive gear assembly snap ring
up (A) in the pump drive port.
LAIL11MG1384A0A 1
3. Align the teeth of gear (B) and (C).

4. Push the auxiliary pump drive gear assembly (B) into
the bore in the front cover.
LAIL11MG1385A0A 2
5. Install the bearing spacer (E).
LAIL11MG1386A0A 3
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snap rings. Wear safety glasses when removing or in-
stalling snap rings. Personal injury to self or bystanders
could result.
6. Install the snap ring (F) into the groove.
LAIL11MG1172A0A 4
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[HBZN0845VBAF00184 - ]

NOTICE: The guide pin must be installed. If left out, trans-
mission will be damaged.
1. Check that the guide pin (A) is in place. If not, install it.
NOTICE: The input housing assembly and the transmis-
sion must be level to avoid damage to the seal ring as it
moves over the input shaft splines.
2. Slowly lower the input housing assembly (B) onto the
front housing, input bearing, and guide pin.
LAIL11MG1399A0A 1
NOTE: The front housing (D) must be mounted flush with

the input housing assembly (C).
3. Check the input housing (C).
LAIL11MG1176A0A 2
4. Remove the lifting tool (E).
LAIL11MG1177A0A 3
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5. Install the seven bolts (F).
LAIL11MG1178A0A 4
6. Tighten the bolts (F) with a torque of 87 N·m (64 lb ft).
LAIL11MG1179A0A 5
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-]

1. Position transmission with input housing up.
2. Remove the seven bolts (A).
LAIL11MG1381A0A 1
NOTICE: Check that the lifting device will lift the entire input
housing assembly. This component weighs approximately
50 kg (110 lb).
3. Install the lifting device (A).
LAIL11MG1863A0A 2
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-]
Idler Gear Shafts

1. Position the input housing assembly (A) engine side up.
LAIL11MG1238A0A 1
2. Install a bolt (C) into the threaded hole (B) in the idler
shaft. Use this bolt to pull idler shafts, the shafts are a
slip fit in their bores. The two idler gears have a sliding
housing.
3. Remove the two idler shafts (B).
NOTE: The O-rings on the bottom of the idler shafts can
remain at the bottom of the idler shaft bores.
4. Remove the two O-rings from the idler shafts and the
two O-rings from the bottom of the idler shaft bores.
Discard the O-rings.
5. Inspect idler shaft for wear or damage.
LAIL11MG1239A0A 2
6. Use a driving tool to remove oil seal and bearing from

input housing.
LAIL11MG1240A0A 3
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-]
Driven Gears
1. Position input housing to have pump ports and driven
gear assemblies up.
2. Remove the driven gear assembly (A) from the charge
pump side.
3. Remove the snap ring (B) from the groove in the auxil-
iary pump side bore.
4. Remove the driven gear assembly and the spacer (C).
LAIL11MG1241A0A 1
5. Use a puller to remove the bearings (D) from the gear

(E).
6. Inspect bearings and gears.
LAIL11MG1242A0A 2
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-]
Driven Gears and Bearings (Feeder Pump Side)

NOTICE: Use a press tool that bears on the inner race of
the bearings.
1. Press the bearing (A) onto the driven gear (B).
2. Turn the gear over and press the bearing (C) onto the
gear.
NOTE: The auxiliary pump port driven gear assembly will
have one bearing with a snap ring. Install this bearing with
snap ring closest to gear.
LAIL11MG1243A0A 1
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-]
Intermediate Gears
1. Remove idler gears through input housing pump ports.
LAIL11MG1244A0A 1
2. Remove the snap ring (A) from the top bearing.

3. Support gear so that the bottom bearing is free to come
out when the top bearing is pressed through.
4. Press top bearing through idler gear, removing both
bearings.
5. Inspect bearings and gears for wear or damage.
LAIL11MG1245A0A 2
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-]
Intermediate Gears
NOTE: Both intermediate gears assemble in the same way.
1. Install bearing into the idler gear correctly. Snap ring
side of bearing to the outside of the gear.
LAIL11MG1246A0A 1
2. Use a press and bearing installation tool to install bear-

ings into idler gear.
LAIL11MG1247A0A 2
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-]
Oil Seal and Ball Bearing

NOTE: Before starting removal, see Input housing -
Overview (21.113).
1. Position input housing with engine side up.
2. Install a new oil seal.
NOTE: If the outside diameter of the oil seal is not already
coated with a sealant, apply LOCTITE® 620™
LAIL11MG1249A0A 1
3. Position input housing with engine side down.

4. Install the guide pin (D).
LAIL11MG1250A0A 2
5. Install new ball bearing (E) into front cover.
LAIL11MG1251A0A 3
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-]
Input Housing Assembly to Main Case Front Housing

1. Install lifting device, make sure the input housing as-
sembly hangs level.
NOTICE: Ensure that the front housing of the main case
is level before attempting to install the input housing as-
sembly. Special attention is required when lowering input
housing onto front housing. Avoid damage to input seal
during installation.
2. Lower input housing assembly carefully over direct
drive input bearing retainer onto front housing.
NOTE: Ensure that the input housing goes down com-
pletely and sits flush with the front housing.
LAIL11MG1863A0A 1
3. Install the seven bolts (A).
LAIL11MG1381A0A 2
LAIL11MG2122A0A 3
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Index
Transmission - 21

Drive oil dipstick line - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Drive oil dipstick line - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Drive oil dipstick line - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Front housing - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Front housing - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Front housing - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Front housing - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Front housing - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Front housing - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Front housing - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Front housing - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Front housing - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Front housing - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Front housing - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Front housing - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Input housing - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Input housing - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Input housing - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Input housing - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
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Input housing - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Input housing - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Input housing - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Input housing - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Input housing - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Input shaft - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Input shaft - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Input shaft - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Input shaft - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Input shaft - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Input shaft - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Input shaft coupling - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Input shaft coupling - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Input shaft coupling - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Powershift transmission - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Powershift transmission - Calibrate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Powershift transmission - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Powershift transmission - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Powershift transmission - Identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Powershift transmission - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Powershift transmission - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Powershift transmission - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Powershift transmission - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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Powershift transmission - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Powershift transmission - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Powershift transmission - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Powershift transmission - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Powershift transmission - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rear housing - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Rear housing - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Rear housing - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Rear housing - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Rear housing - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Rear housing - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Rear housing - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Transmission/Converter oil pump - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Transmission/Converter oil pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Transmission/Converter oil pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Transmission/Converter oil pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
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Transmission - 21
Powershift transmission external controls - 135

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Contents
Transmission - 21
TECHNICAL DATA
Transmission control valve

Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA

Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE

Transmission control valve - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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Transmission - Powershift transmission external controls
Transmission control valve - General specification

[HBZN0845VBAF00184 - ]
-]
Lube
Name Usage
Weight
Name Specification
Valve assembly 25 kg (55 lb)
Proportional valves
The proportional valve is a pilot operated cartridge valve.
The amount of electrical current going to the coil creates
a magnetic force which opens a pilot valve allowing flow
to exit the pilot cavity. The pilot cavity is fed a controlled
amount of flow from the inlet pressure port of the valve
via a fixed pilot feed orifice. The difference between the
restrictions of the pilot inlet orifice and pilot exit valve con-
trols the oil pressure in the pilot cavity.
This pressure acts on the area on one end of the main

spool causing it to open. There is a light spring on the
opposite end of the main spool resisting this pressure plus
the clutch port pressure is fed to the spring end of the main
spool as a feedback, causing the valve spool to close as
the clutch pressure and spring force becomes equal to the
pilot pressure. The output pressure from the valve is zero
at zero current and increases to within 15 psi of the inlet
pressure as the current to the coil is increased.
Transmission control valve - Torque

[HBZN0845VBAF00184 - ]
-]
Control valve to the front housing screws (27)

40 N·m (30 lb ft)
Proportional valve nut to the proportional solenoid assembly (8)
1.7 – 2.8 N·m (1 – 2 lb ft)
Plug 7/16 in- 20 mm to the valve housing (12)
12 N·m (9 lb ft)
Plug 9/16 in- 18 mm to the valve housing (2)
25 N·m (18 lb ft)
Temperature sensor to the valve housing.
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16 N·m (12 lb ft)

Proportional valve to the valve housing (8)
16 – 20 N·m (12 – 15 lb ft)
Main regulator assembly to the valve housing
142 N·m (105 lb ft)
Relief valve assembly to the valve housing
102 N·m (75 lb ft)
Transmission control valve - Torque

[HBZN0845VBAF00184 - ]
-]
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LAIL11MG1592G0A 1
NOTICE: Tighten the bolts in the rotational sequence shown in the illustration.
1. In the first rotational sequence, tighten all of the bolts to a torque of 40 N·m (30 lb ft).
2. Repeat Step 1.
NOTICE: Torque specification for the check valve bolts: 40 N·m (30 lb ft).
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Transmission control valve - Sectional view

[HBZN0845VCAF01093 - ]
BRCE12GRCCM029A 1
BRCE12GRCCM030A 2
1. 16+2 bar Lead-in valve 10. Pressure limiter

2. Pressure reducing valve 9 bar 11. Follow-on slide
3. Electrical Wiring Harness 12. 16+2 bar Lead-in valve
4. Tap 13. Hydraulic distributor
5. Casing 14. Electrical Wiring Harness
6. Hydraulic distributor 15. Duct plate
7. Casing 16. Pressure reducing valve 9 bar
8. Tap P5. Proportional Valve
9. Vibration damper
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Transmission control valve - Exploded view

[HBZN0845VBAF00184 - ]
-]
LAIL11MG1591G0A 1
A. Join F. Bolt M8 x 45 10.9 mm (5)

B. Deck Plate G. Bolt M8 x 75 10.9 mm (13)
C. Join H. Temperature sender
D. Valve assembly I. O-Ring
E. Smooth washer (27) J. Bolt M8 x 90 10.9 mm (9)
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Transmission control valve - Exploded view

[HBZN0845VBAF00184 - ]
-]
LAIL11MG0516G0A 1
A. Valve casing G. Hex socket plug

B. Hex socket plug 9/16 in - 18 mm (2)
7/16 in - 20 mm (12) H. Plug
C. Proportional valve of 12 V or 24 V (7) I. O-Ring
D. 90 Relief Valve J. O-Ring
E. Main Regulator Assembly K. O-Ring
F. Steel ball 9/32 in (4) L. Proportional Solenoid Plug
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Transmission control valve - Remove

[HBZN0845VCAF01093 - ]
1. Remove the gear-shift control (1).

2. Loosen the Torx screws (2) and separate the gear-shift
control housing from the intermediate plate.
(S) Socket TX-27 5873 042 002
(S) Adjusting screws M6 5870 204 063
LAIL11MG1555A0A 1
3. Remove the gear-shift control assembly (1) and the

sealing plate (2).
(S) Adjusting screws M6 5870 204 063
LAIL11MG1556A0A 2
4. Remove the differential pressure switch for the fine filter

from the duct plate (4).
(1) Switch with an O-ring
(2) Piston
(3) Compression spring
LAIL11MG1557A0A 3
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5. Loosen the hexagonal nuts and the Torx screws and

separate the duct plate (1) and seal (2) from the rear
part of the housing.
LAIL11MG1558A0A 4
6. Pull the converter safety valve (1) out of the housing

hole.
LAIL11MG1559A0A 5
7. Mark the installation position of the wiring harness (1)

in relation to the valve block (2).
LAIL11MG1560A0A 6
8. Loosen the Torx screws (1).

(S) Socket TX-27 5873 042 002
LAIL11MG1561A0A 7
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9. Separate the duct plate (1) and the sealing plate (2)
from the valve block (3).
LAIL11MG1562A0A 8
10. Remove the check clamp (1).
LAIL11MG1563A0A 9
11. Loosen the Torx screws (1) and remove the cover (2).
Remove the opposite cover (3) in the same way.
(S) Socket TX-27 5873 042 002
LAIL11MG1564A0A 10
12. Remove the wiring harness (1).

13. Loosen the Allen screws (3), remove the fixing plates,
and remove the pressure controllers (2).
LAIL11MG1565A0A 11
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14. Loosen the Allen screws, remove the fixing plates,

and remove the pressure controllers (1) on the oppo-
site side.
LAIL11MG1566A0A 12
15. Loosen two Torx screws (1) and preliminarily fix the
housing using the set screws (S). (The housing takes
the load from the spring). Then loosen the remaining
Torx screws.
(S) Adjusting screws 5870 204 036
LAIL11MG1567A0A 13
16. Separate the housing from the valve housing by loos-

ening the set screws equally.
LAIL11MG1568A0A 14
17. Remove the individual parts:

(1) Pressure reducing valve
(2) Vibration dampers
(3) Follow-on slide
LAIL11MG1569A0A 15
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18. Remove individual parts of opposite side analogously.

(1) Main pressure valve
(2) Vibration dampers
(3) Follow-on slide
LAIL11MG1570A0A 16
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Transmission control valve - Install

[HBZN0845VCAF01093 - ]
NOTE: Different versions regarding the wiring harness po-

sition are possible.
NOTE: Refer to Transmission control valve - Sectional
view (21.135).
NOTE: All single parts are to be checked for damage and
replaced, if required.
NOTE: Ensure free travel of the moving parts in the valve
block prior to installation. Pistons can be exchanged indi-
vidually.
NOTE: Before installation, lubricate the separated parts
with the recommended lubricant.
1. With the concave side facing upwards, insert the orifice
(1) until contact is obtained.
LAIL11MG0446A0A 1
NOTE: See the arrows for the installation position.

2. Use the following individual parts, as illustrated:
(1) Pressure reducing valve (1x, piston, and compres-
sion spring)
(2) Vibration damper (3x, piston, and compression
spring)
(3) Follow-on slide (3x, piston, and compression spring)
LAIL11MG0447A0A 2
3. Install the individual parts, as shown in illustration 2.

NOTE: Preload the compression springs of the follow-on
slides and preliminarily fix pistons using cylindrical pins
5.0 mm (assembly aid), see arrows (S).
LAIL11MG0448A0A 3
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4. Fit two adjusting screws.

5. Install the seal (1) and the housing (2).
6. Then position housing equally by means of adjusting
screws until contact is obtained.
LAIL11MG0449A0A 4
7. Bring the housing (1) into the contact position using

Torx screws. This will preload the pistons, and you can
remove the cylindrical pins (assembly aid).
LAIL11MG0450A0A 5
8. Fix the housing using Torx screws (1).

Tightening torque (M5/10.9 x 30) MA = 5.5 N·m
(S) Reducing adapter 5870 656 056
(S) Socket TX-27 5873 042 002
LAIL11MG0451A0A 6
9. Mount the pressure controllers (1) and fasten them with

fixing plates (2) and Allen screws (3).
NOTE: Install fixing plate, with the claw showing down-
wards.
NOTE: Pay attention to the radial installation position of the
pressure controllers, as illustrated.
(S) Socket TX-27 5873 042 002
LAIL11MG0452A0A 7
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Preassembly of opposite side

1. Use the following individual parts, as illustrated:
(1) Pressure reducing valve (1x, piston, and compres-
sion spring)
(2) Vibration damper (3x, piston, and compression
spring)
(3) Follow-on slide (3x, piston, and compression spring)
LAIL11MG0453A0A 8
2. Install the individual parts, as shown in illustration 8.

NOTE: Preload the compression springs of the follow-on
slides and preliminarily fix pistons using cylindrical pins
5.0 mm (assembly aid), see arrows (S).
(S) Adjusting screws, M5 5870 204 036
4. Mount the seal (1) and housing (2) and position the
housing evenly with the adjusting screws until contact
is obtained.
LAIL11MG0454A0A 9
5. Bring the housing (1) into the contact position using

Torx screws. This will preload the pistons, and you can
remove the cylindrical pins (assembly aid).
6. Secure the housing using Torx screws (1).
(S)Socket TX-27 5873 042 002
LAIL11MG0455A0A 10
7. Mount the pressure controllers (1) and fasten them with

fixing plates and Allen screws .
NOTE: Install fixing plate, with the claw showing down-
wards.
NOTE: Pay attention to the radial installation position of the
pressure controllers, as illustrated.
LAIL11MG0456A0A 11
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8. Mount the wiring harness (1) and connect the pressure

controllers (6x).
NOTE: For the installation position of the pressure con-
trollers, see Transmission control valve - Sectional view
(21.135).
NOTE: Pay attention to the installation position of the wiring
harness. Refer to the markings done during disassembly.
LAIL11MG0457A0A 12
9. Fit the seal (1).

10. With the groove showing to the cover plug nose,
mount socket until contact is obtained.
11. Fix cover by means of Torx screws.
12. Tightening torque (M5/10.9 x 30) MA = 5.5 N·m
(S) Socket TX-27 5873 042 002
LAIL11MG0461A0A 13
13. Secure the wiring harness using the retaining clamp

(1).
NOTE: Fit the opposite cover.
LAIL11MG0462A0A 14

LAIL11MG0463A0A 15
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15. Flush-mount the screens (1) into the holes of the seal-
ing plate, see arrows.
NOTE: Pay attention to the installation position – screens
to show upwards (towards the duct plate).
LAIL11MG0464A0A 16
NOTICE: In the first quarter of 2007, the shift unit paper

seal was changed to seal plates (coated plates) in series
production, as illustrated.
16. In case of repairs, the paper seals (1) and the inter-
mediate plate (2) must be replaced by the seal plate,
see illustration 18.
17. The fixing screws must be changed for shorter screws,
OLD Torx M6 x 25 screw (paper plate)
NEW Torx M6 x 23 screw (sealing plate)
LAIL11MG0465A0A 17
18. Install the sealing plate (1) and duct plate (2).
NOTE: The baffles (3) must face upwards.
NOTE: It is not permitted to re-assemble the seal plate after
opening the threaded joint shift unit/duct plate.
NOTE: In case of repair it is always necessary to mount a
new seal plate.
LAIL11MG0466A0A 18
19. Install the duct plate (1) and secure it uniformly using
Torx screws (2).
(S) Socket TX-27 5873 042 002
LAIL11MG0467A0A 19
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20. Install screw plugs with new 8 x 1.5 O-rings (1) and
install them.
Tightening torque (M10 x 1) MA = 6 N·m
LAIL11MG0468A0A 20
21. Insert a torque converter safety valve (1) into the hous-
ing hole until contact is obtained.
LAIL11MG0469A0A 21
22. Mount the stud bolts (1).

NOTE: Lubricate the bolt thread with LOCTITE® 243™.
23. Install the seal (2) and duct plate (3) at the rear part of
the housing until contact is obtained.
NOTE: Use assembly grease.
LAIL11MG0470A0A 22
24. Secure the duct plate (1) with Torx screws (2) and hex
nuts (3).
Tightening torque (M8) MA = 23 N·m
25. Mount the screw plug (4) with a new 13 x 2 O-ring.
Tightening torque (M16 x 1.5) MA = 30 N·m
(S) Socket TX-40 5873 042 004
LAIL11MG0471A0A 23
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26. Mount the compression spring (4), piston (3), and

switch (2) with a new 13 x 2 O-ring.
(1) Filter differential pressure valve
(2) Switch with an O-ring
(3) Piston
Tightening torque MA = 30 N·m
NOTE: Versions without a filter differential pressure valve:
Mount the screw plug with a new O-ring instead of a switch
(2). LAIL11MG0472A0A 24
NOTICE: In the first quarter of 2007, the shift unit paper

seal was changed to seal plates (coated plates) in series
production, as illustrated.
27. In case of repairs, the paper seals (1) and the inter-
mediate plate (2) must be replaced by the seal plate,
28. The fixing screws must be changed for shorter screws,
OLD Torx M6 x 80 screw (paper plate)
NEW Torx M6 x 76 screw (sealing plate)
LAIL11MG0473A0A 25

30. Mount the sealing plate (1) and the electro-hydraulic
control unit (2).
NOTE: It is not permitted to re-assemble the seal plate after
opening the threaded joint shift unit/gearbox housing.
NOTE: In case of repair it is always necessary to mount a
new seal plate.
LAIL11MG0474A0A 26
31. Fix the electro-hydraulic control unit (1) uniformly with

Torx screws (2).
(S) Socket TX-27 5873 042 002
LAIL11MG0475A0A 27
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Transmission control valve - Remove

[HBZN0845VBAF00184 - ]
-]
1. Tag all electrical connections.

2. Remove wiring harness.
3. Remove charge pump group.
4. Remove the input housing assembly
LAIL11MG1659A0A 1
5. Remove temperature sensor.

NOTE: When installing the temperature sensor, tighten it
to a torque of 24 – 27 N·m (18 – 20 lb ft).
LAIL11MG1943A0A 2
NOTICE: Do not allow any of the flat washers (B) to fall

into the openings of the control valve assembly or of the
transmission. The transmission may not operate properly
or damage may result.
6. Remove the 27 screws (A) and the flat washers (B).
NOTICE: The approximate weight of the control valve as-
sembly is 25 kg (55 lb).
7. Remove the valve assembly.
LAIL11MG1944A0A 3
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8. Remove and discard the joint (D).

NOTICE: Do not bend the plate (E).
9. Remove plate (E).
10. Remove and discard the joint (F).
11. Clean and inspect all gasket surfaces.
LAIL11MG1401A0A 4
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Transmission control valve - Disassemble

[HBZN0845VBAF00184 - ]
-]
NOTICE: The cartridge-type valves used in this assembly cannot be repaired by the user. Any valve found to be
defective must be replaced as a unit.
NOTE: Before starting disassembly, see Transmission control valve - Exploded view (21.135).
Proportional Solenoid Assembly Removal

1. Remove the proportional solenoid, the nut (A), washer
(B), and coil (C).
LAIL11MG1945A0A 1
2. Remove the proportional valve (D).

3. Inspect for contamination.
LAIL11MG1946A0A 2
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Removing the Relief Valve

1. Remove the relief valve (A).
2. Inspect for wear and contamination.
LAIL11MG1947A0A 3
Remove Main Regulator Assembly

NOTICE: The main regulator is an assembly and therefore
is not repairable and must be replaced as a whole if found
to be defective. The O-rings (3) are replaceable parts.
1. Remove the main regulator assembly (A).
2. Discard the O-rings (3).
LAIL11MG1948A0A 4
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Remove Proportional Plug

1. Remove the solenoid assemblies.
LAIL11MG1949A0A 5
NOTE: In some applications, proportional plugs replace the

solenoids. (The proportional plugs depend on the applica-
tion.).
2. Remove the proportional plug (A).
LAIL11MG1950A0A 6
Remove Plug
1. Remove plug (A).
LAIL11MG1951A0A 7
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Transmission control valve - Assemble

[HBZN0845VBAF00184 - ]
-]
NOTICE: The cartridge-type valves used in this assembly cannot be repaired by the user. Any valve found to be
defective must be replaced as a unit.
NOTICE: Cartridge-type valves require O-rings. When assembling valves grease all o-rings. Use only new o-rings.
Install new o-rings onto cartridge type valve.
NOTE: Before starting installation, see Transmission control valve - Exploded view (21.135).
Install Plug
1. Lubricate new O-ring.
2. Install new o-ring onto plug.
3. Install plug (A).
4. Tighten the plug to a torque of 12 N·m (9 lb ft).
LAIL11MG1951A0A 1
Install Proportional Plug

1. Lubricate the new O-rings (3).
2. Install new o-rings onto proportional plug.
3. Install the proportional plug (A).
4. Tighten proportional plug.
LAIL11MG1950A0A 2
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Install Main Regulator Assembly

2. Install new o-rings.
3. Install the main governor assembly (A).
4. Tighten the main governor assembly to a torque of
142 N·m (105 lb ft).
LAIL11MG1948A0A 3
Install Relief Valve

2. Install the new O-rings (A).
3. Install relief valve.
4. Tighten the relief valve to a torque of 102 N·m (75 lb
ft).
LAIL11MG1947A0A 4
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Install Proportional Solenoid Assembly

1. Install the new O-rings (A), (B), and (C) on the propor-
tional valve.
LAIL11MG1952A0A 5
2. Install the proportional valve (D) in the valve housing.

3. Tighten the proportional valve to a torque of 16 –
20 N·m (12 – 15 lb ft).
LAIL11MG1946A0A 6
4. Install the coil (E), the washer (F), and the nut (G) on
the proportional valve.
LAIL11MG1953A0A 7
5. Tighten the nut at a torque of 1.7 – 2.8 N·m (15 – 25 lb

in).
LAIL11MG1954A0A 8
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[HBZN0845VBAF00184 - ]
-]
Gaskets and Plate to Front Housing to Valve Contact Surface

NOTE: Before starting installation, see Transmission
control valve - Exploded view (21.135).
NOTICE: There are two gaskets (2) and a plate that go
between the valve assembly and the front housing. The
first gasket is cut out to the shape of the casting on the
front housing. The second gasket is cut out to the shape
of the metal plate and has a boot-like shape cut out of it.
NOTE: Guide pins are used in place of bolts with the heads
removed. The guide pin length will need to be long enough
for removal after placing the valve housing assembly onto
the front housing.
1. Install the two guide pins (A).
LAIL11MG1955A0A 1
NOTICE: The gasket must match the opening in the front

housing.
2. Place and fit a new gasket (B) onto the front housing,
fixing it with guide pins (A).
LAIL11MG2051A0A 2
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NOTICE: The opening in the plate must match the opening

in the gasket.
3. Place the plate (C) over the guide pins and onto the
gasket (B).
LAIL11MG1957A0A 3
NOTICE: The opening in the gasket must match the open-

ing in the plate.
4. Place the new gasket (D) over the guide pins and onto
the plate (C).
LAIL11MG1402A0A 4
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[HBZN0845VBAF00184 - ]
-]
Control Valve Group

NOTE: Before starting installation, see Transmission
control valve - Exploded view (21.135).
NOTICE: The approximate weight of the control valve as-
sembly is 25 kg (55 lb).
NOTE: The guide pins should be long enough so that they
can be removed after installation of the valve assembly.
1. Install the valve assembly (A).
2. Install the guide pins (B).
LAIL11MG1958A0A 1
NOTICE: The 27 screws (C) securing the control valve are

of three different lengths. Use proper length cap screws for
each cap screw hole.
NOTICE: Do not allow the washers to fall into any opening
in the control valve assembly or in the transmission.
3. Install the 27 screws (C) and the flat washers.
LAIL11MG2050A0A 2
NOTICE: Tighten the screws (E) evenly in sequence ac-

cording to the instructions given in "screw tightening se-
quence and torque specifications", Transmission control
valve - Torque (21.135).
4. Tighten the screws, following the tightening sequence
and torque specifications, Transmission control
valve - Torque (21.135).
5. Tighten the bolts (E) with a torque of 40 N·m (30 lb ft).
LAIL11MG1959A0A 3
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Transmission control valve - Pressure test

[HBZN0845VBAF00184 - ]
-]
BRCE12GRCCM031A 1
Pressure and Temperature Check Ports
A. Valve casing K. Clutch A Check Port

B. Port to check the pressure L. Auxiliary Pressure Source
of the converter output M. Temperature sensor
C. Port to check the pressure N. Port to check the pressure
of the converter input of the system
D. Port to check the pressure O. Lube In Port
of clutch 1 P. Lube In Port
E. Port to check the pressure Q. Auxiliary Pressure Source
of clutch 2 R. Clutch D Check Port
F. Port to check the pressure R. Clutch C Check Port
of the lubrication T. Solenoid Assembly
G. Converter Relief U. Temperature Sensor
H. Pressure Regulator V. Clutch 4 Check Port
I. Pump In Port W Clutch 3 Check Port
J. Clutch B Check Port
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Operating Condition
• Engine speed at 2000 RPM.
• Transmission temperature band to 65 – 93 °C (149
– 199 °F).
• Pump flow from 87 – 102 l/min (23 – 27 US gpm) to
1655 – 1931 kPa (240 – 280 psi).
Port pressure
In neutral
• Converter input 60 – 115 psi (see note).
• Converter output 40 – 90 psi.
• Lubrication 40 – 60 psi.
Engaged
• Lubrication 20 – 40 psi.
NOTE: In neutral, the “converter in” pressure should al-
ways be higher than the lubrication pressure.
Pressure and Temperature Check Ports

Following is identification of ports as they are marked
on the valve body casting.
• Ports marked 1, 2, 3 and 4 are Direction Clutch
Ports:
• 1 and 2 are forward clutches.
• 3 and 4 are reverse clutches.
NOTE: All check ports are 7/16 in-20 UNF, O-rings SAE,
except when specified otherwise.
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Index
Transmission - 21

Transmission control valve - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission control valve - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Transmission control valve - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Transmission control valve - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Transmission control valve - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Transmission control valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Transmission control valve - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Transmission control valve - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Transmission control valve - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Transmission control valve - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Transmission control valve - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Transmission control valve - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Transmission - 21
Powershift transmission hydraulic components - 105

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Contents
Transmission - 21
FUNCTIONAL DATA
Filter suction line

Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Transmission oil filter

Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Filter suction line
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Transmission - Powershift transmission hydraulic components
Filter suction line - Overview

[HBZN0845VBAF00184 - ]
-]
LAIL11MG0513G0A 1
A. O-ring fitting (2 used) E. Join

B. Suction tube F. Suction manifold
C. Suction screen assembly G. O-Ring
D. Cap screw (2 used)
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Filter suction line - Overview

[HBZN0845VBAF00184 - ]
-]
LAIL11MG1588G0A 1
Suction tube assembly
A. O-ring fitting (2 used) E. Join

B. Suction tube F. Suction manifold
C. Suction screen assembly G. O-Ring
D. Screw (2 used)
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Transmission oil filter - Remove

[HBZN0845VCAF01093 - ]
1. Attach the transmission to the assembly trestle.

(S) Assembly trestle 5870 350 000
(S) Holding fixtures 5870 350 063
(S) Clamping profiles 5870 350 090
NOTE: Drain oil prior to starting disassembly.
LAIL11MG0654B0A 1
2. Separate the fine filter (1) from the filter head using a
belt spanner.
(S) Belt spanner 5870 105 005
LAIL11MG0629A0A 2
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3. Loosen the Torx screws (2) and separate the filter head
(1) from the transmission housing.
(S) Socket TX 40 5873 042 004
NOTE: Remove O-rings.
LAIL11MG0630A0A 3
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Transmission oil filter - Install

[HBZN0845VCAF01093 - ]
1. Fix the filter head (1) with new 34.2 x 3 O-rings to the
rear part of the housing with Torx screws (2).
(S) Socket TX-40 5870 042 004
LAIL11MG0483A0A 1
2. The filter is to be installed as follows:

• Lightly oil the seal.
• Turn the filter in until it is in contact with the sealing
surface and then tighten it by hand approximately 1/3
to 1/2 rotation.
NOTICE: Before putting the transmission into operation, fill
it with oil of the recommended specifications.
LAIL11MG0484A0A 2
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Filter suction line - Remove

[HBZN0845VBAF00184 - ]
Before starting the removal procedure, see Filter suc-

tion line - Overview (21.105).
NOTICE: All oil should be drained from the transmission
before beginning disassembly.
NOTE: Check the intervals for replacing the transmission
fluids and filters when draining the fluid.
1. Loosen the bolts (A).
2. Remove the support (B).
3. Completely loosen the upper O-ring fitting nut (C).
LAIL11MG1376A0A 1
4. Completely loosen the lower O-ring fitting nut (D).
LAIL11MG1902A0A 2
5. Remove the suction screen assembly (G) and gasket

(E) from the suction manifold (F).
LAIL11MG1903A0A 3
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6. Remove the two screws (H).
LAIL11MG1904A0A 4
7. Remove and discard the O-ring (I).
LAIL11MG1905A0A 5
8. Remove the suction tube (J) with the O-ring fitting parts.
9. Clean and inspect all parts for damage.
LAIL11MG1906A0A 6
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Filter suction line - Install

[HBZN0845VBAF00184 - ]
Before starting the installation procedure, see Filter

suction line - Overview (21.105).
1. Insert the upper end of the suction tube (A) into the
O-ring fitting half (B) in the charge pump and lightly
tighten nut (C) by hand.
LAIL11MG1939A0A 1
2. Lubricate and install a new O-ring (D) in the groove in

the suction manifold (E).
LAIL11MG2045A0A 2
3. Place the suction manifold in its working position. Be

sure the O-ring stays in place.
4. Insert the lower end of the suction tube into the O-ring
fitting half (F) and lightly tighten nut (G) by hand.
5. Install the two bolts (H) and tighten them to a torque of
25 N·m (18 lb ft).
6. Grease the joint (I).
LAIL11MG2001A0A 3
48050419D 06/10/2017
21.3 [21.105] / 10
7. Install the suction screen assembly (J) and gasket.

8. Tighten 3/4 to one turn after the gasket contacts the
face of suction manifold.
9. Check for leaks after operating transmission.
LAIL11MG2002A0A 4
10. Tighten the bolt (K) to a torque between 190 N·m

(140 lb ft).
LAIL11MG1902A0A 5
11. Tighten the bolt (L) to a torque between 190 N·m

(140 lb ft).
LAIL11MG2044A0A 6
12. Move the wiring harness support (M) out of position

and tighten the bolts (N) with a torque of 87 N·m (64 lb
ft).
13. Install wiring harness (O). Check that the wiring har-
ness is facing away from the moving parts. Match the
original connections.
LAIL11MG1940A0A 7
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21.3 [21.105] / 11
14. Position the main wiring harness connector (O) in the

bracket.
15. Tighten the nut at a torque of 18 – 27 N·m (13 – 20 lb
ft).
LAIL11MG1941A0A 8
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Filter suction line - Remove

-]
Before starting the removal procedure, see Filter suc-

tion line - Overview (21.105).
NOTICE: All oil should be drained from the transmission
before beginning disassembly.
NOTE: Check the intervals for replacing the transmission
fluid and filters when draining the fluid.
1. Loosen the bolts (A)
LAIL11MG1858A0A 1
2. Remove the support (B).
LAIL11MG1859A0A 2
3. Loosen the wiring harness connector bracket and move

it out of the way.
4. Loosen the nut (A) on the suction tube.
LAIL11MG1860A0A 3
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21.3 [21.105] / 13
5. Remove the suction screen assembly (B). Clean and

inspect.
6. Loosen the nut (C) connecting the suction tube (D) to
the suction manifold.
7. Remove the two screws (E) from the suction manifold.
8. Remove suction manifold and O-ring in groove on back
of manifold.
9. Remove the suction tube (D).
LAIL11MG2028A0A 4
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Filter suction line - Install

-]
NOTICE: There must not be any leaks. Use care assem-

bling and installing the suction tube. A leak may cause the
transmission to not operate properly or the charge pump to
fail.
1. Place the suction tube (D) into the fitting on the charge
pump.
LAIL11MG1860A0A 1
2. Install O-ring on back side of suction manifold.

3. Place one screw (E) in the suction manifold.
4. Position the suction tube (D) in the suction manifold.
5. Install and tighten all the bolts (E) to a torque of 25 N·m
(18 lb ft).
6. Tighten nuts (A) and (C) at the two ends of the suction
tube (D) with a torque of 190 N·m (140 lb ft).
7. Install the suction screen assembly (B).
LAIL11MG2029A0A 2
8. Reposition the wiring harness bracket (F).

9. Tighten the wiring harness support bolts with a torque
of 87 N·m (64 lb ft).
LAIL11MG2030A0A 3
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Index
Transmission - 21

Filter suction line - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Filter suction line - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Filter suction line - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Filter suction line - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Filter suction line - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Filter suction line - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Transmission oil filter - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Transmission oil filter - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Transmission - 21
Powershift transmission internal components - 155

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Contents
Transmission - 21
TECHNICAL DATA
Shaft assemblies
Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
Shaft assemblies
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Output shaft
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rear output shaft flange
Output yoke - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SERVICE
Powershift transmission internal components

Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Shaft assemblies
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Service instruction (Sizing of the seal rings) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
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Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Output shaft
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Clearance (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Clutch
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Reverse clutch - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Clutch stage - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Forward clutch - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Reverse clutch - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Clutch stage - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Calibrate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Rear output shaft flange
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Output yoke - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Output yoke - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
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Transmission - Powershift transmission internal components
Shaft assemblies - General specification

[HBZN0845VBAF00184 - ]
-]
Clutch Assembly
Lube
Name Usage
Weight
Name Specification
Output group 30 kg (66 lb)
Clutch stages less output stage 272 kg (600 lb)
Separator plate-to-clutch plate retainer clearance

Name Specification
Clutch assemblies 2.79 – 5.59 mm (0.110 – 0.220 in)
Endplay
Name Specification
Clutch gear 0.25 mm (0.010 in)
Shaft assemblies - Torque

[HBZN0845VBAF00184 - ]
-]
Clutch Assembly
Name Torque
Oil trough-to-rear housing cap screws. 25 N·m (18 lb ft)
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Shaft assemblies - Exploded view

-]
LAIL11MG1832G0A 1
Idler gears and bearing assemblies
A. Idler shaft (2 used)

B. O-rings (2 used)
C. Bearing (2 used)
D. 37-tooth idler gear (2 used)
E. Bearings (4 used)
F. O-rings (2 used)
G. Input housing
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[HBZN0845VBAF00184 - ]
LAIL11MG0812G0A 1
Second (2nd) stage clutch assembly
A. Sealing ring (3x) K. Clutch separator plate (20)

B. Ball bearing (2) L. Retaining ring (2)
C. Retaining ring (2) M. Snap ring retainer (2)
D. Bearing (2x) N. Clutch return spring (12)
E. 2nd Clutch 54T Gear O. Lube shutoff washer (2)
F. Bearing (2x) P. Clutch piston (2)
G. O-ring (2) Q. Piston outer seal (2)
H. Snap ring (internal), (2) R. O-ring (2)
I. Clutch plate retainer (2) R. 2nd Stage Shaft Assembly
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J. Clutch plates (20) T. 61D clutch gear

(2nd and 3rd stages)
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LAIL11MG1339G0A 2
Third (3rd) stage clutch assembly
A. Sealing ring (2) K. Clutch separator plate (10)

B. Ball bearing (2) L. Clutch plates (10)
C. 3rd stage shaft assembly M. Clutch Plate Retainer
D. O-Ring N. Snap ring
E. Piston Outer Seal O. O-Ring
F. Clutch Piston P. Bearing
G. Lube Shutoff Washer Q. 61D clutch gear
H. Clutch return spring (6) (2nd and 3rd stages)
I. Snap Ring Retainer R. Bearing
J. Circlip R. Circlip
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LAIL11MG1594G0A 3
Fourth (4nd) stage clutch assembly
A. Sealing ring (3x) L. Snap ring retainer (2)

B. Bearing (2x) M. Clutch retainer springs (12)
C. Snap ring (2) N. Lube shutoff piston (2)
D. Bearing O. Clutch piston (2)
E. 4th clutch assembly gear P. Piston outer seal (2)
F. Bearing (2x) Q. O-ring (2)
G. Snap ring (2) R. 4th and 5th stage shaft assembly
H. Clutch plate retainer (2) R. Ball bearing w/bronze cage (2)
I. Clutch plates (20) T. 38th clutch gear
J. Clutch separator plates (20) U. Bearing
K. Retaining ring (2)
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LAIL11MG0813G0A 4
Fifth (5th) stage clutch assembly
A. Sealing ring (3x) J. Clutch separator plates (20)

B. Bearing (2x) K. Retaining ring (2)
C. Snap ring (2) L. Snap ring retainer (2)
D. Bearing (2x) M. Clutch retainer springs (12)
E. 86D clutch gear N. Lube shutoff washer (2)
F. Bearing (2x) O. Clutch piston (2)
G. Snap ring (2) P. Piston outer seal (2)
H. Clutch plate retainer (2) Q. O-ring (2)
I. Clutch plates (20) R. 4th and 5th stage shaft assembly
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-]
LAIL11MG2110G0A 1
Second (2nd) stage clutch assembly
A. Sealing ring (3x) K. Clutch separator plate (26 used)

B. Ball bearing (2) L. Retaining ring (2)
C. Retaining ring (2) M. Snap ring retainer (2)
D. Bearing (2x) N. Clutch return spring (16)
E. 2nd Clutch 54T Gear O. Lube shutoff washer (2)
F. Bearing (2x) P. Clutch piston (2)
G. O-ring (2) Q. Piston outer seal (2)
H. Snap ring (internal), (2) R. O-ring (2)
I. Clutch plate retainer (2) R. 2nd Stage Shaft Assembly
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J. Clutch plates (22) T. 61D clutch gear

(2nd and 3rd stages)
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LAIL11MG2111G0A 2
Third (3rd) stage clutch assembly
A. Sealing ring (2) K. Clutch separator plate (13)

B. Ball bearing (2) L. Clutch plates (11)
C. 3rd stage shaft assembly M. Clutch Plate Retainer
D. O-Ring N. Snap ring
E. Piston Outer Seal O. O-Ring
F. Clutch Piston P. Bearing
G. Lube Shutoff Washer Q. 61D clutch gear
H. Clutch return spring (8) (2nd and 3rd stages)
I. Snap Ring Retainer R. Bearing
J. Circlip R. Circlip
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LAIL11MG2112G0A 3
Fourth (4nd) stage clutch assembly
A. Sealing ring (3x) L. Snap ring retainer (2)

B. Bearing (2 used) M. Clutch retainer springs (16)
C. Snap ring (2) N. Lube shutoff piston (2)
D. Bearing O. Spring backup plate (2)
E. 4th clutch assembly gear P. Belleville spring (2)
F. Bearing (2x) Q. Clutch piston (2)
G. Snap ring (2) R. Piston outer seal (2)
H. Clutch plate retainer (2) R. O-ring (2)
I. Clutch plates (20) T. 4th and 5th stage shaft assembly
J. Clutch separator plates (22) U. Bronze cage bearing (2)
K. Retaining ring (2) V. 44 Tooth clutch gear
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LAIL11MG2113G0A 4
Fifth (5th) stage clutch assembly
A. Sealing ring (3x) K. Retaining ring (2)

B. Bearing (2x) L. Snap ring retainer (2)
C. Snap ring (2) M. Clutch retainer springs (16)
D. Bearing (2x) N. Lube shutoff washer (2)
E. 86D clutch gear O. Spring backup plate (2)
F. Bearing (2x) P. Belleville spring (2)
G. Snap ring (2) Q. Clutch piston (2)
H. Clutch plate retainer (2) R. Piston outer seal (2)
I. Clutch plates (20) R. O-ring (2)
J. Clutch separator plates (22) T. 4th and 5th stage shaft assembly.
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[HBZN0845VBAF00184 - ]
-]
LAIL11MG0665G0A 1
Bearing Retainer Assembly and Shims
A. O-Ring E. Bearing retainer

B. 0.51 shim (as required) F. Cap screw M8 x 60 8.8 (6)
C. 0.18 shim (as required) G. Oil seal
D. 0.13 shim (as required)
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Output shaft - Exploded view

[HBZN0845VBAF00184 - ]
-]
LAIL11MG0664G0A 1
Output and oil trough group
A. Bearing cone (2)

B. Seventh stage output shaft gear assembly
C. Oil Trough Assembly
D. Bolt M8 x 12 x 8.8 (2)
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Rear output shaft flange Output yoke - Exploded view

[HBZN0845VBAF00184 - ]
-]
LAIL11MG0213F0A 1
Component identification
A. Seal V-ring
B. Clevis
C. O-Ring
D. Yoke washer
E. Screw
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Powershift transmission internal components - Remove

[HBZN0845VCAF01093 - ]
Input shaft, Output shaft, and Clutches

1. Force out both cylindrical pins (1).
2. Loosen the bolted connection (2) between the front and
rear parts of the housing and separate the rear part of
the housing using a lifting device.
(S) Eye bolt M20 0636 804 003
(S) Eye nut M12 0664 462 774
LAIL11MG0750A0A 1
3. Loosen the oil baffle bolted connection (1).
LAIL11MG0751A0A 2
4. Remove the output shaft (1) and lower the oil baffle (2)
from the housing.
LAIL11MG0752A0A 3
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5. Remove all of the rectangular rings (1) from the

clutches and all of the O-rings (2) from the oil tubes.
LAIL11MG0753A0A 4
6. Use a lifting device to bring the rear part of the housing

(1) back into contact with the front part of the housing
(2).
(S) Eye bolt M20 0636 804 003
(S) Eye nut M12 0664 462 774
LAIL11MG0754A0A 5
NOTICE: Due to the installation conditions, the removal of

single clutches without using the special tool is not possi-
ble. Risk of injury.
7. Fix all of the clutches using the cable (1).
(S) Cable 5870 260 010
LAIL11MG0755A0A 6
8. Separate housing rear part incl. clutches from housing

front part by means of the lifting device and attach it to
the assembly truck.
LAIL11MG0756A0A 7
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9. Loosen the Allen screws in the oil tubes (1) in the front
part of the housing and remove them.
(S) Suction tube 0501 210 712
(S) Special tool 5870 600 003
NOTE: The suction tube (2) and the lubrication lines (3)
are fixed and are difficult to remove. In case of damage,
use of the appropriate special tool is imperative for fitting
or replacing these components.
LAIL11MG0757A0A 8
10. Remove bearing outer rings (arrows) from the housing

front part.
NOTE: If, contrary to the ZF recommendation, the tapered
roller bearings of clutches, input and output are not re-
placed, it is imperative to ensure the previous pairing (bear-
ing outer ring/ bearing inner ring).
11. Bearing outer ring and bearing inner ring must be
marked.
LAIL11MG0758A0A 9
12. Lift the clutches out of the housing in numerical order

as described in the legend.
(1) K1 clutch
(2) K2 clutch
(3) K3 clutch
(4) K4 clutch
(5) KR clutch
(6) KV clutch
(7) Input shaft
LAIL11MG0759A0A 10
13. Remove bearing outer rings (arrows) from the housing

rear part.
NOTE: If the conical clutch input and output roller bear-
ings are not replaced contrary to the recommendation, it
is imperative to ensure the previous pairing (bearing outer
ring/bearing inner ring).
14. Bearing outer ring and bearing inner ring must be
marked.
LAIL11MG0760A0A 11
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NOTE: The lubrication lines (1) and (2) are fixed and are
difficult to remove.
15. In case of damage, use of the appropriate special tool
is imperative for fitting or replacing these components.
LAIL11MG0761A0A 12
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Powershift transmission internal components - Install

[HBZN0845VCAF01093 - ]
Input shaft, Output shaft, and Clutches

NOTE: If the suction tube (1) in the front part of the housing
needs to be replaced, the special ZF tool must be used for
assembly. Then fix the tube with an Allen screw (2).
(S) Lubricant 5870 451 006
LAIL11MG0380A0A 1
1. Mount 22 x 3 O-rings into the annular groove of oil tubes

(1) and (2) and oil them.
2. Then insert the tubes into the front part of the housing
and fix them with the Allen screws (3).
LAIL11MG0381A0A 2
3. Mount the screw plug (1) with a new O-ring .

Screw plug: M38 x 1.5
O-ring: 35 x 2
LAIL11MG0382A0A 3
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NOTE: The spare parts service supplies lubricating oil

tubes (1) and (2) as a complete package only with the rear
part of the housing.
NOTE: Single parts delivery upon request only.
NOTE: Assembly is only possible with the special ZF tool.)
(See also Figure 1).
(S) Lubricant 5870 451 006
LAIL11MG0383A0A 4
4. Insert all bearing outer rings into the bearing holes of

both housing parts
NOTE: Note the installation position, see illustrations 5 and
6.
Housing front part
Inlet (AN)
Output (AB)
(KV) Forward clutch
(KR) Reverse clutch
(K1) 1st gear clutch
(K2) 2nd gear clutch
(K3) 3rd gear clutch
(K4) 4th gear clutch
LAIL11MG0384A0A 5
Rear part of the housing

Inlet (AN)
Output (AB)
(KV) Forward clutch
(KR) Reverse clutch
(K1) 1st gear clutch
(K2) 2nd gear clutch
(K3) 3rd gear clutch
(K4) 4th gear clutch
NOTE: Place bearing outer rings into the bearing holes
using assembly grease.
NOTE: If, contrary to the ZF recommendation, the tapered
roller bearings of clutches, input and output are not re- LAIL11MG0385A0A 6
placed, it is imperative to ensure the previous pairing (bear-

ing inner ring / bearing outer ring) see and , on .
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NOTICE: Due to the installation conditions, the installation

of single clutches without using the special tool is not pos-
sible. Risk of injury.
5. Install clutches by means of housing rear part. (illustra-
tions 6 through 13.
NOTE: Housing rear part will be removed again later.
6. Place the (KR) clutch, the (AN) input shaft, and the
(KV) clutch into the rear part of the housing simulta-
neously.
LAIL11MG0386A0A 7
7. Slightly lift the drive gear and position the (K4) clutch.
LAIL11MG0387A0A 8
8. Mount the clutch (K3).
LAIL11MG0388A0A 9
9. Position the clutch (K2).
LAIL11MG0389A0A 10
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10. Slightly lift the (K4) clutch and position the (K1) clutch.
LAIL11MG0390A0A 11
11. The figure again shows the installation position of the

individual clutches in the rear part of the housing.
12. Check, grease and centrically align rectangular rings
(arrows).
13. Fix all of the clutches using cables (S).
(S) Cable (6 parts required) 5870 260 010
LAIL11MG0391A0A 12
14. Rotate the rear part of the housing 180°, install the
eye bolts, and eye nuts.
(S) Eye nuts (M12) 0664 462 774
(S) Eyes, 2 x (M20) 0636 804 003
LAIL11MG0392A0A 13
15. Use the lifting device to bring the housing rear part
into contact position with the housing front part, by
cautiously assembling the clutches.
16. Then remove handles.
LAIL11MG0393A0A 14
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17. Remove housing rear part again.
LAIL11MG0394A0A 15
18. Fit the baffle (1).

19. Install the preassembled output shaft (2).
LAIL11MG0395A0A 16
20. Fix the baffles using Allen screws (1).

21. Mount 22 x 3 O-rings (2) into the annular groove of the
oil tubes and and oil them.
22. Install, grease and centrically align rectangular rings
(arrows).
23. Moisten the mounting face (3) with sealing agent
LOCTITE® 574™.
LAIL11MG0396A0A 17
24. Carefully bring the housing front part into contact po-
sition with the housing rear part by using the lifting de-
vice.
(S) Eyes, 2 x (M20) 0636 804 003
(S) Eye nuts (M12) 0664 462 774
NOTE: Pay attention that both oil tubes are aligned with
the holes in the housing rear part.
LAIL11MG0397A0A 18
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25. Fit both Allen pins (1) centrally to the mounting face.
LAIL11MG0398A0A 19
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Checking of clearance of the gear drive train

1. Position the driving element (S) and rotate the (KV)
clutch shaft.
(S) Driving element 5870 345 089
(S) Crank handle 5870 280 007
NOTE: If any interference is noted in the moving parts (e.g.
in the baffle or oil tubes), you must correct this fault.
NOTE: Do this step on all clutch shafts.
LAIL11MG0399A0A 20
2. Fix the front and rear parts of the housing with Allen
screws (1).
3. Mount the stud bolts (2).
Tightening torque (M8/10.9 x 25) – MA = 15 N·m
LAIL11MG0400A0A 21
4. Place a 76x3 O-ring (1) into the annular groove of the

cover (2).
LAIL11MG0401A0A 22
5. Secure the cover (1) with hexagonal nuts (2).

Tightening torque (M8/10) MA = 25 N·m
LAIL11MG0402A0A 23
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Shaft assemblies - Install

-]
NOTE: Before starting installation, see Shaft assemblies

- Exploded view (21.155).
1. Place the idler gear assembly (A) into the auxiliary
pump port of the input housing.
LAIL11MG1252A0A 1
2. Position idler gear assembly into its cavity beside aux-

iliary pump port.
LAIL11MG1253A0A 2
3. Install the idler gear assembly (B) into the charge pump
port and place it into the cavity.
LAIL11MG1254A0A 3
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-]
Idler Gear Shafts

NOTE: The through hole located in the idler shaft must be
aligned with the bolt hole in the input housing. Use a bolt
to guide the alignment while installing.
1. Align the bearing bore of the idler gear assemblies (A)
with the input housing shaft bore.
2. Lubricate the O-ring with grease (B) and install it in the
groove on the shaft.
3. Use grease to hold the O-ring (C) to the bottom of the
idler shaft during installation.
LAIL11MG1255A0A 1
NOTE: Alternate the O-ring installation procedure.

4. Position the O-ring (C) at the bottom of the shaft bore
in the input housing .
5. Use bolt to align thru hole in idler shaft with threaded
hole in the input cover.
6. Push the idler shaft (D) through the idler gear assembly
and into the input housing.
LAIL11MG1256A0A 2
7. Install the other idler shaft in this same manner.
LAIL11MG1257A0A 3
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Driven Gear (Auxiliary Pump Port Side)

1. Install driven gear assembly with the snap ring up.
LAIL11MG1258A0A 1
2. Rotate the idler gear (A) to align its teeth with the driven
gear (B).
3. Push idler gear bearing into bore in input housing.
LAIL11MG1259A0A 2
4. Install the bearing spacer (C).
LAIL11MG1260A0A 3
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5. Install snap ring into groove.

NOTICE: Wear eye protection when installing the snap
rings.
LAIL11MG1261A0A 4
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Shaft assemblies - Remove

[HBZN0845VBAF00184 - ]
All clutch stage assemblies

NOTICE: The approximate weight of all the stage assem-
blies is 272 kg (600 lb).
NOTICE: Lift all of the clutch stage assemblies at once
using a lifting tool.
1. Install the lift tool (A).
2. Lock the holders (B) in place.
LAIL11MG1416A0A 1
3. Install a bolt (C) into the sixth stage assembly.

4. Lift all of the clutch stage assemblies out from the rear
housing.
LAIL11MG1417A0A 2
NOTICE: If the lifting tool has more than one threaded hole,
use the hole designed for the model of transmission being
repaired.
LAIL11MG1418A0A 3
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5. Install the lifting eye (D).

6. Use a hoist with a safety latch (E).
NOTE: It may be necessary to shake the stages loose.
Grasp the chain between the hoist and the lifting tool and
forcefully move it back and forth.
7. Lift shaft stage assemblies.
LAIL11MG1419A0A 4
NOTICE: The weight is approximately 272 kg (600 lb). Do

not allow any part of the body under stage assemblies.
8. Place the stage assemblies on a work bench.
NOTICE: Place the shaft stage assemblies in the center of
the work bench to prevent personal injury.
LAIL11MG1667A0A 5
NOTICE: Do not remove the lifting tool until a strap has

been placed around the group of assemblies.
9. Remove the bolt (H).
10. Take the four retainers (I) out of the grooves in the
clutch shafts.
LAIL11MG1668A0A 6
11. Place a strap (J) around the gear ratio group to pre-
vent any of the stages from falling.
12. Remove the lifting tool (K).
LAIL11MG1420A0A 7
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NOTICE: Do not allow the stages to fall or to roll off the

work surface.
13. Block the stages (L) to prevent them from rolling.
LAIL11MG1907A0A 8
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-]

NOTICE: The approximate weight of all the stage assem-
blies is 272 kg (600 lb).
NOTICE: Lift all of the clutch stage assemblies at once
using a lifting tool.
1. Install the lift tool (A).
2. Lock the holders (B) in place.
3. Install a bolt (C) into the sixth stage assembly.
4. Lift all of the clutch stage assemblies out from the rear
housing.
LAIL11MG1872A0A 1
5. Place stages on work table.
LAIL11MG1873A0A 2
NOTICE: Place the clutch stage assemblies in the center

of the work bench to prevent personal injury.
6. Remove lift tool from clutch stage assemblies.
LAIL11MG1469A0A 3
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Shaft assemblies - Disassemble

[HBZN0845VBAF00184 - ]
First (1st) Stage Assembly

1. Remove and discard the seal ring (A).
2. Remove bearing (B).
3. Remove bearing (C).
4. Inspect first stage shaft assembly.
LAIL11MG1201A0A 1
Sixth (6th) Stage Assembly

1. Remove the ball bearing (A).
2. Remove the inner bearing race (B).
LAIL11MG1202A0A 2
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Second (2nd) to Fifth (5th) Stage Assembly

NOTE: Before starting disassembly, see Shaft assem-
blies - Exploded view (21.155).
All clutch stage assemblies in the transmission assem-
ble and disassemble in the same manner. In this man-
ual we show the disassembly and assembly of the sec-
ond stage clutch.
LAIL11MG1421A0A 3
1. Remove the three Teflon seal rings.
LAIL11MG2008A0A 4
2. Install the bearing extractor (A).
LAIL11MG1422A0A 5
3. Install the gear puller (B) onto the bearing removal tool.
4. Remove the bearing (C) from the shaft assembly.
LAIL11MG1203A0A 6
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5. Remove the snap ring (D) from the shaft assembly.
LAIL11MG1204A0A 7
6. Install gear puller.

7. Remove the clutch gear (E).
LAIL11MG1205A0A 8
8. Remove bearing (F).
LAIL11MG1206A0A 9
NOTICE: The fourth stage clutch gear (clutch A) must use

special bearings. Only use approved bronze cage bear-
ings. (Depending on the application).
LAIL11MG1207A0A 10
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NOTE: The O-ring (G) is on the directional clutch only. The

speed clutches will not have an O-ring.
9. Remove the O-ring (G).
LAIL11MG1208A0A 11
NOTICE: Wear eye protection when removing the snap

rings.
11. Remove the snap ring (H).
LAIL11MG1209A0A 12

LAIL11MG1210A0A 13
12. Turn the shaft assembly over. Remove all clutch and
separator plates.
LAIL11MG1423A0A 14
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13. Turn the shaft assembly over.

14. Install puller.
15. Remove ball bearing and discard bearing.
LAIL11MG1211A0A 15
16. Place shaft assembly on press.

17. Use a press tool (I) to compress the clutch return
springs.
LAIL11MG1212A0A 16
18. Remove the snap ring (J).
LAIL11MG2081A0A 17
NOTICE: Pay attention during assembly of the clutch return

springs. They must be reassembled in the same way.
19. Lift out snap ring, retaining ring, and clutch return
springs.
LAIL11MG1213A0A 18
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20. Remove lube shutoff washer.
LAIL11MG1214A0A 19
NOTICE: Wear eye protection when removing the piston

from the cylinder. If cylinder is damaged DO NOT place
hand on top of piston.
21. Apply air pressure through oil passage to force piston
from shaft assembly.
LAIL11MG1215A0A 20
22. Remove piston from cylinder.

23. Remove O-ring and piston outer seal from piston.
24. Inspect all parts.
LAIL11MG1216A0A 21
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Shaft assemblies - Disassemble

-]

1. Remove and discard the seal ring (A).
2. Remove bearing (B).
3. Remove bearing (C).
4. Inspect first stage shaft assembly.
LAIL11MG1201A0A 1

NOTE: Before starting disassembly, see Shaft assem-
blies - Exploded view (21.155).
All clutch stage assemblies in the transmission assem-
ble and disassemble in the same manner. In this man-
ual we show the disassembly and assembly of the sec-
ond stage clutch.
LAIL11MG1421A0A 2
1. Remove the three Teflon seal rings.
LAIL11MG2008A0A 3
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2. Install the bearing extractor (A).
LAIL11MG1422A0A 4
3. Install the gear puller (B) onto the bearing removal tool.
4. Remove the bearing (C) from the shaft assembly.
LAIL11MG1203A0A 5
5. Remove the snap ring (D) from the shaft assembly.
LAIL11MG1204A0A 6
6. Install gear puller.

7. Remove the clutch gear (E).
LAIL11MG1205A0A 7
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8. Remove bearing (F).
LAIL11MG1206A0A 8

LAIL11MG1207A0A 9
NOTE: The O-ring (G) is on the directional clutch only. The

speed clutches will not have an O-ring.
9. Remove the O-ring (G).
LAIL11MG1208A0A 10

rings.
11. Remove the snap ring (H).
LAIL11MG1209A0A 11
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LAIL11MG1210A0A 12
12. Turn the shaft assembly over. Remove all clutch and
separator plates.
LAIL11MG1423A0A 13
NOTICE: The 4th and 5th stage assemblies will have spe-
cial clutch assemblies. The spring backup plate (A) and
Bellville spring (B) are not interchangeable with the sec-
ond and third stage assemblies. (Depending on the appli-
cation).
LAIL11MG1262A0A 14
13. Turn the shaft assembly over.

14. Install puller.
15. Remove ball bearing and discard bearing.
LAIL11MG1669A0A 15
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16. Place shaft assembly on press.

17. Use a press tool (I) to compress the clutch return
springs.
LAIL11MG1212A0A 16
18. Remove the snap ring (J).
LAIL11MG2081A0A 17
NOTICE: Pay attention during assembly of the clutch return

springs. They must be reassembled in the same way.
19. Lift out snap ring, retaining ring, and clutch return
springs.
LAIL11MG1213A0A 18
20. Remove lube shutoff washer.
LAIL11MG1214A0A 19
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NOTICE: Wear eye protection when removing the piston

from the cylinder. If cylinder is damaged DO NOT place
hand on top of piston.
21. Apply air pressure through oil passage to force piston
from shaft assembly.
LAIL11MG1215A0A 20
NOTICE: The 4th and 5th stages have special pistons and
are not interchangeable with the second and third stage
assemblies. (Depending on the application).
LAIL11MG2116A0A 21
22. Remove piston from cylinder.

23. Remove O-ring and piston outer seal from piston.
24. Inspect all parts.
LAIL11MG1216A0A 22
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Shaft assemblies - Assemble

[HBZN0845VBAF00184 - ]

NOTE: Only press on the inner race of the bearing.
1. Install a new bearing (B).
2. Install the new bearing (C).
NOTE: Refer to Shaft assemblies - Service instruction
(Sizing of the seal rings) (21.155).
3. Install a new seal ring (A).
4. Lubricate ball bearings.
LAIL11MG1201A0A 1
Sixth (6th) Stage Assembly

1. Install a new ball bearing (A).
2. Install the new bearing inner race (B).
3. Lubricate all of the bearings with clean transmission
fluid.
LAIL11MG1202A0A 2
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1. Install a new O-ring (A).
2. Install a new piston outer seal (B).
LAIL11MG1217A0A 3
3. Install the clutch piston (C).

4. Install the lubrication shutoff washer (D).
LAIL11MG1218A0A 4
NOTICE: Install the clutch return springs correctly. Use

Figure 6 as a guide.
LAIL11MG1219A0A 5
5. Install the clutch return springs (E).
LAIL11MG1220A0A 6
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6. Place the press tool (F) over the shaft.

7. Place the snap ring retainer (G) and retaining ring (H)
over the shaft.
LAIL11MG1221A0A 7
8. Compress clutch return springs.

9. Install the circlip (I).
10. Release pressure on clutch return springs slowly, be
sure snap ring retainer is properly positioned.
LAIL11MG1424A0A 8
NOTE: The clutch separator plates are all steel with ex-
ternal spline teeth. Clutch plates have a lining material on
the face and internal spline teeth. Lubricate and install one
plate at a time. First install a clutch separator plate then a
clutch plate. Continue until all plates are installed.
11. Install the clutch separator plate (L).
12. Install the clutch plate (M).
Repeat Steps 11 and 12 until all of the plates are in-
stalled.
LAIL11MG1425A0A 9
13. Install the clutch plate retainer (N).
LAIL11MG1426A0A 10
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rings.
14. Install the snap ring (O).
NOTE: Check that the clutch and the separator plates
are not stuck together. The clearance between the clutch
plates and the plate retainer should be 2.79 – 5.59 mm
(0.110 – 0.220 in).
LAIL11MG1222A0A 11
NOTICE: The clutch plate splines must be aligned before

installing the bearings on the shaft assembly to avoid dam-
age to the plates.
15. Use clutch gear assembly to align clutch plates and
separator plates.
16. After aligning clutch plates remove clutch gear assem-
bly.
LAIL11MG1427A0A 12
NOTICE: The seal side of the bearing goes towards the

clutch plates.
NOTICE: The fourth stage clutch gear (Clutch A) must use
17. Install new bearing with seal side of bearing toward
clutch plates.
LAIL11MG1428A0A 13
18. Press bearing, seal side down, until bearing contacts

shoulder of shaft.
LAIL11MG1429A0A 14
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19. Install the clutch gear assembly (P).

NOTICE: Place a steel ruler or sight across the gear face
(P) to check that the clutch gear is installed properly. Sight-
ing or steel ruler will be below snap ring groove in cylinder
shaft.
20. Place a new bearing (Q) on the shaft and start in-
stalling the bearing into the clutch gear assembly.
NOTICE: Start installing the bearing into the clutch gear.
LAIL11MG1430A0A 15
Do not press bearing below snap ring groove in shaft.
Pressing the bearing too far into the gear will overload the
bearing. This will cause the bearing to fail.
21. PARTIALLY install bearing into clutch gear hub as-
sembly.
22. Position the snap ring (R) on top of the bearing.
LAIL11MG1908A0A 16
23. Place press tool on top of snap ring.

24. Press only on snap ring. Press until snap ring slips
into snap ring groove.
LAIL11MG1909A0A 17
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25. Install a new outer bearing (S).

NOTICE: Check the clutch gear for axial play. It should be
0.25 mm (0.010 in).
LAIL11MG1431A0A 18
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Shaft assemblies - Assemble

-]

NOTE: Only press on the inner race of the bearing.
1. Install a new bearing (B).
2. Install the new bearing (C).
NOTE: Refer to Shaft assemblies - Service instruction
(Sizing of the seal rings) (21.155).
3. Install a new seal ring (A).
4. Lubricate ball bearings.
LAIL11MG1201A0A 1

2. Install a new piston outer seal (B).
LAIL11MG1217A0A 2
3. Install the clutch piston (C).

4. Install the lubrication shutoff washer (D).
LAIL11MG1218A0A 3
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NOTICE: The 4th and 5th stages have special pistons and
are not interchangeable with the second and third stage
assemblies. (Depending on the application).
LAIL11MG2117A0A 4
NOTICE: Install the clutch return springs correctly. Use

Figure 6 as a guide.
LAIL11MG1219A0A 5
5. Install the clutch return springs (E).
LAIL11MG1220A0A 6
6. Place the press tool (F) over the shaft.

7. Place the snap ring retainer (G) and retaining ring (H)
over the shaft.
LAIL11MG1221A0A 7
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8. Compress clutch return springs.

9. Install the circlip (I).
10. Release pressure on clutch return springs slowly, be
sure snap ring retainer is properly positioned.
LAIL11MG1424A0A 8
NOTE: The Bellville spring (J) must be installed with its in-
ternal diameter in contact with the piston (see “Fourth (4th)
and fifth (5th) stage clutch assembly” in Shaft assemblies
LAIL11MG1686A0A 9
NOTE: The spring support plate (K) must be installed with

its plane facing upwards (see “Fourth (4th) and fifth (5th)
stage clutch assembly” in Shaft assemblies - Exploded
view (21.155).
LAIL11MG1714A0A 10
NOTE: The clutch separator plates are all steel with ex-
ternal spline teeth. Clutch plates have a lining material on
the face and internal spline teeth. Lubricate and install one
plate at a time. First install a clutch separator plate then a
clutch plate. Continue until all plates are installed.
11. Install the clutch separator plate (L).
12. Install the clutch plate (M).
Repeat Steps 11 and 12 until all of the plates are in-
stalled.
LAIL11MG1425A0A 11
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13. Install the clutch plate retainer (N).
LAIL11MG1426A0A 12

rings.
14. Install the snap ring (O).
NOTE: Check that the clutch and the separator plates
are not stuck together. The clearance between the clutch
plates and the plate retainer should be 2.79 – 5.59 mm
(0.110 – 0.220 in).
LAIL11MG1222A0A 13
NOTICE: The clutch plate splines must be aligned before

installing the bearings on the shaft assembly to avoid dam-
age to the plates.
15. Use clutch gear assembly to align clutch plates and
separator plates.
16. After aligning clutch plates remove clutch gear assem-
bly.
LAIL11MG1427A0A 14
NOTICE: The seal side of the bearing goes towards the

clutch plates.
17. Install new bearing with seal side of bearing toward
clutch plates.
LAIL11MG1428A0A 15
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18. Press bearing, seal side down, until bearing contacts

shoulder of shaft.
LAIL11MG1429A0A 16
19. Install the clutch gear assembly (P).

NOTICE: Place a steel ruler or sight across the gear face
(P) to check that the clutch gear is installed properly. Sight-
ing or steel ruler will be below snap ring groove in cylinder
shaft.
20. Place a new bearing (Q) on the shaft and start in-
stalling the bearing into the clutch gear assembly.
NOTICE: Start installing the bearing into the clutch gear.
LAIL11MG1430A0A 17
Do not press bearing below snap ring groove in shaft.
Pressing the bearing too far into the gear will overload the
bearing. This will cause the bearing to fail.
21. PARTIALLY install bearing into clutch gear hub as-
sembly.
22. Position the snap ring (R) on top of the bearing.
LAIL11MG1908A0A 18
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23. Place press tool on top of snap ring.

24. Press only on snap ring. Press until snap ring slips
into snap ring groove.
LAIL11MG1909A0A 19
25. Install a new outer bearing (S).

NOTICE: Check the clutch gear for axial play. It should be
0.25 mm (0.010 in).
LAIL11MG1431A0A 20
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Shaft assemblies - Service instruction (Sizing of the seal rings)

[HBZN0845VBAF00184 - ]
-]
NOTICE: Always use new seal rings. The seal rings must
be sized to fit the shaft groove tightly to avoid damage dur-
ing installation of front housing. Check and size seal rings
before installation of front housing.
LAIL11MG1432A0A 1
1. Turn the seal ring in a circle of approximately 3/4 in.
LAIL11MG1433A0A 2
2. Install three seal rings in the ring grooves in the shaft

assembly.
LAIL11MG1434A0A 3
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[HBZN0845VBAF00184 - ]

NOTE: The output group is installed separately.
1. Arrange stage assemblies.
• First stage assembly (A).
• Second stage assembly (B).
• Third stage assembly (C).
• Fourth stage assembly (D).
• Fifth stage assembly (E).
• Sixth stage assembly (F).
LAIL11MG1910A0A 1
LAIL11MG1672A0A 2
2. Keep the stage assemblies secured with a strap until

they are all fitted in the lifting tool.
NOTICE: The weight of the stage assemblies is approxi-
mately 272 kg (600 lb). Use the special lifting tool to move
all of the stages at once.
LAIL11MG1435A0A 3
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3. Install lifting tool (A).

4. Lock the four retainers (B) in place in the grooves in the
clutch shafts.
5. Install a screw (C) in the threaded hole in the end of the
sixth stage shaft.
6. Remove the safety chain (D).
LAIL11MG1436A0A 4
NOTICE: Before lowering the stage assemblies into the

rear housing, lubricate all of the bearings on the bottom
of the stages, as well as the races and bearing cups in the
rear housing.
NOTICE: Do not put your hands inside the rear housing
while installing the stage assemblies.
7. Lower the stage assemblies (A) into the rear housing.
LAIL11MG1673A0A 5
NOTICE: All stages must be pushed completely down in

their bores or bearings.
8. Check stages; must be in bottom of rear housing bores.
9. Take the four retainers (B) out of the grooves in the
clutch shafts.
10. Remove the bolt (C).
11. Remove the lifting tool (D).
NOTICE: Size and install the seal rings before installing the
front housing, see Shaft assemblies - Service instruc-
tion (Sizing of the seal rings) (21.155).
LAIL11MG1437A0A 6
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-]

1. Arrange stage assemblies.
2. Install lifting tool (A).
LAIL11MG1470A0A 1
3. Secure all stage assemblies to lifting tool.
LAIL11MG1874A0A 2
ATTENTION: Both the stage assemblies and rear housing

must be aligned. If either is at an angle binding will occur
and/or damage will occur.
4. Install stage assemblies.
5. Move the locks away from the shaft grooves (B) and
remove the bolt (C) from the lifting tool (A).
LAIL11MG1875A0A 3
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6. Remove lifting tool carefully from stage assemblies to

avoid damage to seal rings.
LAIL11MG1917A0A 4
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[HBZN0845VBAF00184 - ]
-]
NOTE: Before starting removal, see Shaft assemblies -


1. Position rear housing with bearing retainer up.
2. Remove the two cap screws (A).
3. Install the two guide pins (B).
4. Remove the remaining cap screws.
LAIL11MG1442A0A 1
5. Remove the bearing retainer assembly (C) and shims

(D).
NOTE: Save the shims and keep them together. They may
be reused if they are in good condition.
LAIL11MG1911A0A 2
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Oil Seal in the Bearing Retainer

1. Remove and discard the oil seal (A).
2. Clean and inspect bearing retainer..
LAIL11MG1912A0A 3
Bearing Retainer O-ring

1. Remove and discard the O-ring (B).
LAIL11MG1443A0A 4
Rear Housing Bearing Cup

1. Remove the bearing cup (A).
2. Clean and inspect the bearing bore in the housing.
LAIL11MG1444A0A 5
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-]
NOTE: Before starting removal, see Shaft assemblies -


1. Position rear housing with bearing retainer up.
2. Remove from the bearing retainer (B) the bolts (A).
LAIL11MG1263A0A 1
3. Remove the bearing retainer assembly and shims.

NOTE: Save the shims and keep them together. They may
be reused if they are in good condition.
LAIL11MG1264A0A 2
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1. Remove and discard the oil seal (A).
2. Clean and inspect bearing retainer..
LAIL11MG1912A0A 3
Bearing Retainer O-ring

1. Remove and discard the O-ring (B).
LAIL11MG1443A0A 4

1. Remove the bearing cup (A).
2. Clean and inspect the bearing bore in the housing.
LAIL11MG1687A0A 5
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[HBZN0845VBAF00184 - ]


NOTICE: If the new oil seal does not have the outside di-
ameter coated with a sealant, apply LOCTITE® 620™.
1. Install a new oil seal (A).
2. Seat oil seal on the bottom of the bore in bearing re-
tainer.
LAIL11MG1913A0A 1

1. Lubricate the new bearing cup with clean transmission
fluid.
2. Install a new bearing cup (B) 6 mm deeper than flush
level.
LAIL11MG1445A0A 2
NOTICE: Set the bearing cup no more than 6 mm (0.24 in)

deeper than flush with the face of the bearing bore.
NOTE: The bearing retainer and shim arrangement will set
the exact depth for the bearing cup during the end play
adjustment procedure.
LAIL11MG1446A0A 3
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1. Install the two guide pins (A).
NOTE: Use all of the original shims and one more of
0.254 mm (0.01 in) to adjust the axial play of the output
shaft assembly. The additional shim is to help prevent
damage to the output shaft assembly tapered roller bear-
ing during the initial assembly, before the proper shim
thickness has been established.
2. Place the shims (B) on the guide pins.
LAIL11MG1447A0A 4
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-]


NOTICE: If the new oil seal does not have the outside di-
ameter coated with a sealant, apply LOCTITE® 620™.
1. Install new oil seal.
LAIL11MG1266A0A 1
LAIL11MG1267A0A 2
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1. Lubricate the new bearing cup with clean transmission
fluid.
2. Install a new bearing cup (B) 6 mm deeper than flush
level.
LAIL11MG1445A0A 3
NOTICE: Set the bearing cup no more than 6 mm (0.24 in)

deeper than flush with the face of the bearing bore.
NOTE: Rear housing bore is a light fit for setting end play
of the seventh stage assembly.
LAIL11MG1446A0A 4
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NOTE: Use all of the original shims and one more of
0.25 mm (0.010 in) on the bearing retainer to adjust the
axial play of the seventh output stage.
1. Place shims on bearing retainer.
LAIL11MG2075A0A 5
2. Install bearing retainer with shims.

3. Install the bolts (A) through the bearing retainer into the
rear housing.
4. Tighten the bolts but do not tighten to their final torque.
LAIL11MG2076A0A 6
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Output shaft - Disassemble

[HBZN0845VCAF01093 - ]
1. Pull the tapered bearing (inner ring) off the output shaft
and remove the oil baffle (1).
(S) Basic tool 5873 001 000
(S) Rapid grip 5873 011 014
LAIL11MG0966A0A 1
2. Turn output shaft by 180° and pull off tapered roller

bearing (inner ring).
(S) Basic tool 5873 001 000
(S) Rapid grip 5873 011 014
LAIL11MG0967A0A 2
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Output shaft - Assemble

[HBZN0845VCAF01093 - ]
1. Press the tapered bearing (inner ring) (1) onto the out-
put shaft until contact is obtained.
LAIL11MG0973A0A 1
2. Mount the baffle (2) and press the tapered bearing (in-
ner ring) (1) onto the output shaft until contact is ob-
tained.
LAIL11MG0974A0A 2
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Output shaft - Remove

[HBZN0845VBAF00184 - ]
Oil Output and Trough Assembly

NOTE: Before starting removal, see Output shaft - Ex-
ploded view (21.155)
1. Remove the two fixing bolts (A) holding the oil trough
assembly (B).
NOTICE: The output assembly weighs approximately
30 kg (66 lb).
NOTICE: The oil trough has sharp edges. Personal injury
could occur.
LAIL11MG1415A0A 1
2. Remove the output group (C) and the oil trough (B).
NOTE: The oil trough must be removed with the output
group.
LAIL11MG2007A0A 2
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Output shaft - Remove

-]

NOTE: Before starting removal, see Output shaft - Ex-
1. Remove the two screws (C) from the oil trough assem-
bly (D).
LAIL11MG1871A0A 1
2. Remove the output group (A) and the oil trough (B).
NOTE: The weight of the output assembly is approximately
30 kg (66 lb).
LAIL11MG1438A0A 2
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Output shaft - Disassemble

[HBZN0845VBAF00184 - ]
NOTE: Before starting disassembly, see Output shaft -

Exploded view (21.155)
NOTICE: Do not attempt to remove the gear from the shaft.
This is a permanent assembly. The parts will be damaged.
1. Remove bearing cones.
LAIL11MG1200A0A 1
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Output shaft - Assemble

[HBZN0845VBAF00184 - ]
NOTE: Before starting installation, see Output shaft - Ex-

1. Install the new bearing cones (A).
2. Lubricate two new bearings with clean transmission
fluid.
LAIL11MG1200A0A 1
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Output shaft - Install

[HBZN0845VBAF00184 - ]

ploded view (21.155) .
NOTE: Ensure that the new bearing cups have been in-
stalled in the main case rear housing. Lubricate the bear-
ing cups with oil before installing the output group.
NOTE: The output group can be installed upside down.
Install as shown in illustration.
1. Install the output group (A) and oil trough (B) into the
main case rear housing.
LAIL11MG1438A0A 1
NOTICE: Apply LOCTITE® 262™ to the thread of the bolts

before installation.
2. Install the two bolts (C).
3. Tighten the bolts (C) with a torque of 25 N·m (18 lb ft).
NOTE: Consult Front housing - Assemble (21.113) when
mounting the housing.
LAIL11MG2009A0A 2
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Output shaft - Install

-]

ploded view (21.155) .
NOTE: Ensure that the new bearing cups have been in-
stalled in the main case rear housing. Lubricate the bear-
ing cups with oil before installing the output group.
NOTE: The output group can be installed upside down.
Install as shown in illustration.
1. Install the output group (A) and oil trough (B) into the
main case rear housing.
LAIL11MG1438A0A 1
NOTICE: Apply LOCTITE® 262™ to the thread of the bolts

before installation.
2. Install the two bolts (C).
3. Tighten the bolts (C) with a torque of 25 N·m (18 lb ft).
NOTE: Consult Front housing - Assemble (21.113) when
mounting the housing.
LAIL11MG2009A0A 2
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Output shaft - Clearance

[HBZN0845VBAF00184 - ]
-]
Setting End Play of Output Group

1. Install the yoke (B) with the V-ring seal (A) onto the
splined output shaft.
2. Install the O-ring (C), yoke washer (D), and cap screw
(E).
3. Tighten the cap screw with a torque of 215 N·m (159 lb
ft).
LAIL11MG1816A0A 1
NOTICE: Check and reset the output shaft axial play when-
ever new parts are installed. Adjust the axial clearance to
-0.51 – 0.51 mm (-0.02 – 0.02 in).
NOTICE: Check the axial play with the dial indicator on the
cap screw.
4. Place dial indicator on cap screw.
5. Use pry bars under yoke to check end play.
LAIL11MG1448A0A 2
6. Remove cap screw, washer and yoke from output shaft.
LAIL11MG1675A0A 3
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7. Remove bolts from bearing retainer.

8. Remove bearing retainer from rear housing.
LAIL11MG1914A0A 4
NOTE: Use the guide pins to install the shims and retainer.
If the shims are 0.003 thick, they can twist on the retainers'
outside diameter causing a possible leak or damage to the
O-rings.
9. Remove or install the right amount of the shims to ob-
tain an axial play of -0.51 – 0.51 mm (-0.02 – 0.02 in).
LAIL11MG1449A0A 5
10. Align bearing retainer bolt holes with bolt hole circle in
the rear housing.
11. Install the cap screws.
12. Tighten the cap screws to a torque of 25 N·m (18 lb
ft).
LAIL11MG1915A0A 6
13. Install yoke, O-ring, washer and cap screw.
LAIL11MG1450A0A 7
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14. Tighten the cap screw with a torque of 215 N·m

(159 lb ft).
NOTE: Refer to group 55 for the installation of the brake
calipers.
LAIL11MG1676A0A 8
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Clutch - Remove
[HBZN0845VCAF01093 - ]
Input and output shaft for clutches KV/KR/K1/K2/K3/K4

1. (K1) Clutch
2. (K2) Clutch
3. (K3) Clutch
4. (K4) Clutch
5. (KR) Clutch
6. (KV) Clutch
7. Input shaft (AN)
LAIL11MG0343A0A 1
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Clutch - Disassemble
[HBZN0845VCAF01093 - ]
KV clutch
1. Remove the stud bolt (1) and the piston ring (2).
LAIL11MG0344A0A 1
2. Pull tapered roller bearing (inner ring) off the shaft.

(S) Compression device 5870 026 100
(S) Rapid grip 5873 011 011
LAIL11MG0345A0A 2
3. Pull the clutch (1) off the shaft.

NOTE: Disassembling the clutch (1).
LAIL11MG0346A0A 3
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4. Loosen the retaining ring (1).
LAIL11MG0347A0A 4
5. Fix idler gear (1) using the cut-off device (S) and press
it off the clutch shaft (2).
(S) Cut-off device 5870 300 028
LAIL11MG0348A0A 5
6. Snap the retaining ring (2) out of the idler gear (1) and
remove the ball bearing (3).
LAIL11MG0349A0A 6
7. Remove the needle cage (1) from the shaft (2).
LAIL11MG0350A0A 7
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8. Turn the shaft (2) 180° and remove the piston ring (1).
LAIL11MG0351A0A 8

(S) Rapid grip 5873 011 011
LAIL11MG0352A0A 9
10. Loosen the snap ring (1).
LAIL11MG0353A0A 10
11. Remove the end shim (1) and disc set (2) from the
disc drum (3).
LAIL11MG0354A0A 11
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12. Preload compression spring (1) and unsnap snap ring.

(S) Mounting device 5870 345 088
LAIL11MG0355A0A 12
13. Remove the guide ring (1), compression spring (2),

and washer (3).
LAIL11MG0356A0A 13
14. Lift the piston (1), using compressed air, out of the
cylinder bore and remove it.
LAIL11MG0357A0A 14
15. Remove both O-rings, (1) and (2).
LAIL11MG0358A0A 15
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Clutch Reverse clutch - Disassemble

[HBZN0845VCAF01093 - ]
KR clutch
LAIL11MG0344A0A 1

(S) Grab sleeve 5873 001 057
(S) Rapid grip 5873 011 011
LAIL11MG0345A0A 2

LAIL11MG0346A0A 3
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LAIL11MG0347A0A 4
5. Fix the idler gear (1) using the cut-off device (S) and
press it off the clutch shaft (2).
(S) Cut-off device 5870 300 028
LAIL11MG0348A0A 5
6. Snap the retaining ring (2) out of the idler gear (1) and
remove the ball bearing (3).
LAIL11MG0349A0A 6
7. Remove the needle cage (1) from the shaft (2).
LAIL11MG0350A0A 7
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LAIL11MG0351A0A 8

(S) Grab sleeve 5873 001 057
(S) Rapid grip 5873 011 011
LAIL11MG0352A0A 9
LAIL11MG1571A0A 10
disc drum (3).
LAIL11MG1572A0A 11
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12. Preload compression spring (1) and unsnap snap ring.

LAIL11MG1573A0A 12

and washer (3).
LAIL11MG0356A0A 13
LAIL11MG1574A0A 14
LAIL11MG0358A0A 15
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Clutch Clutch stage - Disassemble

[HBZN0845VCAF01093 - ]
K1 clutch
LAIL11MG0762A0A 1

(S) Grab sleeve 5873 001 057
or
(S) Rapid grip 5873 011 011
LAIL11MG0763A0A 2
LAIL11MG0764A0A 3
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4. Remove the axial bearing assembly (1).
LAIL11MG0765A0A 4
5. Take off the idler gear (1), remove the needle cage (2),
and axial bearing assembly (3).
LAIL11MG0766A0A 5

LAIL11MG0767A0A 6
LAIL11MG0768A0A 7
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(S) Grab sleeve 5873 001 057
or
(S) Rapid grip 5873 011 011
LAIL11MG0769A0A 8
LAIL11MG0770A0A 9
disc drum (3).
LAIL11MG0771A0A 10
11. Preload the compression spring (1) and unsnap the

snap ring.
LAIL11MG0772A0A 11
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and washer (3).
LAIL11MG0773A0A 12
LAIL11MG0774A0A 13
LAIL11MG0775A0A 14
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K2 clutch
LAIL11MG1786A0A 15

(S) Grab sleeve 5873 001 057
or
(S) Rapid grip 5873 011 011
LAIL11MG1787A0A 16
LAIL11MG1788A0A 17
LAIL11MG1789A0A 18
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LAIL11MG1790A0A 19

LAIL11MG1791A0A 20
LAIL11MG1792A0A 21

(S) Grab sleeve 5873 001 057
or
(S) Rapid grip 5873 011 011
LAIL11MG1793A0A 22
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LAIL11MG1794A0A 23
disc drum (3).
LAIL11MG1795A0A 24

snap ring.
LAIL11MG1796A0A 25

and washer (3).
LAIL11MG1797A0A 26
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LAIL11MG1798A0A 27
LAIL11MG1799A0A 28
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K3 clutch
LAIL11MG1304A0A 29

(S) Grab sleeve 5873 001 058
or
(S) Rapid grip 5873 011 011
LAIL11MG1305A0A 30
LAIL11MG1306A0A 31
LAIL11MG1307A0A 32
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LAIL11MG1308A0A 33
LAIL11MG1309A0A 34

(S) Grab sleeve 5873 001 057
or
(S) Rapid grip 5873 011 011
LAIL11MG1310A0A 35
LAIL11MG1311A0A 36
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9. Remove the end shim (1) and disc set (2) from the disc
drum (3).
LAIL11MG1312A0A 37

snap ring.
LAIL11MG1313A0A 38

and washer (3).
LAIL11MG1314A0A 39
LAIL11MG1315A0A 40
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LAIL11MG1316A0A 41
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K4 clutch
LAIL11MG0840A0A 42

or
(S) Rapid grip 5873 011 011
LAIL11MG0841A0A 43
3. Remove the retaining ring.
LAIL11MG0842A0A 44

LAIL11MG0843A0A 45
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5. Remove the axial bearing assembly (1) and idler gear

(2).
LAIL11MG0844A0A 46
6. Remove the needle cage (1) and axial bearing assem-

bly (2).
NOTE: The gear (3) cannot be removed (shrink fit)!
LAIL11MG0845A0A 47
LAIL11MG0846A0A 48

or
(S) Rapid grip 5873 011 011
LAIL11MG0847A0A 49
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LAIL11MG0848A0A 50
disc drum (3).
LAIL11MG0849A0A 51

snap ring.
LAIL11MG0850A0A 52

and washer (3).
LAIL11MG0851A0A 53
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LAIL11MG0852A0A 54
LAIL11MG0853A0A 55
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Clutch Forward clutch - Assemble

[HBZN0845VCAF01093 - ]
KV clutch
1. Press the conical bearing (inner ring) (1) onto the shaft
LAIL11MG1986A0A 1
2. Install the piston ring (1).
LAIL11MG1987A0A 2
3. Mount the needle bearing (1) onto the shaft.
LAIL11MG1988A0A 3
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4. Install the ball bearing (2) into the idler gear (1) until
contact is obtained and fix it by means of a retaining
ring (3).
LAIL11MG1989A0A 4
5. Press in the preassembled idler gear (1) until contact

is obtained.
LAIL11MG1990A0A 5
6. Fix the idler gear (1) using the retaining ring (2).
LAIL11MG1991A0A 6
7. Place both O-rings (1) and (2) into the piston grooves
and oil them.
(1) 75 x 3
(2) 142 x 3
NOTE: Check the function of the drain valve (3) – The ball
must not jam.
LAIL11MG0857A0A 7
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8. Place the piston (1) into the disc carrier.

NOTE: Note the installation position, as shown.
LAIL11MG0852A0A 8
9. Use a hand-operated press to place piston into the disk

carrier by means of the assembly aid.
LAIL11MG0858A0A 9
10. Mount the washer (1), compression spring (2), and

guide ring (3).
LAIL11MG0859A0A 10
11. Preload compression spring by means of assembly

aid and install snap ring 64 x 3.2 (1) in the annular
groove.
NOTE: Different clutches (disc arrangements with the rel-
evant disc clearance) can be installed, depending on the
part list version.
NOTE: The actually installed clutch and disc arrangement
must be taken from the corresponding spare parts list.
NOTE: Figure 12 and figure 13 show the different disc ar-
rangements.
LAIL11MG0860A0A 11
NOTE: The spare parts list shall be binding.
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12. Install external and internal discs alternately in the disc

carrier (4), as illustrated.
(1)Friction disk – Coated on one side (2 parts)
(2) External discs (9 parts)
(3) Internal discs (10 parts)
NOTE: Ensure that the uncoated (blank) side of the friction
disk (1) is facing towards the piston or end plate.
Number of friction surfaces: 20.
LAIL11MG1992A0A 12
13. Install external and internal disks alternately in the disk

Number of friction surfaces: 12!
LAIL11MG1993A0A 13
14. Mount the end board (1) and fix the disc pack using
the snap ring (2) (e.g. thickness = 2.65 mm / recom-
mended value).
LAIL11MG0862A0A 14
15. Press the end board with (F) (approximately 100 N =

10 kg and adjust the indicator to “zero”.
LAIL11MG0863A0A 15
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16. Then press the end plate against the snap ring (up-
wards) and read the disc clearance.
NOTE: Disc clearance: 2.45 – 2.75 mm (see illustration
12)
13)
NOTE: In case of deviations, the disc clearance must be
corrected with an appropriate snap ring (optional thick-
nesses = 2.1 – 4.2 mm).
LAIL11MG0864A0A 16
17. Heat the internal diameter of the clutch (approximately

120 °C).
LAIL11MG0865A0A 17
18. Install clutch until contact is obtained.

19. Mount the inner discs onto the inner disc carrier by
means of short left/right rotations.
NOTICE: Wear protective gloves!
LAIL11MG1994A0A 18
LAIL11MG1995A0A 19
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21. Mount the stud bolt (1).

NOTE: Check the closing and opening of the clutch using
compressed air at the hole (2).
NOTE: Closing and opening of the clutch must be clearly
audible.
LAIL11MG1996A0A 20
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Clutch Reverse clutch - Assemble

[HBZN0845VCAF01093 - ]
KR clutch
LAIL11MG1986A0A 1
LAIL11MG1987A0A 2
3. Mount the needle bearing (1) onto the shaft.
LAIL11MG1988A0A 3
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4. Install the ball bearing (2) into the idler gear (1) until
contact is obtained and fix it by means of a retaining
ring (3).
LAIL11MG1989A0A 4
5. Press in the preassembled idler gear (1) until contact

is obtained.
LAIL11MG1990A0A 5
6. Fix the idler gear (1) using the retaining ring (2).
LAIL11MG1991A0A 6
and oil them.
(1) 75 x 3
(2) 142 x 3
must not jam.
LAIL11MG0857A0A 7
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LAIL11MG0852A0A 8

LAIL11MG0858A0A 9

guide ring (3).
LAIL11MG0859A0A 10
11. Preload compression spring by means of assembly

aid and install snap ring 64 x 3.2 (1) in the annular
groove.
NOTE: Different clutches (disc arrangements with relevant
disc clearance) can be installed, depending on the parts
list version.
NOTE: The actually installed clutch and disc arrangement
must be taken from the corresponding spare parts list.
NOTE: Figure 12 and figure 13 show the different disc ar-
rangements.
LAIL11MG0860A0A 11
NOTE: The spare parts list shall be binding.
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(1) Friction disc – Coated on one side (2 parts)
LAIL11MG1992A0A 12

LAIL11MG1993A0A 13
mended value).
LAIL11MG0862A0A 14
15. Press the end board with (F) (approximately 100 N =

10 kg and adjust the indicator to “zero”.
LAIL11MG0863A0A 15
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12)
13)
nesses = 2.1 – 4.2 mm).
LAIL11MG0864A0A 16

120 °C).
LAIL11MG0865A0A 17
18. Install clutch until contact is obtained.

19. Mount the inner discs onto the inner disc carrier by
LAIL11MG1994A0A 18
20. Press the conical bearing (inner ring) (1) until contact
is obtained.
LAIL11MG1995A0A 19
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21. Mount stud bolt (1).

audible.
LAIL11MG1996A0A 20
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Clutch Clutch stage - Assemble

[HBZN0845VCAF01093 - ]
K1 clutch
1. Press the tapered roller bearing (inner ring) (1) onto the
LAIL11MG1800A0A 1
LAIL11MG1801A0A 2
and oil them.
(1) 75 x 3
(1) 75 x 3
LAIL11MG1802A0A 3
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LAIL11MG1803A0A 4

LAIL11MG1804A0A 5

guide ring (3).
LAIL11MG1805A0A 6
7. Preload the compression spring by means of an as-

sembly aid and install a 64 x 3.2 snap ring (1) in the
annular groove.
LAIL11MG1806A0A 7
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(2) External discs - (8 parts)
(3) Internal discs - (9 parts)
LAIL11MG1807A0A 8
mended value).
LAIL11MG0862A0A 9
10. Press the end board with F (approximately 100 N =

10 kg) and adjust the indicator to “zero”.
LAIL11MG0863A0A 10
NOTE: Disc clearance: 2.5 – 2.8 mm.
nesses = 2.1 – 4.2 mm).
LAIL11MG0864A0A 11
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120 °C).
LAIL11MG0865A0A 12
13. Mount the clutch (1) until contact is obtained.

LAIL11MG1808A0A 13
14. Mount the running disc (1), axial cage (2), and axial
washer (3).
NOTE: Install the chamfer (see arrow) of the running disc
(1) facing towards the axial cage.
LAIL11MG1809A0A 14
15. Mount the needle cage (1).
LAIL11MG1810A0A 15
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16. Install the idler gear (1).

17. Mount inner disks onto the inner disk carrier (idler) by
LAIL11MG1811A0A 16
18. Mount the axial washer (1), axial cage (2), and running
disk (3).
LAIL11MG1812A0A 17
19. Fix the idler gear (1) and single parts using a retaining
ring (2).
LAIL11MG1813A0A 18
is obtained.
LAIL11MG1814A0A 19
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audible.
LAIL11MG1815A0A 20
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K2 clutch
LAIL11MG1317A0A 21
LAIL11MG1318A0A 22
and oil them.
(1) 75 x 3
(2) 142 x 3
must not jam.
LAIL11MG1319A0A 23

LAIL11MG1320A0A 24
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LAIL11MG1321A0A 25

guide ring (3).
LAIL11MG1322A0A 26

annular groove.
LAIL11MG1323A0A 27
8. Install the external and internal discs alternately in the

disc carrier (4), as illustrated.
NOTE: Ensure that the uncoated side of the friction disc (1)
is facing towards the piston or end plate.
LAIL11MG1324A0A 28
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9. Mount the end board (1) and fix the disc pack using a
snap ring (2) (e.g. thickness = 2.65 mm/recommended
value).
LAIL11MG1325A0A 29
10. Press the end board with F (F) (approximately 100 N

= 10 kg and adjust the indicator to “zero”.
LAIL11MG1326A0A 30
nesses = 2.1 – 4.2 mm).
LAIL11MG1327A0A 31

120 °C).
LAIL11MG1328A0A 32
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LAIL11MG1329A0A 33
washer (3).
LAIL11MG1330A0A 34
LAIL11MG1331A0A 35

LAIL11MG1332A0A 36
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disk (3).
LAIL11MG1333A0A 37
19. Fix the idler gear (1) and single parts using a retaining
ring (2).
LAIL11MG1334A0A 38
is obtained.
LAIL11MG1335A0A 39

audible.
LAIL11MG1336A0A 40
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K3 clutch
LAIL11MG0854A0A 41
LAIL11MG0855A0A 42

LAIL11MG0856A0A 43
and oil them.
(1) 75 x 3
(2) 142 x 3
must not jam.
LAIL11MG0857A0A 44
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LAIL11MG0852A0A 45

LAIL11MG0858A0A 46

guide ring (3).
LAIL11MG0859A0A 47

annular groove.
LAIL11MG0860A0A 48
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LAIL11MG0861A0A 49
mended value).
LAIL11MG0862A0A 50

LAIL11MG0863A0A 51
nesses = 2.1 – 4.2 mm).
LAIL11MG0864A0A 52
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120 °C).
LAIL11MG0865A0A 53

NOTICE: Wear protective gloves.
LAIL11MG0866A0A 54
washer (3).
LAIL11MG0867A0A 55
LAIL11MG0868A0A 56
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LAIL11MG0869A0A 57

disk (4).
NOTE: Pay attention that the running disk is flush with the
shaft collar to ensure that all inner disks are mounted on
the idler gear teeth.
LAIL11MG0870A0A 58
is obtained.
LAIL11MG0871A0A 59

audible.
LAIL11MG0872A0A 60
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K4 clutch
LAIL11MG0359A0A 61
LAIL11MG0360A0A 62
3. Re-cool the shaft (1) (approximately -80 °C), heat the

clutch (2) (approximately +120 °C), and mount until
NOTICE: Wear protective gloves.
LAIL11MG0361A0A 63
4. Secure the drive gear with a 80 x 2.5 retaining ring (1).
LAIL11MG0362A0A 64
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5. Mount the lower axial washer (1), axial needle cage (2),
and upper axial washer (1).
NOTE: Upper and lower axial washer are identical (50 x 70
x 1).
LAIL11MG0363A0A 65
6. Mount both needle bearings (1).
LAIL11MG0364A0A 66
LAIL11MG0365A0A 67
8. Mount the axial washer (1), needle cage (2), and run-
ning disc (3).
NOTE: Mount the running disc (3) with the chamfer facing
the needle cage.
LAIL11MG0366A0A 68
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guide ring (3).
LAIL11MG0367A0A 69

annular groove.
LAIL11MG0368A0A 70
11. Use a hand-operated press to place piston into the

disk carrier by means of the assembly aid.
LAIL11MG0369A0A 71

guide ring (3).
LAIL11MG0370A0A 72
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annular groove.
LAIL11MG0371A0A 73

LAIL11MG0372A0A 74
mended value).
LAIL11MG0373A0A 75

LAIL11MG0863A0A 76
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nesses = 2.1 – 4.2 mm).
LAIL11MG0375A0A 77

120 °C).
LAIL11MG0376A0A 78
19. Mount the clutch (1) until contact is obtained and fix it
using a 50x2 retaining ring (2).
20. Mount inner disks onto the inner disk carrier by means
of short left/right rotations.
LAIL11MG0377A0A 79
is obtained.
LAIL11MG0378A0A 80
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audible.
LAIL11MG0379A0A 81
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Clutch - Install
[HBZN0845VCAF01093 - ]
Input and output shaft for clutches KV/KR/K1/K2/K3/K4

NOTE: In our striving for continuous technical upgrading
we have changed the FLOW clutch (which was only ex-
changeable as a complete unit) to a version which allows
replacement of the individual parts.
“OLD” clutch version (FLOW clutch)

NOTE: Exchange and delivery of the clutch are only pos-
sible as a complete unit.
LAIL11MG0631A0A 1
“NEW” clutch version

In case of damage, this clutch allows exchange of all
individual parts.
NOTE: However, the clutch can also be supplied and ex-
changed as a complete unit.
NOTE: For the binding part numbers please refer to the
spare parts list.
LAIL11MG0632A0A 2
Assembly instructions for the repairs

NOTE: The change over to the “NEW” clutch was imple-
mented from transmission No. 842654 economy transmis-
sions.
NOTE: In case of damage, please bear in mind the fol-
lowing information:The “old” clutch (FLOW clutch) and the
“new” clutch are interchangeable, i.e. in case of repair the
“old” clutch must be replaced by the “new” clutch.
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Please find below some information regarding the change-over of the clutches involved
Description Old New
Clutch KV and KR 0501 212 261 4656 275 001
Clutch KV and KR 0501 212 263 4656 275 002
K1 clutch 0501 212 262 4656 271 006
Clutch K2 and K3 0501 212 259 4656 272 007
K4 clutch 0501 212 260 4656 274 001
These part numbers are just for information purposes.

For the binding part numbers please refer to the spare
parts list.
You will find the part number of the clutch assy indicated
on both versions.
“OLD” clutch version (FLOW clutch)

NOTE: The part number (2) of the clutch (3) is indicated on
the rear side of the disc drum (1).
LAIL11MG0633A0A 3
“NEW” clutch
NOTE: The part number (2) of the clutch (3) is indicated on
the front side of the end plate (1).
LAIL11MG0634A0A 4
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Clutch - Calibrate
[HBZN0845VCAF01093 - ]
Calibration of the clutches (Models with “Torque Converter” transmission)

NOTE: Use the following procedure to calibrate the transmission clutches every 1000 hours of work.
1. Keep all unauthorized personnel clear of the area.
2. Park the machine on a flat, level, firm surface, away
from any obstacles.
3. Before you go into the programming screen, you should
warm up the transmission fluid.
4. Put the machine's engine into operation to warm up the
fluid.
5. Perform short movements, forward and backward, until
the fluid reaches working temperature.
6. The normal working temperature of the fluid is 70 –
80 °C (158 – 176 °F). COIL14GRD0079AA 1
7. Place the transmission control lever in the Neutral po-

sition.
8. Set the park brake.
9. To exit the “Desengage Park Break!” screen, throttle
the engine above 1500 RPM for a few seconds, until
the “Desengage Park Break!” screen disappears. After
the rotation goes back to idle speed, the panel will be
unlocked.
COIL15GRD0145AA 2
10. With the engine in operation, at idle speed, go into

the service screen menu. Use the up arrow and down
arrow to scroll to the “Config” option.
COIL15GRD0146AA 3
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11. Use down arrow button to scroll to the “Clutch Calib”

option. Press the “Confirm” key.
12. Always follow the screen prompts.
NOTE: If an error occurs, use the “Esc” key to start over.
13. The screen will display a confirmation message “Con-
firm Please”.
14. If you do not have authorization to perform this opera-
tion, press the “Esc” key and get help from your CASE
CONSTRUCTION Authorized Dealer.
COIL15GRD0147AA 4
15. If calibration conditions are incorrect, an error mes-

sage will appear.
NOTE: The calibration procedure will not completed.
16. Follow the prompts to aid in correcting any machine
conditions.
17. The screen may show the following messages to
guide the user in correcting some machine conditions:
• Not in neutral
• Park Brake Released
• Machine in motion
COIL15GRD0148AA 5
• Fluid temperature very low
• Fluid temperature very high
• Engine RPM too low
• Engine RPM too high
18. If the calibration conditions are correct, the opera-
tor or technician will see a sequence of 6 calibration
screens. The calibration screens will appear in the fol-
lowing order:
• K1 setup
• K2 setup
• K3 setup
• K4 setup
• KV setup
• KR setup
• WK setup (Lock-up) COIL15GRD0149AA 6
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19. Once the process is complete, the screen will prompt

the operator or technician to shut down the engine and
then turn the engine back on.
20. At this time, the transmission will be calibrated.
21. If the calibration process is not complete for any rea-
son, the operator or technician will need to exit the
screen.
COIL15GRD0150AA 7
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Rear output shaft flange - Remove

[HBZN0845VCAF01093 - ]
Output Flange on Output Side Without Parking Brake

1. Remove the locking plate (1), loosen the hexagonal
screws, and remove the washer and O-ring.
LAIL11MG1282A0A 1
2. Pull off the output flange (1) and remove the shaft seal
(2).
LAIL11MG1283A0A 2
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Output Flange on Output Side With Parking Brake

1. Connect the HP pump at the port (1) and apply approx.
80 bar pressure to the hydraulically actuated parking
brake (2) until the brake disc (3) can be rotated by hand.
(S) Manual pump 5870 287 007
(S) MINIMESS coupling (M12 x 1.5) 5870 950 101
LAIL11MG1284A0A 3
2. Loosen the hexagonal screws (1) of the bolted connec-

tion between the parking brake and the bracket.
LAIL11MG1285A0A 4
3. Remove the parking brake (1).

Types:
M-90 (mechanical actuation)
FSG-75 (hydraulic actuation)
FSG-90 / 110 (hydraulic actuation)
NOTE: In case of wear marks in the pump housing or on the
control disk, the oil pressure pump assy must be replaced.
LAIL11MG1286A0A 5
(2).
6. Loosen the Allen screws (3) of the bolted connection
between the bracket and the transmission housing/rear
part and remove the bracket.
LAIL11MG1287A0A 6
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Rear output shaft flange - Remove

[HBZN0845VCAF01093 - ]
Flange on the torque converter output side (without axle disconnection)

LAIL11MG1288A0A 1
(2).
LAIL11MG1289A0A 2
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Flange on the torque converter output side (with axle disconnection)

1. Loosen the Allen screws (1) and separate the axle dis-
connection (2) with two assembly levers from the hous-
ing.
(S) Mounting lever 5870 345 036
LAIL11MG1290A0A 3
LAIL11MG1291A0A 4
3. Remove the shim (1) and the bushing (2).
LAIL11MG1292A0A 5
4. Pull off the output flange (1), loosen the Allen screws
(2), and remove the washer (3), intermediate disc, and
bushing (4).
LAIL11MG1293A0A 6
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5. Remove the seal from the shaft (1).
LAIL11MG1294A0A 7
LAIL11MG1295A0A 8
7. Force out the output shaft (1) using a plastic hammer.
LAIL11MG1296A0A 9
8. Press the ball bearing (1) from output shaft (2).
LAIL11MG1297A0A 10
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9. Remove the sliding sleeve (1).
LAIL11MG1298A0A 11
10. Remove the sliding pads (1) and loosen the hexagonal
screws (2).
LAIL11MG1299A0A 12
11. Remove the pin (1) and release the shift fork (2).
LAIL11MG1300A0A 13
12. Dismantle the switch (1) and the locking pin (2).
LAIL11MG1301A0A 14
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13. Loosen the Allen screws (1), remove the cylinder (2),
and the seal.
LAIL11MG1302A0A 15
14. Remove releasing single components.

(1) Piston
(3) Spring cup
LAIL11MG1303A0A 16
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Rear output shaft flange - Install

[HBZN0845VCAF01093 - ]
Output Flange on Output Side Without Parking Brake

1. Use a driver (S) to mount the shaft seal with the sealing
lip facing the oil sump.
(S) Installer 5870 048 057
NOTE: Using the specified driver (S) ensures an exact in-
stallation position.
NOTE: Fill up space between sealing lip and dust lip with
grease.
NOTE: Wet outer diameter (rubber-coated) with spirit.
LAIL11MG0168A0A 1
2. Mount the output flange (1) until contact is obtained.
LAIL11MG0169A0A 2
3. Insert a 38 x 4 O-ring in the space between the output

flange and the shaft.
4. Fix output flange using washer (1) and hexagonal
screws (2).
LAIL11MG0170A0A 3
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5. Fix the locking plate using the installer (S).

(S) Installer 5870 057 011
(S) Cable 5870 260 002
LAIL11MG0171A0A 4
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Output Flange on Output Side With Parking Brake

1. Use driver to mount shaft seal, with the sealing lip
showing to the oil sump.
(S) Installer 5870 048 057
NOTE: Using the specified driver (S) ensures an exact in-
grease.
LAIL11MG0168A0A 5
Water-immersible version
2. Install the 1st shaft seal with the sealing lip facing the
oil sump.
3. Install the 2nd shaft seal with the sealing lip facing away
from the oil sump.
NOTE: Use the specified driver (S) to obtain an exact in-
stallation position. (Driver with retaining ring for 1st shaft
seal) (Driver without retaining ring for 2nd shaft seal).
(S) Installer 5870 048 301
NOTE: Fill up space between shaft seals with grease.
LAIL11MG0172A0A 6
4. Fix the brake disc (1) at the output flange (2) using
hexagonal screws (3) and washers.
5. Bring the bracket (4) into contact position with the trans-
mission housing rear part and fix it using Allen screws
(5).
LAIL11MG0173A0A 7

8. Fix output flange using washer (1) and hexagonal
screws (2).
LAIL11MG0174A0A 8
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9. Fix locking plate by means of driver.

(S) Installer 5870 057 011
(S) Cable 5870 260 002
LAIL11MG0175A0A 9
10. Connect the HP-pump to the port (1), apply approx.

80 bar pressure to the parking brake (2) and position
it until contact with the bracket is obtained.
(S) HP hand pump 5870 287 007
(S) MINIMESS coupling (M10 x 1) 0501 207 939
(S)MINIMESS coupling (M12 x 1.5) 5870 950 101
NOTE: Check the connecting thread (1).
LAIL11MG0176A0A 10
11. Fix the FSG-75 parking brake (1) to the bracket using
hexagonal screws (2).
Tightening torque (M16 x 1.5/10.9 x 85) MA = 300 N·m
LAIL11MG0177A0A 11
NOTE: All installation, fitting and maintenance instructions,

functional characteristics and setting specifications for the
parking brake see original Knott documentation.
NOTE: Types:
M-90 (mechanical actuation)
FSG-75 (hydraulic actuation)
FSG-90 / 110 (hydraulic actuation)
NOTE: FSG-75 / 90
Release clearance: 0.5 – 1.5 mm
Nominal release clearance: 1.0 mm
NOTE: FSG-110
Release clearance: 1.5 – 2.0 mm LAIL11MG0178A0A 12
Nominal release clearance: 1.7 mm
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Rear output shaft flange - Install

[HBZN0845VCAF01093 - ]
Output flange on converter side (without axle disconnection)

1. Install the shaft seal with a driver, with the sealing lip
facing the oil sump.
(S) Installer 5870 048 057
grease.
LAIL11MG0638A0A 1
LAIL11MG0639A0A 2

4. Fix the output flange using a washer (1) and hexagonal
screws (2).
LAIL11MG0640A0A 3
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(S) Installer 5870 057 011
(S) Cable 5870 260 002
LAIL11MG0641A0A 4
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Output flange on the torque converter side (with axle disconnection)

1. Install a spring cup (1) and compression spring (2).
LAIL11MG0976A0A 5
2. Put the rectangular ring (Viton) 40x47x2 (1) into the

annular groove and grease it.
3. Insert the piston (2).
NOTE: Ensure radial installation position of piston. Contact
face of locking pin must show to hole (see arrows).
LAIL11MG0977A0A 6
4. Mount two adjusting screws (S) and position the gasket

(1).
5. Insert the cylinder (2).
LAIL11MG0978A0A 7
6. Mount the cylinder (2) evenly using Torx screws (1) until
LAIL11MG0979A0A 8
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7. Install a threaded pin M6 x 8 x 10.9 (1)

LAIL11MG0980A0A 9
8. Bring the shift fork (1) into the correct position.

NOTE: Observe installation position.
LAIL11MG0981A0A 10
9. Fit the 8 x 2 O-rings (1) in the annular grooves in the

bolts (2) and grease them.
10. Fix the shift fork (4) using studs (2) and fasten with
hexagonal screws.
LAIL11MG0982A0A 11
11. Mount both sliding pads (1) and insert the sliding
sleeve (2).
LAIL11MG0983A0A 12
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12. Install the 15 x 2 O-ring (1) in the switch (2) and grease
it.
13. Install the locking pin (2) and switch (3).
LAIL11MG0984A0A 13
14. Press the ball bearing (1) with a tube (S) on the output
shaft (2) until contact is obtained.
LAIL11MG0985A0A 14
15. Install the output shaft (1) (mounting the sliding sleeve
at the same time) and press until contact is obtained.
LAIL11MG0986A0A 15
16. Fix the output shaft (1) using the 120 x 4 retaining ring
(2).
NOTE: Ensure radial installation position of retaining ring,
to keep oil groove (arrow) clear.
LAIL11MG0987A0A 16
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Standard version
17. Install shaft seal (1) with the sealing lip facing the oil
sump.
(S) Installer 5870 048 237
grease.
LAIL11MG0988A0A 17
Water-immersible version
18. Install the shaft seal (1) with the sealing lip facing the
oil sump.
(S) Installer 5870 048 300
stallation position. (Driver without retaining ring).
LAIL11MG0989A0A 18
19. Install shaft seal (1) with the sealing lip facing away
from the oil sump.
(S) Installer 5870 048 300
stallation position. (Driver with retaining ring).
NOTE: Fill up space between shaft seals with grease.
LAIL11MG0990A0A 19
20. Press the baffle (1) onto the output flange (2) in a flush
position using a pressure sleeve (S).
(S) Pressure sleeve 5870 506 142
LAIL11MG0991A0A 20
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Version with movable output flange

21. Mount the bushing (1) onto the output flange.
22. Put the intermediate disc and washer (2) into the bush-
ing and secure using Allen bolts (3).
NOTE: Lubricate the thread with LOCTITE® 262™.
LAIL11MG0992A0A 21
23. Mount the output flange (1) onto the output shaft (2).
LAIL11MG0993A0A 22
Version with threaded output flange

24. Mount the output flange (1) onto the output shaft (2).
LAIL11MG0994A0A 23
25. Put the 48 x 4 O-ring and washer (1) into the space
between the output flange and the shaft and fix with
NOTE: Lubricate the thread with LOCTITE® 262™.
LAIL11MG0995A0A 24
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Check the switch function using the resistance measurement

1. When actuating the axle disconnection using com-
pressed air, the resistance changes if the switch is in
good order.
(S) Measuring device (multimeter) 5870 221 196
LAIL11MG2108A0A 25
2. Insert a limiting disc (perforated plate) into the hole (1).

3. Apply assembly grease to the 146 x 2.65 O-ring (2) and
place it into the annular groove.
LAIL11MG0403A0A 26
4. Insert the needle sleeve carefully (1) into the hole of

the output shaft (2) until contact is obtained, with the
reinforced part of the cage facing the special tools (S).
5. Then grease needle rollers.
(S) Centering bush 5870 506 099
(S) Installer 5870 048 132
LAIL11MG0404A0A 27
6. Mount the bush (1) and the shim (2) on the output shaft
(3).
NOTE: Observe installation position.
LAIL11MG0405A0A 28
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7. Fix the bush (1) with the shim (suggested value =

2.4 mm) and V-ring (2).
NOTE: Ensure that the bush axial play is a maximum of
0.2 mm.
LAIL11MG0406A0A 29
8. Insert a preassembled axle disconnection (1) and fix

using Allen bolts (2).
Tightening torque - 7 Parts (M12 / 8.8 x 75) MA =
80 N·m
Tightening torque - 2 Parts (M12 / 8.8 x 80) MA =
80 N·m
LAIL11MG0407A0A 30
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Rear output shaft flange Output yoke - Remove

[HBZN0845VBAF00184 - ]
-]
NOTE: Before starting removal, see Rear output shaft

flange Output yoke - Exploded view (21.155).
NOTE: The output yoke will turn when removing the screw.
Place a block of wood (F) or a similar object between the
yoke (B) and the housing to help remove the output yoke
assembly.
1. Loosen bolt (E).
LAIL11MG2004A0A 1
2. Remove the bolt (E), washer (D), and O-ring (C).
LAIL11MG1403A0A 2
3. Remove the output yoke (B) and the seal V-ring (A).
LAIL11MG1960A0A 3
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Rear output shaft flange Output yoke - Install

[HBZN0845VBAF00184 - ]
-]
NOTE: Before starting installation, see Rear output shaft

flange Output yoke - Exploded view (21.155).
1. Lubricate the seal and the seal surfaces on the output
yoke (A).
LAIL11MG1196A0A 1
2. Install the output yoke (A).
LAIL11MG1197A0A 2
3. Lubricate a new O-ring (E).

4. Install a new O-ring (E).
5. Install washer (D).
6. Install the bolt (C).
LAIL11MG1198A0A 3
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7. Use a block of wood (F) or a similar object to prevent

the output yoke from turning.
8. Torque bolt (C) to 215 N·m (159 lb ft).
LAIL11MG1199A0A 4
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Index
Transmission - 21

Clutch - Calibrate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Clutch - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Clutch - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Clutch - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Clutch Clutch stage - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Clutch Clutch stage - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Clutch Forward clutch - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Clutch Reverse clutch - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Clutch Reverse clutch - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Output shaft - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Output shaft - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Output shaft - Clearance (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Output shaft - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Output shaft - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Output shaft - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Output shaft - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Output shaft - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Output shaft - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Output shaft - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Powershift transmission internal components - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Powershift transmission internal components - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Rear output shaft flange - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Rear output shaft flange - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Rear output shaft flange - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Rear output shaft flange - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Rear output shaft flange Output yoke - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rear output shaft flange Output yoke - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Rear output shaft flange Output yoke - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Shaft assemblies - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Shaft assemblies - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Shaft assemblies - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Shaft assemblies - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Shaft assemblies - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Shaft assemblies - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Shaft assemblies - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Shaft assemblies - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Shaft assemblies - Service instruction (Sizing of the seal rings) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Shaft assemblies - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Transmission - 21
Torque converter - 700

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Contents
Transmission - 21
SERVICE
Torque converter
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Converter oil pressure adjustment valve
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lock-up valve
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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Transmission - Torque converter
Torque converter - Remove

[HBZN0845VCAF01093 - ]
Engine connection (Direct mount)

1. Loosen the hexagonal screw (2) and separate the Flex-
plate (1) from the torque converter (3).
LAIL11MG0733A0A 1
2. Separate the torque converter (1) from the transmis-

sion using a lifting device.
(S) Eye bolt assortment 5870 204 002
LAIL11MG0734A0A 2
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Engine connection (Direct mount)

screw, and remove the washer.
2. Loosen the bolted connection (2) of the cover/torque
converter housing.
NOTE: Mark radial installation position of cover/converter
bellhousing by center punch.
LAIL11MG0735A0A 3
3. Separate cover from converter bellhousing by means

of lifting device.
LAIL11MG0736A0A 4
4. Pull off output flange.
LAIL11MG0737A0A 5
5. Press the input shaft and the torque converter out of

the cover (ball bearing).
LAIL11MG0738A0A 6
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6. Snap out the retaining ring (1) and remove the ball
bearing (2).
LAIL11MG0739A0A 7
7. Loosen the hexagonal screws (1) and remove the flex-

plate (2) from the torque converter.
LAIL11MG0740A0A 8
8. Loosen the hexagonal screws (1) and remove the flex-

plate (2) from the input shaft (3).
LAIL11MG0741A0A 9
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Oil pressure pump

1. Loosen the bolted connection (1) from the torque con-
verter housing/oil feed housing and remove the con-
verter housing (2).
LAIL11MG0742A0A 10
2. Loosen the bolted connection (1) from the oil feed

housing/front part of the transmission housing with
Torx screws and the bolted connection (2) from the oil
pressure pump/front part of the transmission housing
with Allen screws.
NOTE: Separate oil feed housing together with oil pressure
pump from transmission housing front part.
LAIL11MG0743A0A 11
3. the Separate oil pressure pump (1) from the oil feed
housing (2).
LAIL11MG0744A0A 12
4. Loosen both Allen screws (1) and remove the control

disk.
NOTE: In case of wear marks in the pump housing or on the
control disk, the oil pressure pump assy must be replaced.
LAIL11MG1480A0A 13
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5. Remove the snap ring (1) and the individual parts.

(1) Pump housing with rotor
(2) Pressure ring
(3) Shaft seal ring
(4) Support shim
Needle bearing (5)
(6) Ring
LAIL11MG0745A0A 14
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Converter back-pressure valve

1. Preload the torque converter safety valve (1) using a
screwdriver or assembly aid (S) and remove the locking
plate (2).
LAIL11MG0746A0A 15
2. Remove individual parts of converter safety valve

which are getting released.
Pressure plate (1)
(3) Piston
LAIL11MG0747A0A 16
3. Remove the temperature sensor (1).
LAIL11MG0748A0A 17
4. Remove the stator shaft (1).

5. Pull the pressure relief valve (2) out of the housing hole.
LAIL11MG0749A0A 18
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Torque converter - Install

[HBZN0845VCAF01093 - ]
Engine connection (direct mount)

1. Position the torque converter (1) using the lifting device
LAIL11MG0421A0A 1
2. Fix the flexplate (1) with hexagonal bolts (2).

NOTE: Fit washers between the torque converter (3) and
the flexplate (1) and under the hexagonal screws.
NOTE: Hold the hexagonal screws with LOCTITE® 262™.
LAIL11MG0422A0A 2
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Engine connection (remote mount)

1. Fix the input shaft (1) on the flexplate (2) with hexago-
nal screws (3).
LAIL11MG0423A0A 3
2. Fix the flexplate (1) to the torque converter (3) with

NOTE: Lubricate the threads of the hexagonal screws with
LOCTITE® 262™.
LAIL11MG0424A0A 4
3. Install a ball bearing (1) and fix it with V-ring JV 100 (2).
LAIL11MG0425A0A 5
4. Put the cover (1) onto the torque converter and press it
NOTE: Support the pressure sleeve (S) on the bearing in-
ner ring.
LAIL11MG0426A0A 6
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5. Press the deflector (1) onto the input flange (2).
LAIL11MG0427A0A 7
6. Heat up clutch inner diameter (approx. 120 °C) can be

varied.
LAIL11MG0428A0A 8
7. Mount the input flange (1) until contact is obtained.
LAIL11MG0429A0A 9
8. Fix the input flange using a washer (3) and hexagonal

screws (1). (2)
LAIL11MG0430A0A 10
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(S) Installer 5870 057 010
(S) Cable 5870 260 002
LAIL11MG0431A0A 11
10. Position the torque converter using the lifting device

(1) until the cover is in contact with the torque con-
verter housing (2).
LAIL11MG0432A0A 12
11. Bolt the torque converter housing (1) to the cover (2)
with Allen screws and hexagonal nuts.
NOTE: Pay attention to radial installation position, see
markings done during disassembly (arrows).
Tightening torque (M10/8.8) MA = 46 N·m
LAIL11MG0433A0A 13
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Converter oil pressure adjustment valve - Install

[HBZN0845VCAF01093 - ]
1. Note the separate parts of the torque convertor oil pres-

sure adjustment valve.
(1) Oil fill sump
(2) Piston
Pressure plate (4)
(5) Lock Plate
NOTE: Install the pressure plate (4), with the pin (Ø 6 mm)
facing the lock plate (5).
LAIL11MG0408A0A 1
2. Assemble the single parts, preload them with assembly

aid (S), and fix them using the lock plate (1).
LAIL11MG0409A0A 2
3. Mount the temperature sensor (1) with a new 11 x 2

O-ring.
NOTE: Version without a temperature sensor: Fit a screw
plug (1) with a new 11 x 2 O-ring.
LAIL11MG0410A0A 3
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Lock-up valve - Assemble

[HBZN0845VCAF01093 - ]
Lock-up Valve “Lock-up”

1. Insert the M8 x 8 threaded pin (1) into the cover with
Loctite 649.
Tightening torque (threaded pin) MA = 18 N·m
LAIL11MG0476A0A 1
2. Install the single components of the “Lock-up” valve.

(1) M5 x 12 Allen bolt
(2) A5 spring washer
(3) Solenoid valve
(4) Gear shift control housing
(5) Piston
(6) 4 x 8 x 0.5 adjustment washers (3 parts – Reference
value)
LAIL11MG0477A0A 2
(8) Stop
(9) 13 x 2 O-ring
(10) L12A-M fitting
Tightening torque
Allen bolts (M5/8.8 x 12) MA = 5.5 N·m
Fitting L12A-M (M16 x 1.5) MA = 46 N·m
NOTE: The adjustment washers (6) are used to determine
a pressure of 15 – 16 bar of “Lock-up”. Install the stop (9)
with the flat side facing the compression spring.
3. Mount the seal (2) and the pre-mounted “Lock-up”
valve (3) on the cover (1) and secure with Allen screws
and washers (4) and (5).
LAIL11MG0478A0A 3
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4. Fix the “Lock-up” valve with Allen bolts (1) and (2) and
install the threaded plug (3) with a new 8 x 1.5 O-ring.
Tightening torque
Threaded bolt (10 x 1) MA = 6.0 N·m
LAIL11MG0479A0A 4
5. Secure the plate (1) on the housing with Allen screws

(2).
6. Fix the “Lock-up” valve on the board (1) with hexagonal
bolts and nuts (3).
LAIL11MG0480A0A 5
7. Secure the plate (1) on the housing with Allen screws

(2).
8. Fix the “Lock-up” valve on the board (1) with hexagonal
bolts and nuts (3).
LAIL11MG0481A0A 6
Tightening torque:
Hose (1)
Banjo bolt (6) M12 x 1.5 MA = 35 N·m
Hose (2)
Fitting, L12A-M (M16 x 1.5) MA = 46 N·m
MA hose = 35 N·m
Hose (3)
9. Insert the threaded bush with an 23 x 2 O-ring into the
housing
Threaded bush tightening torque (M26 x 1.5) MA = LAIL11MG0482A0A 7
80 N·m
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Index
Transmission - 21

Converter oil pressure adjustment valve - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lock-up valve - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Torque converter - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Torque converter - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Transmission - 21
Hydraulic pump drive - 900

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Contents
Transmission - 21
SERVICE
Hydraulic pump drive

Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Transmission - Hydraulic pump drive
Hydraulic pump drive - Remove

[HBZN0845VCAF01093 - ]
Version without emergency steering pump

1. Loosen the bolted connection (1) from the cover/front
part of the housing and remove the cover (2) and seal.
LAIL11MG1279A0A 1
Version with emergency steering pump

2. Loosen the Allen screws (1) and separate the emer-
gency steering pump (2) from the cover.
NOTE: Mark radial installation position (see arrows).
LAIL11MG1280A0A 2
3. Loosen the bolted connection (1) from the cover/front

part of the housing and remove the cover (2) and seal.
LAIL11MG1281A0A 3
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Hydraulic pump drive - Install

[HBZN0845VCAF01093 - ]

1. Fit the adjusting screws (S) and assemble the seal (1)
and cover (2).
LAIL11MG0434A0A 1
2. Fix the cover using hexagonal screws (1).

LAIL11MG0435A0A 2
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1. Press sliding bearing into the cover (1) in alignment with
the flat face.
(S) Installer 5870 048 080
LAIL11MG0436A0A 3
2. Place an 100x3 O-ring (1) into the annular groove of

the piston pump (2) and grease it.
LAIL11MG0437A0A 4
3. Fit the adjusting screws (S) and assemble the seal (1)
and cover (2).
LAIL11MG0438A0A 5
4. Fix the cover (1) using Torx screws (2).

5. Mount the emergency steering pump (3) and fix it with
Allen screws (4).
Tightening torque (M8/8 x 135) MA = 23 N·m
NOTE: Pay attention to radial installation position, see
markings done during disassembly (arrows).
LAIL11MG0439A0A 6
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Index
Transmission - 21

Hydraulic pump drive - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic pump drive - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Av. General David Sarnoff, 2237 - Inconfidentes, Contagem (MG) - Brasil, CEP:32210-900
SERVICE - Technical Publications & Tools
PRINTED IN BRAZIL
© 2017 CNH Industrial Latin America LTDA All rights reserved.
No part of the text or illustrations of this publication may be reproduced.
CNH Industrial Latin America LTDA reserves the right to make improvements in design and changes in specifications
at any time without notice and without incurring any obligation to install them on units previously sold. Specifications,
descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject
to change without notice.
Availability of some models and equipment builds varies according to the country in which the equipment is being
used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer.
CASE CONSTRUCTION is a trademark registered in the United States and many other countries, owned or
licensed to CNH Industrial N.V., its subsidiaries or affiliates.
Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or
licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.
48050419D 06/10/2017
EN
SERVICE MANUAL
Front axle system

48050419D 06/10/2017
25
Contents
Front axle system - 25
[25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1
[25.400] Non-powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2
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25
Final drive hub, steering knuckles, and shafts - 108

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Contents
SERVICE
Wheel hub
Assemble (Models with AWD front-wheel drive system) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Front axle system - Final drive hub, steering knuckles, and shafts
Wheel hub - Assemble (Models with AWD front-wheel drive system)

865B NA (AWD)
885B NA (AWD)
Tools and auxiliary equipment for installation

Lint-free cotton cloth.
COIL15GRD0022AA 1
Auxiliary O-ring.
COIL15GRD0021AA 2
Oil for assembly.
COIL15GRD0023AA 3
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Protective plastic ring for the seal (874579-1)
COIL15GRD0024AA 4
COIL15GRD0103AA 5
Plastic hub alignment device (874579-2)
COIL15GRD0025AA 6
COIL15GRD0104AA 7
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Assembly instructions for wheel hub with traction

1. Position the wheel hub on a clean surface. The wheel
hub must be clean and free of oxidation or rust. Always
use clean gloves during this procedure.
COIL15GRD0001AA 8
2. Use a lint-free cotton cloth to clean parts. Moisten the

cloth with ethanol to remove all the fat from the parts.
COIL15GRD0002AA 9
3. Clean the seating surface of the rubber ring for the seal
assembly with the cloth. The surface must be com-
pletely free of oil and grease.
NOTE: Make sure that the surface is very clean: Pass an-
other piece of dry cloth all around the seat of the rubber
ring for the seal.
COIL15GRD0026AA 10
4. Separate the parts for use in the new seal assembly of

the wheel hub. Make sure all of the parts are available.
COIL15GRD0003AB 11
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5. The wheel hub seal comprises two identical halves.

Each half comprises a metal bevel ring and a rubber
or synthetic seal ring. Clean the bevel surface with a
cloth moistened with ethanol. The bevel part must be
free of oil and grease. This bevel ring has another ma-
chined and polished flat surface. Do not remove the oil
on the polished surface. After the operation, keep the
polished surfaces of the two rings in contact. Clean the
two halves the same way.
COIL15GRD0005AA 12
6. Clean the rubber seal rings with a cloth moistened with

ethanol. The entire surface of the rings must be free of
oil or grease.
COIL15GRD0006AA 13
7. Keep the polished surface of the bevel ring in contact

with the same surface of the other ring. Assemble the
seal ring on the bevel side. Do not let the ring become
twisted. Check the alignment of the ring using the mark
left by the opening of the mold of the part manufacturer.
(1) Manufacturer mold mark
COIL15GRD0007AA 14
COIL15GRD0008AA 15
48050419D 06/10/2017
25.1 [25.108] / 6
8. Take the auxiliary O-ring assembly. You will use this

ring for correct alignment of the seal ring during assem-
bly. However, you should remove the ring on comple-
tion. This ring is not part of the installed assembly.
COIL15GRD0009AA 16
9. Assemble the auxiliary ring between the metal bevel

ring and the rubber seal ring.
NOTE: Tie a piece of string to the auxiliary O-ring to facili-
tate removal. Do not change the position of the rings at the
end of assembly.
COIL15GRD0010AA 17
10. Check if the seating of the rings is correct. The string

should face outward.
COIL15GRD0027AA 18
11. Take the protective plastic ring (green) for the seal.
Fit the ring on the metal bevel ring, on the side of
the polished surface. The plastic ring will protect the
polished surface.
COIL15GRD0011AA 19
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12. Take the wheel hub. Pre-install the seal rings along
with the protective plastic ring.
COIL15GRD0029AA 20
13. Align the string to the outside.
COIL15GRD0028AA 21
14. Press the protective ring against the wheel hub to seat
the seal rings assembly
COIL15GRD0012AA 22
15. Remove the protective ring (green). Check the perfect

seating of the seal rings assembly on the bottom of the
hub seat. Do not allow the seal ring to settle so that
it is wavy. If this happens, there will be oil leaks from
the wheel hub seal.
COIL15GRD0013AA 23
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16. Pull the string to remove the auxiliary O-ring from the
wheel hub seal assembly. Be careful not to change
the position of the parts in the previous assembly.
COIL15GRD0030AA 24
17. Using a depth micrometer, measure the parallelism

between the polished surface of the seal ring and the
outer face of the wheel hub, every 90°. You must carry
out the measurement at 3 mm of the polished surface
of the seal ring. The maximum difference between the
four measurements should not exceed 0,4 mm.
ATTENTION: The measuring instrument should not touch
the polished surface. Only the machined part should touch
the polished surface.
COIL15GRD0014AA 25
18. Now take the planetary reduction hub. On a clean

surface, clean the mounting seat of the seal rings with
a cloth dampened with ethanol. The mounting surface
must be free of oil and grease. Use another dry cloth
to make sure that the surface is clean.
COIL15GRD0015AA 26
19. Follow a similar procedure to the assembly on the

wheel hub: Install the seal assembly, with the protec-
tive plastic ring (green), on the seat of the planetary
hub.
COIL15GRD0016AA 27
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20. Press over the entire circumference of the protective

ring to ensure the correct seating of the seal assembly.
COIL15GRD0017AA 28
21. Pull the string to remove the auxiliary O-ring from the
planetary hub seal assembly. Be careful not to change
the position of the parts in the previous assembly.
COIL15GRD0031AA 29
22. Using a depth micrometer, measure the parallelism

between the polished surface of the seal ring and the
outer face of the wheel hub, every 90°. You must carry
out the measurement at 3 mm of the polished surface
of the seal ring. The maximum difference between the
four measurements should not exceed 0,4 mm.
ATTENTION: The measuring instrument should not touch
the polished surface. Only the machined part should touch
the polished surface.
COIL15GRD0018AA 30
23. Clean the machined surface (the polished also) of the

metal ring of the seal assembly with a dry, lint-free
cloth.
COIL15GRD0019AA 31
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25.1 [25.108] / 10
24. Put a small amount of oil on the cloth.
COIL15GRD0020AA 32
25. Apply a thin layer of oil on the machined and polished

surfaces of the metal ring seal.
NOTICE: Do not allow oil to fall on the rubber ring.
COIL15GRD0036AA 33
26. Fit the plastic alignment device on the outer surface

of planetary hub. The device will guarantee the con-
centricity of the hubs during final assembly.
COIL15GRD0032AA 34
27. Support the wheel hub on two pieces of wood.

NOTICE: Do not allow the seal rings assembly to touch in
any way. If this happens, you lose the alignment of the
parts and it may cause oil leak.
COIL15GRD0033AA 35
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28. Lift the wheel hub using lifting equipment. Use eye
bolts on the wheel studs.
COIL15GRD0034AA 36
29. Carefully lower the wheel hub over the plastic align-
ment device on the planetary hub.
COIL15GRD0035AA 37
30. Make sure the assembly is correct. There should be

no clearance.
NOTE: The illustrations do not show the bearing cones.
You must also assemble the bearing cones. The end of
stroke of the assembly is given by the thrust of the cone
with the bearing cup.
COIL15GRD0037AA 38
31. Remove the plastic alignment device from the hubs.

The assembly is complete.
COIL15GRD0038AA 39
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Index

Wheel hub - Assemble (Models with AWD front-wheel drive system) (*) . . . . . . . . . . . . . . . . . . . . . . . 3
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Non-powered front axle - 400

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Contents
TECHNICAL DATA
Non-powered front axle

Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUNCTIONAL DATA

Exploded view - Wheel hub (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE

- Assemble - Camber (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Lubricate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Front axle system - Non-powered front axle
Non-powered front axle - General specification

845B 865B 885B

Axle High-resistance welded steel
Linkage (camber) High-resistance welded steel
Wheel flange High-resistance welded steel
Camber bearings Angular contact ball bearing
Internal diameter of upper bearing 45 mm (1.77 in)
Internal diameter of lower bearing 45 mm (1.77 in)
Degree of axle sway in each direction 15.3°
Direction of each wheel 20.3°
Steering cylinder ( 80 mm x 203 mm x 44.4 mm) ( 3.15 in
x 7.99 in x 1.75 in)
Left- and right-hand steering angle 42°
Non-powered front axle - Special tools

NOTICE: The operations described in this section should only be performed using the ESSENTIAL tools that appear
below with the symbol (X). However, for greater safety and to obtain the best results, saving time and effort, it is
recommended that these essential tools be used together with the specific tools listed below and certain tools that
should be made according to the construction designs supplied in this manual.
Tools necessary for the installation of the front axle.
48050419D 06/10/2017
25.2 [25.400] / 3
COIL14GRD0016AA 1
Nylon tool (AA).
Part number: 381000147.
48050419D 06/10/2017
25.2 [25.400] / 4
COIL14GRD0019AA 2
Nylon tool (BB).
48050419D 06/10/2017
25.2 [25.400] / 5
COIL14GRD0017HA 3
Steel tool (CC).
Part number 381000149.
48050419D 06/10/2017
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COIL14GRD0018HA 4
Steel tool (DD).
Non-powered front axle - Torque

Description Torque
M12 x 40 mm bolt 100 N·m (74 lb ft)
M8 x 25 mm bolt 28.8 N·m (21 lb ft)
Ball joint nut 270 – 290 N·m (200 – 215 lb ft)
Steering rod nut 270 – 290 N·m (200 – 215 lb ft)
M16 x 50 mm bolt 248 N·m (183 lb ft)
48050419D 06/10/2017
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Non-powered front axle - Exploded view - Wheel hub

COIL14GRD0003GA 1
Reference Component Reference Component

(1) Bolt (10) Hex.
(2) Washer (11) Bearing
(3) Shaft (half shaft) (12) Washer
(4) Seal ring (13) Pin
(5) Seal (14) Castle nut
(6) Bearing (15) O-ring
(7) Bolt (16) Boot
(8) Wheel hub (17) Washer
(9) Grease fitting (18) Bolt
48050419D 06/10/2017
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Non-powered front axle - Exploded view

COIL14GRD0001GA 1

(1) Bushing (6) Bolt 110 N·m
(2) Shim (7) Washer
(3) Shim (8) Grease fitting
(4) Axle (9) Front chassis
(5) Spacer (10) Front axle assembly (non-driven)
NOTE: Apply a torque of 110 N·m to bolt (6).
48050419D 06/10/2017
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Non-powered front axle - Exploded view

COIL14GRD0002GA 1

(1) Axle (20) Plate
(2) Right-hand linkage (21) Pin
(3) Left-hand linkage (23) Ring
(4) Right-hand flange (24) Washer
(5) Left-hand flange (26) Angular joint
(6) Tilt bar (27) Radial bushing/joint
(7) Steering rod (28) Washer
(8) Ball joint of steering cylinder (29) Castle nut
(9) Steering cylinder (30) Pin
(10) Tilt cylinder (31) Grease fitting
48050419D 06/10/2017
25.2 [25.400] / 10

(16) Pin (39) Bolt M10X90 mm
(17) Seal (41) Hex.
(18) Pin (42) Bolt M8X20mm
(19) Lock disk
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Non-powered front axle - Assemble - Camber

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
WARNING
Crushing hazard!
Engage the safety lock link before service or transport.
W1154A
1. Use an appropriate lifting device, secure it to the cam-

ber (1) and position it on a workbench.
COIL14GRD0070AA 1
2. Install the outer ring (1) of the ball joint assembly using
special tool (2).
NOTE: Carry out installation on both sides of the camber.
NOTE: Before installing the outer rings (1) of the ball joint
assembly, soak them in a nitrogen reservoir for 5 min.
COIL14GRD0069AA 2
48050419D 06/10/2017
25.2 [25.400] / 12
3. Position the camber on the end of the workbench and

install the rings (4).
4. Insert the bearing (2) into the housing. Position the
flange (5) and fit the pins (3).
NOTE: Fit both pins to the top and bottom of the flange.
5. Install the ring of the ball joint assembly with angled
contact (2) on the pin (2). Torque the bolts (1) to
100 N·m (74 lb ft).
COIL14GRD0022AA 3
6. Install the upper cover (1). Apply a torque of 28.8 N·m

(21.2 lb ft).
COIL14GRD0067AA 4
7. Install the lower cover (1). Pre-torque to 200 N·m

(148 lb ft). Then loosen and reapply the final torque of
60 N·m (44 lb ft).
COIL14GRD0066AA 5
48050419D 06/10/2017
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Non-powered front axle - Assemble

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.
D0076A
1. Use an appropriate lifting device, secure it to the axle

(1) and position it on a workbench.
COIL14GRD0065AA 1
2. Install the ball joint with angled contact (1) on the cam-
ber assembly.
3. Position the seal ring (2) and lock washer (3). Then
install the pin (4).
NOTE: Before installing the pin (4), soak for 5 min in a
nitrogen reservoir.
COIL14GRD0021AA 2
4. Manually position the castle nut (1) at the end of its

stroke. Then install the cotter pin.
NOTE: Do not use a pneumatic impact wrench for the pro-
cedure described above.
COIL14GRD0064AA 3
48050419D 06/10/2017
25.2 [25.400] / 14
5. Install the hydraulic tilt cylinder assembly (1) on the

shaft.
COIL14GRD0063AA 4
6. Separately install the ring (1) on the tilt bar.
COIL14GRD0062AA 5
7. Install the bar (1) next to the camber.
COIL14GRD0061AA 6
8. Install the radial bushings (1) on the closed ends of the

hydraulic steering cylinder assemblies (2).
9. Install the hydraulic steering cylinder assembly (2) on
the shaft.
COIL14GRD0023AA 7
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25.2 [25.400] / 15
10. Secure the ball joints (1) to the flanges. Apply tighten-
ing torque of 28 N·m (21 lb ft).
11. Check the alignment of the right- and left-hand
flanges. Then install the steering rod (2). Torque to
270 – 290 N·m (200 – 215 lb ft) .
COIL14GRD0071AA 8
12. Install the front axle (1) on the flange. Apply tightening
torque of 248 N·m (183 lb ft).
13. Install the bearings (2) and (4), followed by the seal
rings (5).
NOTE: Use CASE AKCELA MOLY GREASE grease.
14. Install the wheel hub assembly (3) and then lubricate.
COIL14GRD0024AA 9
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Non-powered front axle - Lubricate

NOTE: Use CASE AKCELA MOLY GREASE grease. Grease fittings are available on both sides of the axle.
1. Front wheel trunnion
COIL14GRD0004GA 1
2. Trunnion king pin
COIL14GRD0005GA 2
3. Steering cylinder
COIL14GRD0006AA 3
4. Wheel tilt cylinder
COIL14GRD0007AA 4
48050419D 06/10/2017
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5. Wheel tilt arm
COIL14GRD0008AA 5
6. Wheel hub
COIL14GRD0010GA 6
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Index

Non-powered front axle - Assemble - Camber (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Non-powered front axle - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Non-powered front axle - Exploded view - Wheel hub (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Non-powered front axle - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Non-powered front axle - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Non-powered front axle - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Non-powered front axle - Lubricate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Non-powered front axle - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Non-powered front axle - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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PRINTED IN BRAZIL
48050419D 06/10/2017
EN
SERVICE MANUAL
Rear axle system

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27
Contents
Rear axle system - 27
[27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1
[27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2
[27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3
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Powered rear axle - 100

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Contents
TECHNICAL DATA
Powered rear axle

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FUNCTIONAL DATA
Rear axle
Identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SERVICE
Rear axle
Level make up (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Level make up (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Change fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Change fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disassemble /Repair/Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Rear axle housing
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DIAGNOSTIC
Powered rear axle

Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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Rear axle system - Powered rear axle
Powered rear axle - General specification

845B ANZ (8 x 8 direct drive) OR (6 x 3 torque converter) OR (Tier 1) OR (Tier
3-VHP) --- APAC (8 x 8 direct drive) OR (6 x 3 torque converter) OR (Tier
1) OR (Tier 3-VHP) --- LA (8 x 8 direct drive) OR (6 x 3 torque converter)
OR (Tier 1) OR (Tier 3-VHP) --- MEA (8 x 8 direct drive) OR (6 x 3 torque
converter) OR (Tier 1) OR (Tier 3-VHP) --- NA (8 x 8 direct drive) OR (Tier
3-VHP)
Service interval
Oil level check interval Every 500 h of operation, with the axle in the horizontal
position
Oil change interval After the first 100 h and every 2000 h of operation
Grease lubrication interval Every 100 h of operation
Oil Specifications and Capacity

Central axle Refer to
Tandem box Refer to
Lubrication (Greases)
Grease type Refer to
Powered rear axle - General specification

3-VHP) OR (Tier 0) OR (AWD) --- APAC (8 x 8 direct drive) OR (6 x 3 torque
converter) OR (Tier 2) OR (Tier 3-VHP) OR (Tier 0) OR (AWD) --- LA (8 x 8
direct drive) OR (6 x 3 torque converter) OR (Tier 2) OR (Tier 3-VHP) OR
(Tier 0) OR (AWD) --- MEA (8 x 8 direct drive) OR (6 x 3 torque converter)
OR (Tier 2) OR (Tier 3-VHP) OR (Tier 0) OR (AWD) --- NA (8 x 8 direct
drive) OR (Tier 3-VHP) OR (AWD)
Service interval
Oil level check interval Every 500 h of operation, with the axle in the horizontal
position
Oil change interval After the first 100 h and every 2000 h of operation
Grease lubrication interval Every 100 h of operation
Oil Specifications and Capacity

Central axle Refer to
Tandem box Refer to
Lubrication (Greases)
Grease type Refer to
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Powered rear axle - Special tools
COIL15GRD0667GA 1
Tool No. Tool specification Tool illustration

Check
1 380100284 Tool to install the ring retaining cup
figure 2
Check
2 380100286 Tool for lifting the wheel assy
figure 5
Check
3 380100287 Tool for assembly of the retainers (tabs and/or lips type)
figure 6
Special tool assembly for assembly and disassembly of the Check
4 380100285
retaining cap of the lock rings figure 7
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Tool assembly for installation of the ring retaining cap ( 380100284)
LAIL11MG0221G0A 2
A. Locking ring of the spring retaining cover

B. Not to scale
Description Quantity Material Treatment Dimension Remarks

Temp. and
1 Pin 01 88 Mn 8V KU HRC 60 See figure 3
Quench.
Temp. and
2 Rod 01 88 Mn 8V KU HRC 60 See figure 4
Quench.
3 Knob 01 Elesa PS.50 - M16 – – –
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Pin (Item 1 of assembly 380100284)
LAIL11MG0214F0A 3
C. Scale 2:1
D. Item 1 – Tapered pin
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Rod (Item 2 of assembly 380100284)
LAIL11MG0215F0A 4
E. Sharp corner
F. Item 2 – Rod
G. Identification area and/or marking zone
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Tool to lift the wheel hub assembly ( 380100286)
LAIL11MG0220G0A 5
H. Identification area – PN 380100286
Material = FE 37 B
Treatment = Norm. / Polished
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Tool for assembly of the retainers (tabs and/or lips type) ( 380100287)
LAIL11MG0666G0A 6
I. Identification area – PN 380100287

J. Tool for installation of the sealer
Material = 18 NiCrMo5
Treatment = Cementation / Tempering
Dimension = HRc.60-62
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Special tool assembly for assembly and disassembly of the retaining cap of the lock rings
( 380100285)
LAIL11MG1367G0A 7
K. Total thread
L. Three M10 through-holes
Description Quantity Material Treatment Dimension Remarks

1 Plate 01 C40 Polished – –
2 Bar 03 M10 – – –
03/N Nut 03 M10 – – –
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Powered rear axle - Dimension

3-VHP)
LAIL11MG0069G0A 1
SMT-type differential
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Powered rear axle - Dimension

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LAIL11MG1021H0A 1
Maximum torque for each brake: 55930 N·m
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Rear axle - Identification

3-VHP)
Rear axle identification plate

The axle is identified by two numbers punched into the
rear part of the axle housing:.
A. Axle type identification number.
B. Manufacturer serial number.
LAIL11MG1005A0A 1
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Rear axle - Level make up

3-VHP)
Rear axle oil vent

Remove the filling plug (2). Add oil as necessary to
bring oil level to bottom of plug hole. Install plug and be
sure it is properly tightened.
LAIL11MG1268A0A 1
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Rear axle - Level make up

Rear axle oil vent

Remove the filling plug (2). Add oil as necessary to
bring oil level to bottom of plug hole. Install plug and be
sure it is properly tightened.
LAIL11MG1270A0A 1
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Rear axle - Change fluid

3-VHP)
Rear axle oil change
Rear axle housing compartment

Change the axle oil every 2000 h hours of operation.
1. Park the machine on a level surface. Apply the parking
brake and stop the engin.
2. Clean the oil level and drain plugs.
3. Make sure the oil in the rear axle is near normal oper-
ating temperature.
4. Remove the drain plug (1) and the filler plug (2) to help
the oil drain more rapidly.
5. After draining, reinstall the drain plug and fill the hous-
ing to the level of the filler hole with the specified oil.
Allow sufficient time for oil to fill all axle compartments. LAIL11MG1269A0A 1
Wait 15 min and stand back. Install and tighten the filler
plug.
NOTICE: The warranty will be invalidated if the mainte-
nance is not performed in the correct manner and also if
any lubricants are used on the shaft other than those ap-
proved and recommended by CNH, as described in the lu-
bricant sections of this manual and in the respective oper-
ating manuals.
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Rear axle - Change fluid

Rear axle oil change
Rear axle housing compartment

Change the axle oil every 2000 h hours of operation.
1. Park the machine on a level surface. Apply the parking
brake and stop the engin.
2. Clean the oil level and drain plugs.
3. Make sure the oil in the rear axle is near normal oper-
ating temperature.
4. Remove the drain plug (1) and the filler plug (2) to help
the oil drain more rapidly.
5. After draining, reinstall the drain plug and fill the hous-
ing to the level of the filler hole with the specified oil.
Allow sufficient time for oil to fill all axle compartments. LAIL11MG1271A0A 1
Wait 15 min and stand back. Install and tighten the filler
plug.
NOTICE: The warranty will be invalidated if the mainte-
nance is not performed in the correct manner and also if
any lubricants are used on the shaft other than those ap-
proved and recommended by CNH, as described in the lu-
bricant sections of this manual and in the respective oper-
ating manuals.
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Rear axle - Disassemble /Repair/Assemble

3-VHP)
Read the following points before starting the disman-

tling or assembling procedures on the axle.
1. When working on the axle observe high standards of
cleanliness. All parts must be cleaned thoroughly prior
to assembly.
2. The area where the procedure will be carried out must
be fully dust-free and clean.
3. Make sure that all the required tools are available, par-
ticularly those identified in this manual. Parts fitted in-
correctly can cause serious damages, as well as metal
chips or foreign objects.
4. During the axle overhaul, it is recommended to replace
the following components with new parts: sealing rings,
gaskets, retaining rings and any parts damaged during
dismantling.
5. In case of breakages inside the gearbox, all lines, cas-
ings must be cleaned thoroughly to prevent damage
caused by residues left inside the system.
Shims
During any adjustment, select the shims and measure
them one by one with a micrometer gauge, then sum
up all the values measured; do not trust in an incor-
rect measurement of a full pack or in the nominal value
printed on each shim.
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Retainers
Proceed as follows for correct fitting of oil seals on re-
volving shafts:
• Before assembly, the retainers should be soaked for
at least half an hour in the same oil to be sealed.
• Clean thoroughly shaft and make sure that working
surface is not damaged; put the sealing lip against
the fluid to be sealed. In case of a hydrodynamic lip,
the lines should be oriented to take into account the
direction of the shaft rotation.
• Smear the sealing lip with a film of lubricant (oil is
better than grease) and fill the space between the
sealing lip and the dust shield lip with grease, using
double-sealing-lip retainers.
• Press the retainer into the relevant position or use a
proper fitter with a flat contact surface. Never use a
hammer or mallet to fit the retainer.
• When pressing the retainer mounting, make sure
that it is correctly driven into the relevant position.
When installation is complete, make sure that the re-
tainer itself is in contact with the thrust if necessary.
• To prevent damage of seal lip when inserting shaft,
cautiously protect components during assembly.
O-rings
Lubricate the sealing O-rings upon assembly to prevent
twisting which would impair the correct sealing/water-
proofing.
Sealing compounds
For surfaces identified by an X, use LOCTITE® 510™ or
similar.
Clean the relevant surfaces before applying the sealing
compounds as follows:
• Remove old deposits using a metal brush.
• Carefully remove any grease from the surface.
Ball Bearings
When installing the bearings, it is recommended to pro-
ceed as follows.
• Heat them to 80 – 90 °C before installing in the re-
spective shafts.
• cool them before inserting into relevant external po-
sition.
Spring pins
When using coil/spring pins, make sure that the groove
is in the longitudinal position towards the pin.
The coil/spring pins do not require any specific posi-
tions.
NOTICE: Dispose of used and replaced materials accord-
ing to the local regulations.
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Rear axle - Service instruction

3-VHP)
Equipment storage instructions

In order to ensure the right condition, handling, and use
of the equipment, comply with the following instructions:
• During handling of the equipment, avoid any shock
in order not to damage the external and the internal
components.
• In case of long inactivity of the equipment, before
installing or starting it, be sure that the equipment
has not suffered any damage.
Do not energize the electrical components with incom-
patible voltage.
Never use petrol, solvents or other inflammable fluids,
use only approved commercial solvents that are both
not flammable no toxic.
When stopping, before leaving the vehicle, make sure
that the parking brake is engaged.
Non compliance with these instructions or an incorrect
use of the equipment, may result in injuries to persons
and damage to the equipment.
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Rear axle housing - Disassemble

converter) OR (Tier 1) OR (Tier 3-VHP) --- NA (8 x 8 direct drive) OR (6 x 3
torque converter) OR (Tier 3-VHP)
Before dismantling the differential unit, remove the

wheel hub assembly, oscillation assemblies, supports,
and half-shafts.
NOTICE: Lift and handle each component with suitable lift-
ing equipment rated for the correct weight. Make sure that
the assemblies or the components are suitably secured us-
ing adequate slings and hooks.
1. Unlock and undo the bolts (1) holding the differential
unit (2) and then remove it from the central axle case.
LAIL11MG1577A0A 1
2. Place on proper support and lock the differential.

3. Loosen the screws of the bevel gear.
NOTE: Mark the position of the trunnion caps before dis-
assembly.
LAIL11MG1578A0A 2
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Powered rear axle - Troubleshooting

3-VHP)
Problem Possible Cause Correction

Oil leakage from the wheel Incorrect screws torque. O-rings damaged • Check the torque
assembly
• Replace the O-Ring
Oil leakage from the Incorrect installation. Retainers/seals dam- Replace retainers and/or seals
retainers and seals aged
Oil leakage from the High oil level Check the oil level
breather
Lubricant with excessive Incorrect Lubricant Replace the oil
foam
Final drive noise Incorrect lubricant Replace the oil
Oil level low Check the oil level
Incorrect bearing adjustment Verify and adjust the bearing setting
Damaged bearings Check and change the damaged bearings
Damaged gears Check and replace the damaged gears
Differential assembly Incorrect lubricant Replace the oil
noise
Incorrect Backlash Check and adjust
Incorrect bearing preload. Check and adjust
Incorrect bevel pinion position. Verify the pinion position.
Side gears thrust washer damaged. Verify and replace.
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Index

Powered rear axle - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Powered rear axle - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Powered rear axle - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Powered rear axle - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Powered rear axle - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Powered rear axle - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Rear axle - Change fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rear axle - Change fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rear axle - Disassemble /Repair/Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Rear axle - Identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Rear axle - Level make up (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Rear axle - Level make up (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Rear axle - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Rear axle housing - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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Rear bevel gear set and differential - 106

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Contents
TECHNICAL DATA
Differential
Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
Differential
Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Bevel pinion
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SERVICE
Differential
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Repair (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Repair (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Bevel gear
Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Gear tooth contact (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Gear tooth contact (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Bevel pinion
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Measure /Adjustment (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Preload (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
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Rear axle system - Rear bevel gear set and differential
Differential - Special tools

drive) OR (6 x 3 torque converter) OR (Tier 3-VHP) OR (AWD)
Differential Support Removal Tool
LAIL11MG0655F0A 1
A. Rod 1. Nut M24

B. Flange 2. Rod thread M24 L = 650 mm
C. Nut
D. Flange
E. Nut
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Differential Support Removal and Fitting Tool
LAIL11MG0504F0A 2
a. Rod d. Flange
b. Flange e. Nut
Trac- Nut
tors
with
tur-
boc-
har-
ged
engi-
nes
1. Insert the rod (a) with the flange (b) and nut (c) fitted.
Position on the opposite side of the flange (d) and
tighten the nut (e).
2. Tighten the nut (c) until the spring lock ring has been
removed.
3. Loosen the nut (e) and remove the tool.
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Differential - Component identification

3-VHP)
LAIL11MG1019G0A 1
Differential Shaft Section
1. Differential support 13. Roller bearing (Tapered)

2. Ring gear and pinion kit 14. Ring nut
3. Roller bearing (Tapered) 15. Pin
4. Roller bearing (Tapered) 16. Differential casing
5. Nut 17. Steel discs
6. Washer 18. Clutch discs (Intermediate)
7. Drive flange 19. Clutch discs
8. Retainer (with lip) 20. Planetary gear
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9. Adjusting spacer 21. Crosshead shaft

10. Pinion Adjusting Spacer 22. Bevel Thrust Washer of Side Gear
11. Ball bearing 23. Gear (Side)
12. Flange 24. Roller bearing (Tapered)
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LAIL11MG0662G0A 1
Differential Shaft Section
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1. Driving/drive flange 23. Pressure jacket

2. Nut 24. Thrust ring
3. Washer 25. Roller bearing shaft
4. Retainer 26. Spring
5. Roller bearing 27. Locking ring
6. Adjusting spacer 28. O-ring retainer
7. Spacer 29. Oil passage dowel
8. Adjusting spacer 30. Roller bearing
9. Roller bearing 31. Pinion
10. Screw 32. Ring gear guard
11. Differential support 33. Screw
12. Roller bearing 34. Piston
13. Adjusting nut 35. Lock plate
14. Snap pin 36. Friction plate
15. Differential case 37. Lock washer
16. Ring gear 38. Lock washer
17. Screw 39. Pinion gear
18. Adjusting nut 40. Lock washer
19. Retainer 41. Ring gear
20. Piston 42. Planetary gear
21. Reduction plate 43. Pinion gear
22. O-ring retainer
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LAIL11MG0657F0A 1
1. Screw 7. Shield
2. Differential unit 8. Fixing bolt
6. Screw 9. Differential case
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Differential - Exploded view

LAIL11MG1349G0A 1
16. Collet 26. Screw

17. Deck Plate 27. Ball pin
18. O-Ring 28. Anti-rotation bolt
19. O-Ring 29. Bushing
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20. Piston 30. Bushing

21. O-Ring 31. Nut
22. Compression spring 32. Nut
23. Thrust sleeve 33. Pin
24. Axial roller bearing 34. O-Ring
25. Deck Plate 35. Differential assembly
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Differential - Exploded view

LAIL11MG0663G0A 1
1. Screw 10. Adjustment washers

2. Differential case 11. Pinion gear
3. Actuating sleeve 12. Adjustment washers
4. Counter plates 13. Adjustment washers
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5. Friction plates 14. Fixing bolt

6. Pinion gear 15. Ring gear
7. Differential case/half-casing 16. Differential half-casing
8. Crosshead shaft 17. Bearing
9. Gears 18. Bearing
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Bevel pinion - Exploded view

LAIL11MG0808F0A 1
2. Differential support 21. Hub

17. Nut 23. Adjusting spacer
18. Washer 26. Pinion
19. Drive flange
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Bevel pinion - Exploded view

LAIL11MG0505F0A 1
2. Differential support 40. External cap ring

36. Pinion 41. Bearing cup
37. Retainer 42. Adjusting spacer
38. Hub 43. Spacer
39. Adjusting spacer 44. Hub/conical bearing
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Differential - Remove
LAIL11MG0807F0A 1
Dismantling the Differential from the Support
1. Rotate the drive head back (90°) into the position
shown in the illustration 1.
2. Remove the spring pin (3).
3. Loosen and remove the bolt (4).
4. Remove the bearing/shell (5), adjustment nuts (6) - (10)
and bearing caps, items (7) - (9)
5. Remove the differential assembly (8).
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Differential - Disassemble
3-VHP)
1. Replace bearings (31) and (32) if required, removing

them with a suitable puller. When fitting the new bear-
ings, heat them to a temperature of 120 °C.
LAIL11MG0793A0A 1
2. Mark the two half-casings, remove the screws (33), and

open them.
LAIL11MG0794A0A 2
3. Remove the planetary gear (34) with a steel disc (a),

the intermediate clutch discs (b), and the clutch discs
(c).
4. Remove the crosshead shaft (35) with the four side
gears and adjustment washers.
LAIL11MG0795A0A 3
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5. Remove the planetary gear (36) with the steel discs (a),
intermediate clutch discs (b), and clutch discs (c) on the
half-casing.
LAIL11MG0796A0A 4
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Differential - Repair
3-VHP)
Overhaul, repair, and maintenance of the differential components

1. Have visual and dimensional check of wear on sun and
side gear, relevant thrust washers and spider.
2. Clean thoroughly every differential component.
3. Lubricate bearings and make turn freely the rollers car-
rying cage; rotation must be regular and without ob-
structions.
4. Check support surfaces of ring gear and seat surface of
half-case in order to have perfect ring gear adherence.
NOTE: Deformations to these surfaces will cause vibra-
tions in the fixing screws and will compromise performance.
5. Clean thoroughly all thread to obtain correct adjusting
and exact torques.
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Differential - Assemble
3-VHP)
1. Before re-assembling, each smooth contact surface

should be lubricated with oil.
2. Insert a first steel disc (a) into the housing, then a clutch
friction disc (b) (both surfaces are made of sintered
material). Alternate the other discs.
3. Insert the outer clutch disc (c) with the smooth surface
turned to the planetary gear.
4. Apply oil and insert the planetary gear (36).
LAIL11MG1997A0A 1
5. Assemble the side gears with the thrust washers on

the crosshead shaft (35) and position them on the half-
casing.
6. Apply oil and position the planetary gear (34).
7. Insert the outer clutch disc (c) with the smooth surface
turned towards the planetary gear.
8. Insert the first steel disc (a), then a friction disc (clutch)
(b) and the other alternately.
LAIL11MG1998A0A 2
9. Align the steel discs (a).

10. Mount the half-casing, aligned with the intermediate
and shim discs. Close the two half-casings, taking
care to align them correctly, according to the marking
made.
LAIL11MG1580A0A 3
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11. Tighten the (4) screws to a torque of 90 – 120 N·m.

12. Remove or add intermediate discs of adequate shims.
13. Lock the screws (33) and re-tighten them to a final
torque of 110 – 120 N·m.
LAIL11MG1581A0A 4
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Before dismantling the differential unit, dismantle the

axle support and remove the two half shafts, as de-
scribed in “Axle Repair”.
NOTICE: Lift and handle each component with suitable lift-
ing equipment rated for the correct weight. Check the cor-
rect mounting points of the lifts, cables, and winches.
LAIL11MG0883F0A 1
1. Unlock and undo the screws (1) retaining the differen-

tial (2) then remove it from axle case .
2. Place the differential on a suitable support/bench.
Straighten the notches on the pinion nut (3) then posi-
tion the reaction tool on the PTO flange and unlock the
nut; release the pinion nut.
3. Remove the washer (4) and drive flange (5) from the
pinion shank.
4. Unscrew the three screws (6) and remove the protector
(7).
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5. If the bevel gear set is renewed or replaced, unlock the

screws (8) from the differential case (9).
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LAIL11MG1349G0A 1
16. 26. Screw

17. Deck Plate 27. Ball pin
18. O-Ring 28. Anti-rotation bolt
19. O-Ring 29. Bushing
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20. Piston 30. Bushing

21. O-Ring 31. Nut
22. Compression spring 32. Nut
23. Thrust sleeve 33. Pin
24. Axial roller bearing 34. O-Ring
25. Deck Plate 35. Differential assembly
1. Rotate drive head back through (90°) to left in as the

position shown in the illustration.
2. Remove the piston back plate (17) from the differential
lock housing.
3. Remove and discard O-rings (18) and (19).
4. Remove piston (20). Remove and discard the O-ring
(21).
5. Remove the compression spring (22), thrust sleeve
(23), axial roller bearing (24), and the board (25).
6. Unlock and remove the bolts (26).
7. Remove the ball pin (27). Loosen the anti-rotation bolt
(28), remove bushings (29) and (30) and adjust nuts
(31) and (32).
8. Remove the pin (33).
9. Remove and discard the O-rings (34).
10. Remove the differential assembly (35).
11. Lift and handle each component with a lifting equip-
ment with adequate lifting capability.
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LAIL11MG0505F0A 1
2. Differential support 40. External cap ring

36. Pinion 41. Bearing cup
37. Retainer 42. Adjusting spacer
38. Hub 43. Spacer
39. Adjusting spacer 44. Hub/conical bearing
1. Remove the pinion (36) from the differential support (2)

by tapping with a soft hammer or rod extractor.
NOTICE: Take care not to damage the thread and tabs.
2. Remove the retainer (37) from the flange PTO
3. Remove the (38) hub and the adjustment spacer (39).
4. Remove the external cap ring (40) and the bearing cap
(41), remove carefully and save the adjustment spacer
(42) and spacer (43).
5. Remove the hub/tapered bearing (44) from the pinion
housing (36).
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LAIL11MG0663G0A 1

48050419D 06/10/2017
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1. Remove the bolts (1) and separate the differential case

(2) from the rest of the assembly.
2. Remove the actuating sleeve (3).
3. Remove seven counter plates (4) and six friction plates
(5) from the differential pinion gear (6).
4. Remove the half-casing of the differential (7).
5. Remove the pinion gear (6), the crosshead shaft (8),
the four gears (9), the adjustment washers (10), the
pinion gear (11), and adjustment washers (12) and (13)
from the differential half-casing.
6. If the ring gear and pinion assembly has been renewed/
replaced, loosen the fixing screws (14) and remove the
ring gear (15) from the differential case (16).
NOTICE: The differential ring gear is supplied with the pin-
ion (i.e. a complete ring gear + pinion kit).
NOTE: The two components must always be replaced to-
gether.
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Differential - Repair
Overhaul, repair, and maintenance of the differential components

1. View and check the dimensions and wear of the sun
and side gears and crosshead and adjustment wash-
ers.
2. Clean thoroughly every differential component.
3. Lubricate bearings and make turn freely the rollers car-
rying cage; rotation must be regular and without ob-
structions.
4. Check support surfaces of ring gear and seat surface of
half-case in order to have perfect ring gear adherence;
deformation of those surfaces would cause vibration of
fixing screw ring gear, thus compromising group good
working.
NOTE: Deformations to these surfaces will cause vibra-
tions in the fixing screws and will compromise performance.
5. Replace the gear fixing screws (14) in case of disas-
sembly.
6. Thoroughly clean all of the threads in order to obtain
the correct required torque settings.
7. If necessary, replace bearings (17) and (18).
8. Fit them with the aid of heating equipment and heat
them to a temperature of 90 – 110 °C, which will ensure
their correct installation.
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Differential - Assemble
LAIL11MG0663G0A 1

48050419D 06/10/2017
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1. Fit the pinion gear (11), washer (12), crosshead shaft

(8), the four gears (9), the thrust washer (10), the pinion
gear (6), and the washer (13) on the differential half-
casing (16).
2. Position the differential half-casing (7) aligned with the
marked letters.
3. Fit the seven counter plates (4) and the six friction
plates (5), starting and finishing with a counter plate.
4. Make sure the counter plate tabs are aligned.
5. Position the sleeve (3) on top of the last counter plate.
Position the differential lock case (2) over the counter
plates and friction plates and align the bolt in the holes
in the differential half-casing (7).
6. Check free rotation of the gears in the horizontal po-
sition (if held vertically the friction and counter plates
would prevent rotation).
7. Tighten the bolts and torque to 115 – 130 N·m.
8. Check the free rotation of the gears in the horizontal
position.
9. Fit the ring gear (15) with the bolts (14).
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Bevel gear - Replace

1. If the bevel/crown and pinion gear set is to be replaced,

release the fixing screws (29) and remove the crown
gear (30) from the differential case (8).
NOTICE: The crown is supplied as a spare part together
with the pinion (bevel gear and pinion kit): the two compo-
nents must always be replaced together.
2. Install the crown gear (30) by fixing it with bolts (29) to
a torque of 315 – 345 N·m.
NOTICE: After replacing the gear, crown, pinion, and dif-
ferential housing as required, check the backlash between
the pinion teeth/crown and the differential roller bearing
pre-load, as described in the previous paragraph. LAIL11MG1579A0A 1
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Bevel gear - Gear tooth contact

LAIL11MG1584F0A 1
1. Install the caps (5), being careful not to reverse the

positions and lock the screws fixing it to the differential
support with a torque of 315 – 345 N·m.
2. Check, by mean of a dial gauge, end play of differential
unit.
3. Turn the nut (6) so that a notch is aligned against the
hole (a) of the lock spring pin (3) and actuate the oppo-
site one (10) to eliminate any play.
4. Then adjust the bearing preload by turning the ring nut
one more notch.
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5. Position a dial gauge perpendicular to the ring gear

tooth and with the pinion steady, check the backlash,
which must be 0.18 – 0.23 mm.
6. If this is not the case, rotate both rings, displacing them
the same number of notches and bringing the crown
gear closer to the pinion if the backlash is excessive,
and moving it away if otherwise.
LAIL11MG1582A0A 2
7. It is a good rule to check the contact impression of the

pinion’s toothing on the bevel gear.
8. Apply a marker to the crown and pinion teeth and turn
them a few revolutions.
9. Check that the impression on the crown is centered with
the respective tooth side (this will be on the movement
side and on “Coast” (50) see figure 3).
(50) “Coast”
(51) “Drive”
LAIL11MG0839A0A 3
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LAIL11MG1585F0A 4
10. If this is not the case, adjust the spacer thickness to

obtain an optimal crown and pinion position (see Fig-
ure 4), making sure that the prescribed backlash and
pre-load conditions are maintained.
(52) Wrong result
(53) Wrong result
(54) Necessary adjustments
48050419D 06/10/2017
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LAIL11MG1586F0A 5
11. Press in the spring pins (3), locking the rings.

12. Fit the two securing notches on the pinion nut (17).
13. Carefully clean the contact surfaces, apply a sealing
compound and then mount the differential unit (2) on
the central axle case.
14. Tighten the differential unit fixing bolts (1) and apply a
final torque of 105 – 115 N·m.
LAIL11MG1577A0A 6
15. Mount the two half-shafts and the shaft support, as

described above in Rear axle - Disassemble /Repair/
Assemble (27.100)
16. Finally, fill the differential shaft with the recommended
amount of the correct lubricant, in line with the infor-
mation in Powered rear axle - General specification
(27.100) and Rear axle - Change fluid (27.100).
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Bevel gear - Gear tooth contact

LAIL11MG0884F0A 1
1. Assemble the differential assembly (34) on the support.

2. Suspend the differential using lifting equipment with an
adequate capacity.
3. Replace the O-ring (34) and mount the pin (33).
4. Install covers (29) and (30) and tighten the fixing bolts
to the differential with a torque of approximately 32 –
35 N·m.
5. Check by a dial gauge end play of differential unit.
6. Screw in a ring (31) so that a notch is aligned against
the spring lock pin (a) and actuate the opposite O-ring
(32) to eliminate any backlash.
7. Once this position is reached, continue with the bearing
pre-load, screwing in the nut (32) one more notch.
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8. Position a dial gauge perpendicular to the crown gear

teeth and with the pinion steady check the backlash,
which must be: 0.20 – 0.28 mm.
9. If this is not the case, rotate both rings (31) and (32),
displacing them the same number of notches and bring-
ing the gear closer to the pinion if the backlash is ex-
cessive, and moving it away if otherwise.
10. Fit the pin (27) and tighten the anti-rotation screw (28).
LAIL11MG0838A0A 2
11. It is a good rule to check the contact impression of the

pinion’s toothing on the bevel gear.
12. Apply a marker to the crown and pinion teeth and turn
them a few revolutions.
13. Check that the impression on the bevel gear is cen-
tered with the respective tooth side (this will be on the
movement side and on “Coast” (50) see figure 3).
(50) “Coast”
(51) “Drive”
LAIL11MG0839A0A 3
48050419D 06/10/2017
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LAIL11MG0885F0A 4
14. If this is not the case, adjust the spacer thickness to

obtain an optimal bevel gear and pinion positioning
(see Figure 4), making sure the prescribed backlash
and pre-load conditions are maintained.
(52) Wrong result
(53) Wrong result
(54) Necessary adjustments
48050419D 06/10/2017
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LAIL11MG0886F0A 5
15. Insert the compression spring (22), thrust sleeve (23),

axial roller bearing (24), and plate (25).
16. Install new O-rings (21) on the piston (20).
17. Fit the piston (20) and position the slit to align it with
the anti-rotation screw (28).
18. Mount the new O-rings (18) and (19) on the rear plate
of the piston (17).
19. Insert the piston (20) plate (17).
20. Mount the rod with the thread (a), flange (b), and nut
(c) fitted. Position on the opposite side of the flange
(d) and tighten (e).
21. Tighten the nut (c) until the spring locking has been
fitted correctly (16).
22. Unscrew the nut (e) and remove the tool.
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BRCE12GRCCM001A 6
23. If the bevel (crown) gear has been replaced, the fixing
bolts (8) for the differential box (9) must be tightened
to a torque of 450 – 480 N·m.
24. Mount the protector (7), applying a sealing compound,
and tighten the three bolts (6) to a torque of 50 –
60 N·m
25. Carefully clean each contact surface, apply a sealing
compound, then install the differential unit (2) on the
central axle case using fixing screws (1).
26. When assembling, tighten the bolts (1) to a torque of
285 – 315 N·m.
27. Mount the two half-shafts and the shaft support, as
described above in Rear axle - Disassemble /Repair/
Assemble (27.100)
28. Finally, fill the differential shaft with the recommended
amount of the correct lubricant, in line with the infor-
mation in Powered rear axle - General specification
(27.100) and Rear axle - Change fluid (27.100).
48050419D 06/10/2017
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Bevel pinion - Service instruction

Lift up the Differential Assembly using a suitable lifting tool

1. Remove the (4) four screws (11) and the support flange
(12), using the extraction holes.
2. Remove the split pin (13) and remove the retaining pin
(15).
3. Replace the pinion bearing (16) on the support flange
(12).
LAIL11MG1492A0A 1
LAIL11MG1494F0A 2
48050419D 06/10/2017
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4. Straighten the notches on the pinion nut (17), then po-

sition the reaction tool on the PTO (19) flange and un-
lock the nut (17); ; release the pinion nut and remove
the washer (18).
5. Remove the drive flange (19) from the pinion notch.
6. Drive the pinion (26) out of the differential housing sup-
port (2) with a soft hammer or a suitable remover, taking
care not to damage the pinion thread and notch.
7. Remove the retainer (20) from the flange PTO .
8. Remove the bearing hub (21) and the adjustment
spacer (23).
LAIL11MG1493A0A 3
9. Remove caps (22) and (25); save the adjustment
spacer (24) for the axial position of the pinion.
10. Remove the hub (27) and the ring (28) fitted on the
pinion (26).
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Bevel pinion - Measure /Adjustment

1. Prior to the installation of the bevel pinion in the differ-

ential support, it is necessary to measure the dimen-
sions to define the thickness of the shim to be placed
between the head bearing and the shoulder in the rel-
evant seal in the differential.
2. Measure the dimension of the gear/crown center line
at the shoulder of the main bearing, designated as “A”,
positioning a cylinder on the cap, then accurately feel
the gap to which the radius of the differential bearing,
62.5 mm, must be added.
3. This is: A = measured dimension + 62.5 mm
4. In this case:
A = 162.60 mm + 62.50 mm = 225.10 mm
5. Each bevel pinion head face is marked with a number
having (±) sign.
6. This number, in tenths of a millimeter, indicates the de-
viation from the theoretical dimension ( 184 mm) under
the head of the pinion from the center line of the bevel
gear.
E.g. 1 = 0.10 mm .
7. In this case:
B = 184.00 mm (theoretical) - 0.10 mm =
183.90 mm
LAIL11MG0797A0A 1
8. Measure the pinion head height from the bearing seat-

ing face to the outer edge (top), as shown in installation
2 as "H".
9. That is: H = 82.00 mm
LAIL11MG0798A0A 2
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10. Measure and record the width of bearing "D".

11. That is: D = 37.00 mm
LAIL11MG0799A0A 3
12. The “S” shim thickness should be determined for the

correct axial position of the bevel pinion:
13. That is: S = A - ( B + D)
14. In this case:
S = 225.10 mm - ( 183.90 mm + 37.00 mm) =
4.20 mm
15. Reduce the theoretical computed thickness by
0.05 mm to compensate for the different dimension
of the bearing after press-fitting.
16. Round up or down to the nearest tenth of millimeter
the computed thickness. LAIL11MG0800A0A 4
(Y) Pinion adjusting spacer

17. Fit the bearing inner ring (28) on the end of the pinion.
18. Install the bearing hub (27).
NOTE: To fit it, heat to a temperature of 80 – 90 °C (176 –
194 °F).
LAIL11MG0801A0A 5
19. Insert the adjusting shim (24) for the axial position of
the pinion. The shim value was determined previ-
ously: furthermore, fit the external cup (25) and ex-
ternal race of the bearing, item (22).
LAIL11MG0802A0A 6
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20. To ensure the correct assembly of the differential, the

pinion must be positioned in its seat and the cylinder
on the cover, and distance "E" measured.
E = B - ( 62.50 mm + H)
21. In this case:
E = 183.90 mm - ( 62.50 mm + 82.00 mm) =
39.40 mm
22. In this phase, “E” must be lower (smaller) than 0 –
0.05 mm, in relation to the theoretical calculation.
LAIL11MG0803A0A 7
LAIL11MG0808F0A 8
23. Fit onto the pinion (26) the adjusting spacer (23) for
the bearing preload: to simplify the determination of
the correct preload, it is advisable to insert as many
adjusting spacers as are required to ensure pinion end
play and not a pre-load on the bearings.
24. Position the pinion (26) in its seat on the differential
support (2).
25. Mount the hub (21) on the outer pinion bearing/seat.
26. Mount the drive flange (19) on the pinion, position a
suitable tool, and lock the nut (17) with the washer
(18), tightening it to a torque of 570 – 630 N·m.
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27. Check the end play of the pinion using a dial gauge.
28. Disassemble again and change the adjusting spacer
(23) to obtain the play until the preload .
29. Reassemble the components and check the correct
bearing pre-load: this should correspond to a rotating
torque (no seal/retainer fitted) for the new 2 – 4 N·m
bearings.
LAIL11MG0804A0A 9
30. With the pre-load determined, remove the drive flange

and mount the (lip) retainer, item (20) in the housing
seat.
31. Apply grease to the inner diameter of the surface.
32. Refit the flange (19), washer (18) and nut (3), tighten-
ing them finally with a torque of 570 – 630 N·m.
LAIL11MG0805A0A 10
33. Mount the flange (12) using the (4) four bolts, item
(11).
34. Tighten the bolts (11) with a torque of 315 – 345 N·m.
LAIL11MG0806A0A 11
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Bevel pinion - Preload

865B
885B
LAIL11MG1827G0A 1
1. Deck Plate 2. Deck Plate
1. Prior to re-assembling the pinion on the differential sup-

port, some dimensions must be recorded to compute
the thickness of the spacer to be placed between the
head bearing/pinion end and the relevant shoulder on
the differential seat. Record the dimension from the
gear to the seating surface of the pinion under the head
bearing, which will be identified as "A". To this end a
plate must be positioned in the center of the cap, then
record the exact available space.
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2. Each bevel pinion head face is marked with a number

having (±) sign.
3. This number, expressed in tenths of a millimeter, shows
the displacement of the theoretical dimension from the
pinion head to the central line of the gear.
E.g. -2 mm = -0.20 mm
4. Therefore, the actual dimension, identified as "B" , will
be: B = 208 ± of the movement. In this case:
B = 208 mm - 0.20 mm = 207.8 mm
LAIL11MG1720A0A 2
5. Also measure the pinion head height from the bearing

seating face and mark this as "H" .
LAIL11MG1721A0A 3
6. Measure and record the dimension of bearing "D".

7. Determine the thickness of the shim S to correct the
pinion axial position:
S=A-B-D
8. Add 0.05 mm to the theoretical computed thickness to
compensate for the following bearing pre-load.
9. Round the computed thickness up or down to the near-
est tenth of a millimeter.
LAIL11MG1722A0A 4
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LAIL11MG0656F0A 5

NOTE: for installation, heat or press it.
11. Insert the adjustment shim (42) for the axial position of
the pinion. This value was computed previously; also,
adjust and fit the cap (41) and the bearing cup (40).
12. Insert the spacer (43).
13. Insert the pinion (36) in its seat on the differential sup-
port.
14. Fit the bearing pre-load shims (39) (e.g. a shim of
1.5 mm); mount the pinion bearing hub (38).
15. To simplify determination of pre-load, it is advisable
to fit as many shims as required to warrant a pinion
end play and with a preload (perhaps excessive) of
bearings.
16. Mount the drive sprocket flange (5) on the pinion, the
washer (4), and position a suitable torque wrench and
tighten the nuts (3) to a torque of 665 – 735 N·m.
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17. Use a calibration gauge to check the play in the pinion.

(for example, if the play is 0.20 mm, reduce 0.25 mm
from one adjusting shim); next dismantle and then re-
placed the adjusting shim (39) to eliminate play until a
pre-load is achieved.
18. Reassemble components and check correct bearing
pre-load, it should correspond to a rotating torque (no
seal fitted) of:
For new bearings: 2 – 4 N·m
For bearings in operation: 1 – 2 N·m
LAIL11MG1891A0A 6
19. With the pre-load determined, remove the drive flange

and seal (37) from the seat, taking care to follow the
assembling dimension indicated in figure 7, to apply
the grease (Z) on the inner diameter surface.
LAIL11MG1892A0A 7
20. Refit the flange (5), washer (4), and nut (3) and tighten
them definitively to a torque of 665 – 735 N·m.
21. Fit the two securing notches on the pinion nut .
LAIL11MG1893A0A 8
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Index

Bevel gear - Gear tooth contact (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Bevel gear - Gear tooth contact (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Bevel gear - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Bevel pinion - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Bevel pinion - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Bevel pinion - Measure /Adjustment (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Bevel pinion - Preload (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Bevel pinion - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Differential - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Differential - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Differential - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Differential - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Differential - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Differential - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Differential - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Differential - Repair (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Differential - Repair (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Differential - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Planetary and final drives - 120

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Contents
FUNCTIONAL DATA
Planetary final drive

Wheel hub
SERVICE
Planetary final drive

Planetary final drive - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Planetary final drive - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Planetary final drive - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Planetary final drive - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Planetary final drive - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Wheel hub
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Repair (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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Rear axle system - Planetary and final drives
Planetary final drive - Component identification

Axle Section – Side Reduction Gears
LAIL11MG1018G0A 1
1. Sprocket wheel 8. Reducer Gear 15. Needle roller

2. Adjustment shim 9. Support 16. Pin
3. Washer 10. Roller bearing 17. Adjustment shim
4. Lock plate 11. Plate for the axle shaft 18. Retainer
5. Axle 12. Thrust washer 19. Roller bearing
6. Circlip 13. Planetary gear 20. Hub
7. Tooth gear 14. Spacer 21. Pin
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Planetary final drive - Component identification

Axle Section – Side Reduction Gears
LAIL11MG0216G0A 1
1. Sprocket wheel 8. Reducer Gear 15. Needle roller

2. Adjustment shim 9. Support 16. Pin
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3. Washer 10. Roller bearing 17. Adjustment shim

4. Lock plate 11. Plate for the axle shaft 18. Retainer
5. Axle 12. Thrust washer 19. Roller bearing
6. Circlip 13. Planetary gear 20. Hub
7. Tooth gear 14. Spacer 21. Pin
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Wheel hub - Component identification

3-VHP)
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Wheel Hub Assembly and Brake Section
LAIL11MG1014G0A 1
1. Shield 10. Brake disc - Assembly 19. Screw

2. Spring cover 11. Steel plate 20. Circlip
3. Spring 12. Brake disc drum 21. Retainer
4. Threaded pin 13. Brake support 22. Retainer
5. Sprocket wheel 14. Brake body 23. Circlip
6. Lock plate 15. Adjustment shim 24. Circlip
7. Output shaft - Assembly 16. Roller bearing 25. O-Ring
8. Retaining washer 17. Roller bearing 26. Locking pin
9. Brake piston 18. Retainer
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Planetary final drive - Remove

1. Straighten the plate (B) and remove the bolts (A).

• Remove the locking plates (B).
• Remove plate (C).
• Remove the adjusting shim (D).
• Remove the drive sprocket (E) from the drive/im-
peller shaft.
LAIL11MG1495A0A 1
2. Position vertically with adequate support to avoid acci-

dents.
• Remove the (8) nuts (F).
• Remove the support (H).
LAIL11MG1576A0A 2
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Planetary final drive - Disassemble

Support for Shaft with Planetary

1. Remove reduction support with proper lifting device.
2. Remove the hub cone bearing (4).
LAIL11MG0777A0A 1
3. Remove the ring gear (5).

4. If necessary, replace the inner bearing (6) using a
puller.
5. Refit the bearing, heating it to a temperature of 80 –
90 °C.
LAIL11MG0778A0A 2
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6. Remove the spring pin (7).

7. Remove the gear pin (8).
8. Remove the planetary gear (9).
9. Make the same procedure for the other two planetary
gear.
LAIL11MG0779A0A 3
10. Check the needle bearings (10), thrust washer (13),

pins (8), and planetary gear (9) and replace them if
they are damaged or worn.
LAIL11MG0780A0A 4
11. If the removal of the hub from the support is necessary,

remove the six screws.
12. During reassembly, tighten the screws to a torque of
470 N·m.
LAIL11MG0781A0A 5
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Planetary final drive - Assemble

Support for Shaft with Planetary

1. Apply grease to the needle bearing assemblies (10),
with a total of 62 needles.
NOTICE: In case of replacement, use the same class of
bearing.
2. Place the pin (8) on a flat surface.
• Insert the washer (13) and apply grease to the pin
(8).
• Mount the first needle roller (10).
• Fit the spacer (12).
• Mount the needle bearing (10).
LAIL11MG0782A0A 1
3. Position the planetary gear (9) and the second thrust
washer (10).
NOTICE: Remove the two axial washers and install the pin.
LAIL11MG0783A0A 2
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4. Install the planetary gear assembly (9).
LAIL11MG0784A0A 3
5. Position the pin (8) from the hole side so that it is

aligned with the hole of the planetary spider hub.
6. Align the notch with a punch then install the spring pin
(7).
LAIL11MG0785A0A 4
NOTICE: The spring pin must not be larger than the diam-
eter of the spring pin (7) (Illustration 5).
7. Make sure that the pin rotates freely and check the axial
play.
8. Repeat this procedure for the remaining two planetary
gears.
LAIL11MG0786A0A 5
9. Position and reinstall the ring gear (5).
LAIL11MG0787A0A 6
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10. Inspect the bearings, axle support side, for wear and,
if necessary, replace them.
11. Remove the outer races (14) and (16) using a punch.
12. Install a new lip retainer (15) at 6 mm on the stop on
the bearing outer plate (Figure 9).
13. Use a suitable sleeve having a diameter that will fit
inside the cage I.D. and press in seal.
14. Install the outer rings (14) and (16) with (non-exces-
sive) force using a blunt punch.
LAIL11MG0788A0A 7
15. Position the reduction hub on a base of 150 mm: the

studs must not touch the surface .
LAIL11MG0789A0A 8
16. Mount the reduction unit on the axle support: the lip
retainer (15) must not extend from the seat.
LAIL11MG0790A0A 9
17. Install the bearing cone assembly (4) after heating it

to a temperature of approx. 90 – 100 °Cbolt.
LAIL11MG0791A0A 10
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18. Remove the half-shaft assembly (17).

19. Inspect components of half-shaft assembly for wear
and if necessary replace.
LAIL11MG0792A0A 11
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Planetary final drive - Service instruction

Determination of Shims Between Half-Shaft and Reduction Hub

1. Remove the half shaft thrust washer (18) and save the
shim pack (19).
LAIL11MG0668A0A 1
2. Make a plate the same size as the thrust washer but

with a different thickness, which should be 13 mm.
3. Install this plate stop (STOP) which will have a dimen-
sion of "E" .
4. Install the axle support assembly with a half-shaft and
measure the gap with a feeler gauge at three points and
the average, dimension "F”.
E - F = G i.e.: 13 mm - 0.5 mm = 12.5 mm
5. Subtract the plate stop dimension 13 mm "E" from di-
mension “F” (CLEARANCE) to obtain dimension "G".
LAIL11MG0810A0A 2
6. Determine the thickness of the shim set "X" by subtract-

ing 11.0 mm, and the thickness of the original washer
10.5 mm by adding 0.5 mm final clearance from di-
mension "G" .
7. X = 12.5 mm - 11 mm = 1.5 mm, this is the shim re-
quired between the thrust plate and the reduction sup-
port assembly.
8. Install shims "X" that have already been calculated, ap-
ply LOCTITE® 270 to the original thrust washer (18), and
install this in the reduction support assembly.
LAIL11MG0669A0A 3
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9. Clean with care each contact surfaces, smear sealing

compound to mating surface of central housing.
LAIL11MG0670A0A 4
10. Install the axle support housing (H) on the central

housing, making sure that the reduction hub gears are
correctly positioned with the input shaft.
11. Apply LOCTITE® 242® to the thread of the nuts (F)
then install the washers and nuts, tightening them to
a torque of 290 N·m +/- 5%.
BRCE12GRCCM009A 5
12. Reinstall the drive sprocket (E) in the drive shaft, ad-
justing the shim (D), retaining plate (C), locking plates
(B), and bolts (A) and tighten to a torque of 114 –
126 N·m.
13. Bend the locking plates (B).
LAIL11MG0671A0A 6
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Planetary final drive - Service instruction

Determination of Shims Between Half-Shaft and Reduction Hub

1. Remove the half shaft thrust washer (18) and save the
shim pack (19).
LAIL11MG0668A0A 1
2. Make a plate the same size as the thrust washer but

with a different thickness, which should be 13 mm.
3. Install this plate stop (STOP) which will have a dimen-
sion of “E” .
4. Install the axle support assembly with a half-shaft and
measure the gap with the feeler gauge at three points
and the average, dimension “F”.
E - F = G i.e.: 13 mm - 0.5 mm = 12.5 mm
5. Subtract the plate stop dimension 13 mm “E” from di-
mension “F” (CLEARANCE) to obtain dimension “G”.
LAIL11MG0810A0A 2
6. Determine the thickness of the shim set “X” by subtract-

ing 11.0 mm, and the thickness of the original washer
10.5 mm by adding 0.5 mm final clearance from di-
mension “G” .
7. X = 12.5 mm - 11.5 mm = 1.5 mm, this is the shim re-
quired between the thrust plate and the reduction sup-
port assembly.
8. Install shims “X” that have already been calculated, ap-
ply LOCTITE® 270 to the original thrust washer (18), and
install this in the reduction support assembly.
LAIL11MG0669A0A 3
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9. Clean with care each contact surfaces, smear sealing

compound to mating surface of central housing.
LAIL11MG0670A0A 4
10. Install the axle support housing (H) on the central

housing, making sure that the reduction hub gears are
correctly positioned with the input shaft.
11. Apply LOCTITE® 242® to the thread of the nuts (F)
then install the washers and nuts, tightening them to
a torque of 290 N·m +/- 5%.
12. Tighten the bolts (G) and torque to 300 N·m +/- 5%.
13. Make sure of correct rotation of reduction hub.
LAIL11MG0811A0A 5
14. Reinstall the drive sprocket (E) in the drive shaft, ad-
justing the shim (D), retaining plate (C), locking plates
(B), and bolts (A) and tighten to a torque of 114 –
126 N·m.
15. Bend the locking plates (B).
LAIL11MG0671A0A 6
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Wheel hub - Disassemble

3-VHP)
Disassemble Wheel Assembly with Brake

1. Install the tool, 4A94740, unscrew the screw (1), and
remove the wheel hub assembly (2).
LAIL11MG0828A0A 1
2. Flatten the plate (4) and unscrew the screw (3).

• Remove the retaining plate (4).
• Remove the retaining plate from the sprocket (5).
• Remove the adjusting shim (6).
• Take away sprocket (7).
LAIL11MG1820A0A 2
3. Remove the brake support (8), the cage with the coni-
cal roller bearing (9), and the O-ring (10) from the sup-
port.
4. Inspect the roller bearing hub (9). If worn, remove it
with a suitable puller, during assembly use a buffer.
LAIL11MG1821A0A 3
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5. Remove the snap ring (11), remove the drum from the
drum brake disc (12).
6. Remove the brake discs (13) and the steel plates (14).
LAIL11MG1822A0A 4
7. Remove the locking pin (18).

8. Install tool 4A95444 then tighten the tool nut until the
snap rings (15) have been removed.
9. Remove the tool 4A95444.
LAIL11MG0833A0A 5
10. Remove and retain the spring seat (16) and the
springs (17).
11. Remove the brake piston (19).
LAIL11MG0834A0A 6
12. Press and remove the output shaft (20) from the brake
body (21).
LAIL11MG0820A0A 7
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13. Using a suitable press, push the bearing cap (22) out
of the housing (21).
14. Remove seal rings (23) and (24).
LAIL11MG0835A0A 8
15. Using a suitable tool, extract and remove the bearing

hub (26) from the output shaft.
16. Remove the retainer (25) and the protector (27).
BRCE12GRCCM002A 9
17. Visually inspect the studs (28) for damage or deformi-

ties on the thread.
18. Replace, if required, using a press for removal; fit new
studs, taking care not to damage threads.
BRCE12GRCCM003A 10
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Wheel hub - Disassemble

Disassemble Wheel Assembly with Brake

1. Install the tool, 4A94740, unscrew the screw (1), and
remove the wheel hub assembly (2).
BRCE12GRCCM004A 1
2. Flatten the plate (4) and unscrew the screw (3).

• Remove the retaining plate (4).
• Remove the retaining plate from the sprocket (5).
• Remove the adjusting shim (6).
• Take away sprocket (7).
LAIL11MG0830A0A 2
3. Remove the brake support (8), the cage with the coni-
cal roller bearing (9), and the O-ring (10) from the sup-
port.
4. Inspect the roller bearing hub (9). If worn, remove it
with a suitable puller, during assembly use a buffer.
LAIL11MG0831A0A 3
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5. Remove the snap ring (11), remove the drum from the
drum brake disc (12).
6. Remove the brake discs (13) and the steel plates (14).
LAIL11MG0832A0A 4
7. Remove the locking pin (18).

8. Install tool 4A95444 then tighten the tool nut until the
snap rings (15) have been removed.
9. Remove tool PN 4A95444.
LAIL11MG0833A0A 5
10. Remove and retain the spring seat (16) and the
springs (17).
11. Remove the brake piston (19).
LAIL11MG0834A0A 6
12. Press and remove the output shaft (20) from the brake
body (21).
LAIL11MG1894A0A 7
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27.3 [27.120] / 23
13. Using a suitable press, push the bearing cap (22) out
of the housing (21).
14. Remove seal rings (23) and (24).
LAIL11MG0835A0A 8
15. Using a suitable tool, extract and remove the bearing

hub (26) from the output shaft.
16. Remove the retainer (25) and the protector (27).
LAIL11MG0836A0A 9
17. Visually inspect the studs (28) for damage or deformi-

ties on the thread.
18. Replace if necessary, using a press to remove, and fit
the new studs, taking care not to damage them.
LAIL11MG0837A0A 10
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Wheel hub - Repair

3-VHP)
Wheel Assy Maintenance and Overhaul

1. In order to carry out a visual inspection of the compo-
nents, it is recommended to wash thoroughly all the
metallic parts using a solvent, biodegradable if possi-
ble, then blow them with compressed air.
2. Pay special attention to the internal lubrication chan-
nels, which must be spotlessly clean.
3. Check that the supports and the covers show no inden-
tations and that the seats are intact, without scoring or
ridging. If this is the case, they must be replaced im-
mediately.
4. Make sure that the threading and the grooving on the
shafts are in good condition.
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Wheel hub - Assemble

3-VHP)
Re-assembly of the Wheel Hub Assembly with Brake

1. Apply LOCTITE® 601 sealant or similar to the shelter
(27) and install this on the output shaft.
LAIL11MG0818A0A 1
2. Fit the bearing cup (22) on the brake housing.

3. Lubricate the new seals (23) and (24) with CASE
AKCELA 251H EP MULTI-PURPOSE GREASE or
similar, then insert them into the brake housing.
NOTE: Check rings (23) and (24) on the piston. Supply oil
at a pressure of 80 bar at the inlet point (a) and wait for
7 min. During this time, no drop in pressure is allowed.
5. Use tool 4A95443 to fit the lip retainer (25) on the brake
housing.
LAIL11MG0819A0A 2
6. Install the output shaft (20) on the brake housing (21).
LAIL11MG0820A0A 3
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7. Insert the brake piston (19).

8. Install springs (17) and (16) on the pins.
9. Install the tool 4A95444 and then tighten the nut of the
tool to compress the springs in order to fit the retaining
rings.
LAIL11MG0821A0A 4
10. Put the retaining ring in the appropriate position on

tool ( 4904506).
11. Put the tool in an upright position with the retaining
ring (15) on the pin and press. Repeat this procedure
on the remaining two snap rings.
12. Remove the tool 4A95444.
13. Apply LOCTITE® 270 or similar to the thread of the
locking pin (18) and install it.
LAIL11MG0822A0A 5
14. Install the brake disc drum (12) on the output shaft and
insert the retaining ring (11).
LAIL11MG0823A0A 6
15. First insert a steel plate (14), a brake disc (13), and
alternate steel plates and brake discs.
NOTICE: Be careful as inverting the discs will result in dam-
age to the brake system.
LAIL11MG0824A0A 7
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16. Apply sealant to the contact surface of the body hous-

ing (21).
17. Insert the new O-ring (10) on the brake support (8).
NOTICE: Install the support (8) according to Illustration 9.
The slot (a) must be to the left of the oil inlet on the front
right and rear left brake and to the right of the oil inlet on
the front left and on the rear right brake.
18. Install the roller assembly (9) on the bearing.
LAIL11MG0825A0A 8
LAIL11MG0881F0A 9
29. Oil inlet

30. Front right and rear left
31. Front left and rear right
19. Install the sprocket (7) on the output shaft.
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LAIL11MG0882F0A 10
32. Sprocket assembly on the front right and front left

33. Sprocket assembly on the rear right and rear left
20. Measure the distance (S) between the sprocket plane

and the output shaft.
21. Subtract 0.05 mm from the distance measured. This
is the thickness of the adjustment shim (6).
LAIL11MG0826A0A 11
22. Install the adjustment shim (6) that has already been
calculated.
23. Install the retaining washer (5), the plate (4), and the
screws (3) and tighten them to a torque of 120 –
130 N·m.
24. Check the rolling torque, which must be approx. 15 –
22.5 N·m without any axial play.
25. Fold the locking plate (4).
LAIL11MG0827A0A 12
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26. Install the tool 4A94740 on the wheel assembly (2).

27. Clean and degrease the contact surfaces of the tan-
dem housing and the wheel assy.
28. Apply a uniform and continuous coat of LOCTITE®
510™ to the inner part of the tandem housing contact
surface, circling the holes.
29. Mount the wheel hub assembly (2).
30. Apply a locking compound to the screw (1) and tighten
them to a torque of 190 N·m +/- 5%.
31. Remove the tool 4A94740 from the wheel hub assem-
bly. LAIL11MG0828A0A 13
(K) Mount the wheel assembly with the openings facing

outwards.
LAIL11MG0829A0A 14
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Wheel hub - Assemble

Re-assembly of the Wheel Hub Assembly with Brake
1. Apply LOCTITE® 601 sealant or similar to the shelter
(27) and install this on the output shaft.
BRCE12GRCCM008A 1
2. Fit the bearing cup (22) on the brake housing.

3. Lubricate the new seals (23) and (24) with CASE
AKCELA 251H EP MULTI-PURPOSE GREASE or
similar, then insert them into the brake housing.
NOTE: Check rings (23) and (24) on the piston. Supply oil
at a pressure of 80 bar at the inlet point (a) and wait for
7 min. During this time, no drop in pressure is allowed.
5. Use tool 4A95443 to fit the lip retainer (25) on the brake
housing.
LAIL11MG0819A0A 2
6. Install the output shaft (20) on the brake housing (21).
LAIL11MG1894A0A 3
7. Insert the brake piston (19).

8. Install springs (17) and (16) on the pins.
9. Install the tool 4A95444 and then tighten the nut of the
tool to compress the springs in order to fit the retaining
rings.
LAIL11MG0821A0A 4
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10. Put the retaining ring in the appropriate position on

tool ( 4904506).
11. Put the tool in an upright position with the retaining
ring (15) on the pin and press. Repeat this procedure
on the remaining two snap rings.
12. Remove tool PN 4A95444.
13. Apply LOCTITE® 270 or similar to the thread of the
locking pin (18) and install it.
LAIL11MG0822A0A 5
14. Install the brake disc drum (12) on the output shaft and
insert the retaining ring (11).
LAIL11MG0823A0A 6
15. First insert a steel plate (14), a brake disc (13), and
alternate steel plates and brake discs.
NOTICE: Be careful as inverting the discs will result in dam-
age to the brake system.
LAIL11MG0824A0A 7
16. Apply sealant to the contact surface of the body hous-

ing (21).
17. Insert the new O-ring (10) on the brake support (8).
NOTICE: Install the support (8), as shown in the Illustration
9. The slot (a) must be to the left of the oil inlet on the front
right and rear left brake and to the right of the oil inlet on
the front left and on the rear right brake.
18. Install the roller assembly (9) on the bearing.
LAIL11MG0825A0A 8
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LAIL11MG0881F0A 9
29. Oil inlet

30. Front right and rear left
31. Front left and rear right
19. Install the sprocket (7) on the output shaft.
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BRCE12GRCCM005A 10
32. Sprocket assembly on the front right and front left

33. Sprocket assembly on the rear right and rear left
20. Measure the distance (S) between the sprocket plane

and the output shaft.
21. Subtract 0.05 mm from the distance measured. This
is the thickness of the adjustment shim (6).
BRCE12GRCCM006A 11
22. Install the adjustment shim (6) that has already been
calculated.
23. Install the retaining washer (5), the plate (4), and the
screws (3) and tighten them to a torque of 120 –
130 N·m.
24. Check the rolling torque, which must be approx. 15 –
22.5 N·m without any axial play.
25. Fold the locking plate (4).
BRCE12GRCCM007A 12
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26. Install the tool 4A94740 on the wheel assembly (2).

27. Clean and degrease the contact surfaces of the tan-
dem housing and the wheel assy.
28. Apply a uniform and continuous coat of LOCTITE®
510™ to the inner part of the tandem housing contact
surface, circling the holes.
29. Mount the wheel hub assembly (2).
30. Apply a locking compound to the screw (1) and tighten
them to a torque of 190 N·m +/- 5%.
31. Remove the tool 4A94740 from the wheel hub assem-
bly. BRCE12GRCCM004A 13
(K) Mount the wheel assembly with the openings facing

outwards.
LAIL11MG0829A0A 14
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Index

Planetary final drive - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Planetary final drive - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Planetary final drive - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Planetary final drive - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Planetary final drive - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Planetary final drive - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Planetary final drive - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Wheel hub - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Wheel hub - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Wheel hub - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wheel hub - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Wheel hub - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Wheel hub - Repair (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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PRINTED IN BRAZIL
48050419D 06/10/2017
EN
SERVICE MANUAL
Brakes and controls

48050419D 06/10/2017
33
Contents
Brakes and controls - 33
[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1
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33
Parking brake or parking lock - 110

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33.1 [33.110] / 1
Contents
TECHNICAL DATA
Parking brake or parking lock

Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA

Parking brake or parking lock - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Parking brake caliper
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Sectional view (Models FSG 90/FSG 110) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE

Service instruction (Models FSG 90 and FSG 110) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Parking brake caliper
Service instruction (Model M90) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Shoe - Replace (Model M90) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Disassemble (Model M90) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Cleaning /Inspection (M90 Model) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Assemble (Model M90) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Service instruction (FSG 75 model) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Assemble (FSG 75 model) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Adjust (FSG 75 model) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Service instruction (FSG 75 model) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Lining - Replace (FSG 75 model) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Service instruction (Models FSG 90/FSG 110) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Assemble (Models FSG 90/FSG 110 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Adjust (Models FSG 90/FSG 110 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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Service instruction (Models FSG 90/FSG 110 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Shoe - Replace (Models FSG 90/FSG 110) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Replace (Models FSG 90 and FSG 110) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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Brakes and controls - Parking brake or parking lock
Parking brake or parking lock - Torque

845B ANZ (8 x 8 direct drive) OR (Tier 1) OR (Tier 3-VHP) --- APAC (8 x 8 direct
drive) OR (Tier 1) OR (Tier 3-VHP) --- LA (8 x 8 direct drive) OR (Tier 1) OR
(Tier 3-VHP) --- MEA (8 x 8 direct drive) OR (Tier 1) OR (Tier 3-VHP) --- NA
(8 x 8 direct drive) OR (Tier 3-VHP)
865B ANZ (8 x 8 direct drive) OR (Tier 2) OR (Tier 3-VHP) OR (Tier 0) OR (AWD)
--- APAC (8 x 8 direct drive) OR (Tier 2) OR (Tier 3-VHP) OR (Tier 0) OR
(AWD) --- LA (8 x 8 direct drive) OR (Tier 2) OR (Tier 3-VHP) OR (Tier 0)
OR (AWD) --- MEA (8 x 8 direct drive) OR (Tier 2) OR (Tier 3-VHP) OR (Tier
0) OR (AWD) --- NA (8 x 8 direct drive) OR (Tier 3-VHP) OR (AWD)
Brake disc-to-yoke cap screw

48 N·m (35 lb ft)
Yoke flange-to-output shaft cap screw
215 N·m (159 lb ft)
Caliper assembly-to-brake bracket cap screw
86 N·m (63 lb ft)
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Parking brake or parking lock - Exploded view

LAIL11MG1017G0A 1
Disc brake assembly
A. Yoke flange H. Hex nut (6 used)

B. Yoke washer I. Lock washer (6 used)
C. Cap screw J. Cap screw (6 used)
48050419D 06/10/2017
33.1 [33.110] / 5
D. V-ring seal K. Caliper assembly

E. O-Ring L. Brake support
F. Brake Disc M. Mount pin (2 used)
G. Cap screw (6 used) N. Cotter pin (4 used)
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Parking brake caliper - Exploded view

845B ANZ (6 x 3 torque converter) OR (Tier 1) OR (Tier 3-VHP) --- APAC (6 x 3
torque converter) OR (Tier 1) OR (Tier 3-VHP) --- LA (6 x 3 torque converter)
OR (Tier 1) OR (Tier 3-VHP) --- MEA (6 x 3 torque converter) OR (Tier 1)
OR (Tier 3-VHP) --- NA (6 x 3 torque converter) OR (Tier 3-VHP)
865B ANZ (6 x 3 torque converter) OR (Tier 2) OR (Tier 3-VHP) OR (Tier 0) ---
APAC (6 x 3 torque converter) OR (Tier 2) OR (Tier 3-VHP) OR (Tier 0) ---
LA (6 x 3 torque converter) OR (Tier 2) OR (Tier 3-VHP) OR (Tier 0) --- MEA
(6 x 3 torque converter) OR (Tier 2) OR (Tier 3-VHP) OR (Tier 0) --- NA (6 x
3 torque converter) OR (Tier 3-VHP)
BRCE12GRCCM010A 1
1. Bolt 9. Ball
2. Anti-rotation clamp 10. Ball spacer
3. Washer 11. Rotor assembly
4. Lever 12. Protection washer
5. Spring 13. Plastic cover
6. Shaft seal 14. Lever side friction pad
7. O-ring 15. Support side friction pad
8. Fixing bush
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Parking brake caliper - Sectional view

LAIL11MG1012F0A 1
1. Casing 6. Piston
2. Thrust collar 7. Brake pad cradle
3. Thrust bolt 8. Brake pad cradle
4. Adjustment screw 9. Guide bolt
5. Plate spring assembly
48050419D 06/10/2017
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LAIL11MG0660F0A 2
1. Thrust bolt 6. Threaded cap

2. Cup spring assembly 7. Thrust collar
3. Adjustment screw S8. Size 8 socket
4. Lock nut S18. Size 18 socket
5. Piston P. End face
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Parking brake caliper - Sectional view (Models FSG 90/FSG 110)

LAIL11MG0208F0A 1
1. Casing 6. Piston
2. Pressure ring 7. Lining pad
3. Thrust bolt 8. Lining pad
4. Adjustment screw 9. Gliding bolt
5. Bank of cup springs
48050419D 06/10/2017
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LAIL11MG0209F0A 2
1. Thrust bolt 5. Lock nut

2. Bank of cup springs 6. Piston
3. Adjustment screw P. Leveled surface
4. Screw cap R. Allen key
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Parking brake or parking lock - Service instruction (Models FSG 90

and FSG 110)
Emergency release of the parking brake

If the pressure system fails, release the parking brake
using the manual procedure, as described below:
LAIL11MG0209F0A 1

4. Screw cap R. Fixing key
1. Secure the vehicle to prevent it rolling away.
2. Unscrew and remove the screw cap.
3. Release the lock nut, size 24 or 30 and turn the ad-
justing screw with socket wrench size 8 or 10, counter-
clockwise until the brake disc is free.
NOTE: For emergency release, an activation torque is
needed of 40 N·m and 70 N·m respectively.
48050419D 06/10/2017
33.1 [33.110] / 12
4. Lock the lock nut and screw on the screw cap a few
turns (to protect against contamination).
NOTE: In this state, the vehicle has no parking brake at all
and must be secured by other means to prevent it rolling
away. Adjust the brake before restarting, see Parking
brake or parking lock - Assemble /Adjusting (Models
FSG 90 and FSG 110 (33.110) and Parking brake or park-
ing lock - Adjust (Models FSG 90 and FSG 110) (33.110).
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Maintenance and exchange of brake pads

The brake pads themselves are maintenance free.
They simply have to be checked for damaged parts
and to ensure that the brake disc moves freely.
The thickness of the brake lining must be subjected to a
visual inspection at regular intervals, which depend on
vehicle usage, but every six months at the latest.
If there is minimal residual lining thickness, these inter-
vals must be reduced accordingly to avoid major dam-
age to the brake or disc. The brake pad must be re-
placed when the pad thickness is as follows:
FSG 90 with a minimum residual thickness of 1.0 mm
per brake pad ( 6 mm of drum board thickness).
FSG 100 with a minimum residual thickness of 2.0 mm
LAIL11MG0210F0A 2
1. Piston R. Allen key

2. Adjustment screw S1 Screwdriver
3. Lock nut P. Inside the piston
4. Thrust bolt
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Extending the brake pads

NOTE: Use original spare parts only. CNH cannot assume
responsibility or offer any guarantee for the brakes and
their correct functioning if other spare parts are used.
1. Place the vehicle on a flat surface and secure it to pre-
vent it rolling away.
2. Release the parking brake by pressurizing it with the
required release pressure.
4. Release the lock nut size 24 or 30 and turn the adjusting
screw clockwise with socket wrench size 8 or 10 until it
aligns with the inner side of the piston.
5. Press back the thrust bolt using a suitable screwdriver
until it has contact with the piston.
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Parking brake or parking lock - Disassemble

1. Loosen the cap screw (A) to keep the output shaft from
turning.
LAIL11MG1451A0A 1
2. Remove the four cap screws (A).

3. Remove the caliper assembly and brake bracket (B) as
a group.
LAIL11MG1452A0A 2
4. Remove the two cotter pins (A).

5. Remove the two mount pins (B).
6. Remove the caliper assembly (C) from the brake
bracket (D).
LAIL11MG1453A0A 3
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7. Remove the linch pin (A).

8. Loosen the adjusting nut (B).
9. Remove the operating lever (C). Pay attention to the
position of the operating lever for reassembly pur-
poses.
10. Remove the cam (D).
11. Remove the two actuating pins (E).
12. Remove the two brake pads and spring groups (F)
from the caliper assembly (G).
LAIL11MG1454A0A 4
13. Remove the cap screw (A), yoke washer (B), and
O-ring (C).
LAIL11MG1455A0A 5
14. Loosen the six hex nuts (A).

15. Remove the brake disc (B) and yoke flange (C) as a
group.
LAIL11MG1456A0A 6
16. Remove the six hex nuts (A), six lock washers (B),
and six cap screws (C).
LAIL11MG1457A0A 7
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17. Remove the brake disc.

18. Inspect all components for wear. Replace, if neces-
sary.
LAIL11MG1458A0A 8
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Parking brake or parking lock - Assemble

1. Assemble the yoke flange (A) and brake disc (B).

2. Install six cap screws (C), six lock washers (D), and six
hex nuts (E).
LAIL11MG2107A0A 1
3. Install brake disk and yoke flange group on output shaft

of transmission.
4. Tighten the six cap screws (A) to a torque of 87 N·m
(64 lb ft).
LAIL11MG1459A0A 2
5. Install two brake pads and spring groups (F) to the

caliper assembly (G).
NOTICE: Make sure the end of the actuating pin with the
shoulder is installed into the caliper assembly first.
6. Install the two actuating pins (E).
7. Install the cam (D).
8. Install the operating lever (C) in the same position it
was removed from.
LAIL11MG1454A0A 3
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9. Install the adjusting nut (B). Do not tighten. Allow

enough clearance between pads and disc to prevent
dragging.
10. Install a new cotter pin (A).
11. Install the caliper assembly (C) on the brake bracket
(D).
12. Install the two mounting pins (B).
13. Install two new cotter pins (A).
LAIL11MG1453A0A 4
14. Install the caliper and brake bracket group (A).

15. Install four cap screws (B).
16. Torque to 87 N·m (64 lb ft).
LAIL11MG1460A0A 5
NOTICE: The O-ring is positioned flush against the face of

the output shaft.
17. Lubricate and install a new O-ring (A).
NOTICE: The machined face of the washer must be in-
stalled after the O-ring.
18. Install the yoke washer (B).
19. Install the cap screw (C).
LAIL11MG1677A0A 6
NOTE: Use a brake caliper (B) to keep the output shaft

from turning.
20. Tighten the cap screw with a torque of 215 N·m
(159 lb ft).
LAIL11MG1678A0A 7
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Parking brake caliper - Service instruction (Model M90)

General Instruction
This data sheet covers important service procedures
that apply to the M90A model brake. See the diagram
at Parking brake caliper - Exploded view (33.110) as
the steps are carried out.
Routine Maintenance
The routine maintenance set out below is suggested to
keep the brake system in good working order.
1. Check to insure floating parts move freely and that all
other parts are mounted securely. Tighten hardware as
required.
2. Check actuator linkage to insure that there is adequate
freedom of movement for positive brake operation.
3. Adjustment of pad gap is accomplished by adjusting
the actuating cable or linkage. If adjustment is used
up, back off cable or linkage. Unbend tab on antirota-
tion clip and loosen screw enough to disengage lever
spline. Rotate the lever one tooth, in the direction op-
posite the actuation direction, and retorque the screw
making sure the spline teeth are properly engaged.
Bend up a tab that aligns with one of the screw head
flats, to prevent screw rotation. Both lever and linkage
must be free to return to home position. An external
return spring is required.
4. Check – disc surface condition. Replace if it is badly
warped, pitted, or below minimum recommended thick-
ness. Check for loose mount bolts. Retighten if neces-
sary.
5. Check that the brake pads are at least 1.0 mm
(0.039 in) thick. Replace worn friction pads.
6. Generally, if the disc is still running true and the pad
clearance is still adjustable, no other maintenance is
required. To check for wear, measure the distance from
the carrier side casting face to disc face. If the distance
is less than 1.5 mm (0.059 in), replace the brake pads.
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Replacing the mount bushings

1. Push mount bushings completely out of the brake cast-
ing.
2. Remove the four (4) O-rings from the grooves in the
casting, being careful not to damage the grooves.
Clean the grooves and the bore with denatured alcohol
or cleaning solvent. Allow to dry.
3. Lubricate the grooves and the O-rings with the grease
provided with the service kit. Install the o-rings into the
grooves.
4. Coat the bushings with kit grease. Insert the bushings
through the O-rings. Wipe off any excess grease.
Servicing the rotor assembly

1. Disassemble brake as previously described.
2. Using a sharp knife, make several cuts through the out-
side diameter of the rigid plastic rotor cover.
3. Break apart the plastic, remove and discard.
4. Discard the stainless steel insert from under the plastic
cover.
5. Thoroughly clean all dirt and grease residue from the
rotor.
6. Amply grease one face of the new stainless steel insert
and place it into the new rotor cover, grease to plastic.
Amply grease the other face of the insert.
7. To assemble the new plastic rotor r-over a bench vise
is necessary. Snap a friction pad onto the plastic cover.
Place the plastic cover over the rotor, place in a vice,
and slowly squeeze the cover and rotor until the cover
snaps in place. Remove the friction pad and reassem-
ble the brake as previously described.
NOTE: The mounting bushing O-rings are also supplied in
the rotor service kit. For installation, see ”Replacing the
mounting bushings”
General
If defects or problems are found in parts that are not
shown, they will have to be repaired. Replace with orig-
inal spare parts.
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Parking brake caliper Shoe - Replace (Model M90)

NOTE: Stamped on the back of each friction pad is a code.

The first 1 or 2 characters is a number that specifies the fric-
tion material type. Check to insure new pads are the same
as the worn pads that were removed. Replace friction pads
only in pairs.
1. To replace the friction pads it is necessary to release
the brake and disconnect the actuator from the brake
lever.
2. Remove one brake mounting bolt. Swing the brake
up over the disc to expose the brake pads. In close
clearance applications the brake may be removed from
the vehicle. Using a flat bladed screwdriver, pry out
the used brake pads from their respective positions.
The lever side friction pad is snapped onto the plastic
actuator cover. Care should be used in removing the
friction pad from the plastic actuator cover so as not to
break off the center snap tabs.
3. Place the new friction pads in their respective positions.
The lever side friction pad has a center hole which
snaps over the plastic snap tabs of the actuator cover.
The flat on the lever side pad must align which the flat
on the plastic rotor cover, allowing the pad to sit flat. If
the snap tabs are gone dab some silicone gasket adhe-
sive around the back edge of the friction pad and press
firmly into place aligned as described above. Before
placing the carrier pad in position, clean out the exist-
ing pad glue from the pad compartment.
4. Place a layer of silicone gasket adhesive all along the
back edge of the carrier friction pad and press firmly in
place. Push the lever side pad into the brake as far as
possible.
5. Balance the brake on the disc, install the assembly bolt,
and tighten all assembly bolts.
6. link. Unbend tab on antirotation clip and loosen screw
enough to disengage lever spline. Turn the lever to the
OEM position and tighten the bolt to 12.4 – 15.8 N·m
(110 – 140 lb in). Bend up a tab that aligns with one of
the screw head flats, to prevent screw rotation. Attach
actuating cable or linkage to the lever. Adjustment of
pad gap is accomplished by adjusting the actuating ca-
ble or linkage.
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Parking brake caliper - Disassemble (Model M90)

3 torque converter) OR (Tier 2) OR (Tier 3-VHP) OR (Tier 0)
1. Perform disassembly on a clean work bench.

2. Disconnect the actuator cable or linkage and remove
brake from its mounting.
3. Remove the brake pads, see Parking brake caliper
Shoe - Replace (Model M90) (33.110).
4. Unbend anti-rotation clip tab away from lever holding
screw. Remove screw, anti-rotation clip, washer, lever,
and spring.
5. Push out rotor assembly from the casting.
NOTICE: The ball spacer and the ball bearings may come
out with the rotor assembly. (to dismantle the rotor, see
Parking brake caliper - Service instruction (Model M90)
(33.110).
6. Remove the ball bearings and ball spacer.
7. Shaft seal need only be replaced if excessively worn
or cracked. If it needs to be replaced, press the plastic
seal out of the shaft using a 27.38 mm (1.078 in) diam-
eter steel spacing block 63.5 mm (2.500 in) long and a
shaft press.
NOTE: A normal extension for a 3/8 in cable and a 13/16 in
deep hex socket will work well as a spacer block.
8. After the shaft seal is pressed out, remove the sliver of
plastic that may be left in the groove in the casting.
9. This completes disassembly of the brake.
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Parking brake caliper - Cleaning /Inspection (M90 Model)

1. Clean all parts with denatured alcohol and either wipe

dry with a clean lint free cloth or blow dry with an air
hose.
2. Examine all parts carefully for signs of excessive wear,
damage, or corrosion. Replace any parts found to be
damaged.
3. Check rotor assembly for cracks. Replace, if neces-
sary. The rotor assembly must be replaced as a com-
plete unit. No individual parts are available for service.
4. Inspect the casting ball pockets for scoring, pitting,
cracks or corrosion. A corroded or deeply scored
casting should be replaced. Light scoring and stains
may be removed.
5. Check to see that the disc is not bent or misshapen.
6. Check lever spring for breakage.
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Parking brake caliper - Assemble (Model M90)

1. Prior to assembly make sure all parts are clean and

serviceable.
2. Install a new shaft seal by Leasing the seal from the
outside of the casting with the extended smooth surface
inserted first. Using an arbor press, with a protective
spacer block between the arbor press and the seal,
gently press the seal in until it snaps into the groove
in the casting.
3. Coat with grease, the ball pockets in the casting, the
shaft and ball pockets of the rotor assembly.
4. Insert the ball bearings and ball spacer into the pockets
in the casting.
5. From the inside of the casting slide the shaft of the rotor
assembly thru the shaft seal and seat the ball pockets
against the ball bearings.
6. Place the spring over the large diameter pilot on the
outside of the casting.
7. Install the lever, making sure the small diameter of the
spring is piloted on the outside of the 4 pins in the lever.
Set the lever in the OEM position. (see equipment ser-
vice manual to determine lever position).
8. Install the washer and anti-rotation clip with its tab in-
serted into the lower hole in the lever.
9. Introduce the bolt into the rotor assembly and tighten
to 12.4 – 15 N·m (110 – 133 lb in), then guide the lever
onto the spline on the rotor assembly.
10. After the proper torque is achieved and the lever is in
the OEM position, bend up a tab on the anti-rotation
clip that aligns with one of the screw head flats, to
prevent screw rotation.
11. Install the friction pads onto the rotor assembly and
drum, see Parking brake caliper Shoe - Replace
(Model M90) (33.110).
12. Stroke lever in its proper direction. The lever must ro-
tate through 60°. Return lever to the OEM position
and make sure the lever side friction pad is fully re-
turned.
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Parking brake caliper - Service instruction (FSG 75 model)

Construction and Function
LAIL11MG1012F0A 1
Brake Components
1. Casing 6. Piston
2. Thrust collar 7. Brake pad holder
3. Thrust bolt 8. Brake pad holder
4. Adjustment screw 9. Guide bolt
5. Plate spring assembly
One of the two identical brake pad holders is perma-

nently anchored in the housing. The second brake pad
holder is mounted in the housing and can slide freely.
The actual brake is bolted directly to the gearbox or axle
housing via the guide bolts. The housing moves freely
on the guide bolts.
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When the brake is actuated, a clamping force is gen-

erated on the brake pad holder. This force is trans-
ferred to the brake disc. At the same time, the cup
spring assembly of the piston, together with the ad-
justing screw, moves the thrust bolt and the brake pad
holder in towards the brake disc. When the brake pad
holder comes into contact with the brake disc, the force
of reaction moves the housing on the guide bolts un-
til the second brake pad holder is also pressed against
the brake disc. The braking effect (braking torque) de-
pends on the friction coefficients of the brake pads.
The brake is released by complete pre-tensioning of the
bank of cup springs. During this process, through ap-
plication of the necessary release pressure after over-
coming the cup spring force, the piston must move back
until it comes to rest against the pressure ring.
Wear on the brake pads and the brake disc reduces the
clamping force. The brake must then be adjusted, see
Parking brake caliper - Assemble (FSG 75 model)
(33.110) and Parking brake caliper - Adjust (FSG 75
model) (33.110).
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Parking brake caliper - Assemble (FSG 75 model)

Assembly and Adjustment Instructions

The brake must be adjusted after the installation of new
brake pad holders or new discs after all of the repair
stages or if the braking power is insufficient.
NOTE: The brake must be allowed to cool down before
starting any assembly work or adjustments.
LAIL11MG0660F0A 1
1. Thrust bolt 6. Screw cap

2. Cup spring assembly 7. Thrust collar
3. Adjustment screw S8. Size 8 socket
5. Piston P. End face
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Mounting the brake

3. Use a suitable socket wrench to loosen the lock nut 18
and turn the adjusting screw anti-clockwise with a size
8 socket wrench until the end face of the thrust bolt lies
against the piston.
4. In this state, the brake can be pushed onto the brake
disc and fixed in place.
5. Connect the compressed air connection.
6. Pressurise the brake with the required release pressure
until the cup spring assembly is fully prestressed.
7. Then carry out the basic adjustment, see Parking
brake caliper - Adjust (FSG 75 model) (33.110).
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Parking brake caliper - Adjust (FSG 75 model)

Basic settings
1. Turn the adjusting screw clockwise until both brake pad
holders are in contact with the brake disc.
2. From this point onwards, the adjusting screw cannot be
turned without applying considerable force.
3. Set the clearance by turning the adjusting screw anti-
clockwise as shown in Table 1.
Table 1
Adjustment
Version Clearance Turns
screw
Minimum 0.5 mm 1/3
Size 18
FSG75 Nominal 1.0 mm 2/3
(size 8)
Maximum 1.5 mm 1/1
4. Hold the adjusting screw in position with a hexagonal

socket wrench and lock with lock nut.
5. Mount the screw cap and tighten as far as possible
manually.
6. Mount the pressure connection, following the mounting
instructions.
7. To bleed the piston chamber, use socket spanner size
13 for the bleed valve.
General settings
1. To make adjustments, first release the parking brake,
i.e. the cup spring assembly must be fully prestressed.
5. Loosen the size 18 lock nut and turn the adjusting
screw clockwise with a size 8 socket wrench until the
two brake pad holders are in contact with the brake
disc.
6. Set the clearances by turning the adjusting screw
counter-clockwise. (see Table 1).
7. Hold the adjusting screw in position with the hexagonal
socket wrench and lock with the lock nut.
8. Refit the screw cap and tighten it hand-tight.
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9. Actuate the brake valve several times and check that

the parking brake holds the vehicle while facing up or
down a gradient.
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Parking brake caliper - Service instruction (FSG 75 model)


LAIL11MG0205F0A 1
1. Thrust bolt 6. Piston

2. Cup spring assembly S8. Socket wrench size 8
3. Adjustment screw S18. Socket wrench size 18
4. Screw cap P. End face
5. Lock nut
screw anti-clockwise with a size 8 socket wrench un-
til the brake disc is free.
NOTICE: A torque of at least 40 N·m must be applied to
the adjusting screw for an emergency release.
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NOTICE: In this state, the vehicle has no parking brake at
all and must be secured by other means to prevent it rolling
brake caliper - Assemble (FSG 75 model) (33.110) and
Parking brake caliper - Adjust (FSG 75 model) (33.110).
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Maintenance and replacement of the brake pad holder

FSG-75 with residual minimum thickness of 1.0 mm for
the brake pad support (support plate 5 mm thick).
LAIL11MG0206F0A 2
1. Piston 5. Cup spring assembly

4. Thrust bolt P. Inside the piston
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Releasing the brake pad holder

til the thrust bolt can be pressed fully into the piston.
5. Use a suitable screwdriver inserted between the brake
pad holder and brake disc to turn (lever) the thrust bolt
back until it is lying against the piston.
6. Always loosen both guide bolts and remove the com-
plete brake by pushing it radially to the centre point of
the disc.
7. The brake pad holders can now be removed from the
housing guide by pressing or levering out with a suit-
able tool.
NOTICE: Check the compressed air line. If a compressed
air line is too short, it must be unscrewed so that the brake
can be removed.
NOTICE: Before detaching the compressed air line, carry
out an emergency release of the parking brake.
8. Replace the brake pad holder and bolt the guide bolts
to the axle or gearbox housing once more.
9. If you have removed the complete brake due to insuffi-
cient clearance, you must reinstall it and bolt both guide
bolts to the axle or gearbox housing.
10. Screw on the compressed air line once more and vent
the brake.
NOTE: Adjust the brake after replacing or repairing the
brake pad holder.
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Parking brake caliper Lining - Replace (FSG 75 model)

LAIL11MG0207F0A 1
1. Piston 7. Thrust collar

2. Adjustment screw 8. Thrust bolt
3. Lock nut 9. Cup spring assembly
4. Casing A. Detail of the seal
5. Circlip B. Detail of the seal
6. Sealing
til it is flush with the inside of the piston.
5. Turn the thrust bolt back as far as the stop and actuate
the manual brake valve (unpressurised position).
6. The bank of cup springs is now completely depressur-
ized.
7. Unscrew the pressure hose and remove the brake.
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8. Remove the retaining ring and remove the thrust collar

from the housing.
9. Remove the cup spring assembly and the piston.
NOTICE: The grooved rings must installed the right way
round, otherwise they will leak.
NOTICE: Use a suitable assembly needle with rounded
edges to install the new grooved rings for the sealing lip.
Be careful – Risk of injury.
10. Change all seals and mount the parts of the brake in
other way round order.
11. When mounting the piston, the sliding and sealing sur-
faces must be greased lightly using lubricating grease
to DIN 51825.
12. The dust protection cap is fitted with a vulcanized-in
steel ring which is used to press it through the locat-
ing hole. For exchanging, “lever out” the ring using
a suitable tool. The new dust protection cap must be
pressed in with the aid of a suitable mounting ring and
screw clamps or a lever press.
13. Fit the brake, following the procedures described
above, in the machine/shaft.
NOTE: Any discovered defects or damage to parts not
listed here must naturally be repaired or replaced using
original parts.
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Parking brake caliper - Service instruction (Models FSG 90/FSG 110)

Construction and function
LAIL11MG0208F0A 1
Parts of the Brake
1. Casing 6. Piston
2. Pressure ring 7. Lining pad
3. Thrust bolt 8. Lining pad
4. Adjustment screw 9. Gliding bolt
5. Bank of cup springs
The two identical brake pads and slide freely on the
guide bolt, which is fastened in the housing. The guide
bolts are guided in an additional brake anchor plate
which in turn is screwed onto the vehicle, i.e. its axle.
On actuation, the brake generates a clamping force at
the brake lining pads, which cause a tangential force/
braking moment to be generated at the brake disk, the
extent of which depends on the coefficients of friction
generated by the linings.
The clamping force is generated by the bank of cup
springs, during which the piston is moved together with
the adjusting screw, the thrust bolt and the brake pad
towards the brake disk.
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When the brake pad comes into contact with the brake
disk, the reaction force shifts the housing onto the guide
bolts until the brake pad) is also pressed against the
brake disk.
The brake is released completely by pre-tensioning the
bank of Belleville springs. During this process, through
application of the necessary release pressure after
overcoming the cup spring force, the piston must move
back until it comes to rest against the pressure ring.
The clamping force diminishes with wear of the brake
lining and brake disk. The brake must be adjusted
at the latest at the intervals indicated, in accordance
with the recommended specifications, see Parking
brake caliper - Assemble (Models FSG 90/FSG 110
(33.110) and Parking brake caliper - Adjust (Models
FSG 90/FSG 110 (33.110)
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Parking brake caliper - Assemble (Models FSG 90/FSG 110

Assembly and Adjustment Instructions

The brake must be adjusted after the installation of new
brake pad holders or new discs after all of the repair
stages or if the braking power is insufficient.
NOTE: The brake must be allowed to cool down before
starting any assembly work or adjustments.
LAIL11MG0209F0A 1

4. Screw cap R. Allen key
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Mounting the brake

1. Stand the vehicle on an even surface and secure
against rolling away.
2. Release the screw cap.
3. Release the size 24 or 30 lock nut and turn the adjusting
screw anticlockwise using a size 8 or 10 socket wrench
until the pressure bolt comes to rest against the even
surface of the piston. In this status, the brake can be
mounted onto the brake disk and fastened.
4. Mount the pressure connection again.
5. Apply the necessary release pressure to the brake until
the bank of cup springs is completely pre-tensioned.
6. Then carry out the basic adjustment, see Parking
brake caliper - Adjust (Models FSG 90/FSG 110
(33.110).
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Parking brake caliper - Adjust (Models FSG 90/FSG 110

Basic settings
1. Turn the adjusting screw manually clockwise until both
brake pads make contact with the brake disk.
2. From this point onwards, the adjusting screw cannot be
turned without applying considerable force.
3. Set the clearance by turning the adjusting screw anti-
clockwise as shown in Table 1.
Table 1
Adjust-
Version ment Clearance Turns
screw
Minimum 0.5 mm 1/3
M16 (SW
8)
Maximum 1.5 mm 1/1
Minimum 1.0 mm 2/5
M20 (SW
10)
Maximum 3.0 mm 1 1/5
4. Hold the adjusting screw in position with a hexagonal

socket wrench and lock with lock nut.
5. Mount the screw cap and tighten as far as possible
manually.
6. Mount the pressure connection, following the mounting
instructions.
7. To bleed the piston chamber, use socket spanner size
13 for the bleed valve.
General settings
1. To make adjustments, first release the parking brake,
i.e. the cup spring assembly must be fully prestressed.
5. Loosen the lock nut size 24 or 30 and turn the adjusting
screw clockwise with a size 8 or 10 socket wrench until
the two brake pad holders are in contact with the brake
disc.
6. Set the clearances by turning the adjusting screw
counter-clockwise. (see Table 1).
7. Hold the adjusting screw in position with the hexagonal
socket wrench and lock with the lock nut.
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8. Refit the screw cap and tighten it hand-tight.

9. Actuate the brake valve several times and check that
the parking brake holds the vehicle while facing up or
down a gradient.
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Parking brake caliper - Service instruction (Models FSG 90/FSG 110


LAIL11MG0209F0A 1

4. Screw cap R. Fixing key
3. Release the lock nut, size 24 or 30 and turn the ad-
justing screw with socket wrench size 8 or 10, counter-
clockwise until the brake disc is free.
NOTE: For emergency release, an activation torque is
needed of 40 N·m and 70 N·m respectively.
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NOTE: In this state, the vehicle has no parking brake at all
and must be secured by other means to prevent it rolling
brake caliper - Assemble (Models FSG 90/FSG 110
(33.110) and Parking brake caliper - Adjust (Models
FSG 90/FSG 110 (33.110).
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Maintenance and exchange of brake pads

FSG 90 with minimum residual thickness of 1.0 mm per
brake pad ( 6 mm of drum board thickness).
FSG 100 with minimum residual thickness of 2.0 mm
LAIL11MG0210F0A 2
1. Piston R. Allen key

3. Lock nut P. Inside the piston
4. Thrust bolt
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4. Release the lock nut size 24 or 30 and turn the adjusting

screw clockwise with socket wrench size 8 or 10 until it
aligns with the inner side of the piston.
5. Press back the thrust bolt using a suitable screwdriver
until it has contact with the piston.
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Parking brake caliper Shoe - Replace (Models FSG 90/FSG 110)

LAIL11MG0211F0A 1
1. Guide bolt 5. Castle nut

2. Lining pad 6A. Safety splint
3. Lining pad 6B. Safety clip
4. Permanent magnet
1. Depending on the free space available, release one
of the two guide bolts, removing the safety splint, un-
screwing the castellated nut and pulling the guide bolt
out of the brake anchor plate. Now, the brake lining
pads can be removed tangentially to the brake disk.
NOTE: In the event of minimal clearance, i.e. it is not pos-
sible for space reasons to exchange the brake lining plate
in accordance with these instructions, the brake must be
removed completely. To do this, pull both guide bolts out
of the brake anchor plate.
NOTICE: Check the pressure hose. If the pressure hose
is to short, it must be unscrewed to remove the brake. Be-
fore the pressure hose can be released the brake must be
emergancy released..
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2. Replace the brake pads and insert the guide bolts in the
brake anchor plate. If you have completely removed
the brake, you should now mount it on the two guide
bolts again.
3. Check both permanent magnets if they still have suffi-
cient magnetic force to hold the brake lining plates.
4. Should this not be the case, the permanent magnets
must also be changed by using a suitable screw driver.
5. Secure the guide bolt with the castellated nut and the
safety splint res.
NOTE: After mounting the new brake pads or repairing
them, the brake must be correctly set, in accordance with
the instructions; see Parking brake caliper - Assemble
(Models FSG 90/FSG 110 (33.110) and Parking brake
caliper - Adjust (Models FSG 90/FSG 110 (33.110).
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Parking brake caliper - Replace (Models FSG 90 and FSG 110)

LAIL11MG0212F0A 1
1. Piston 7. Guide bolt

2. Adjustment screw 8. Thrust bolt
3. Lock nut 9. Bank of cup springs
4. Casing A. Detail of the seal
5. Piston pin lock B. Detail of the seal
6. Sealing
4. Release the lock nut 24 or 30 and turn the adjusting
screw with socket wrench size 8 or 10 counter clock-
wise until it is flush with the inner side of the piston.
5. Push back the thrust bolt until it has contact with the pis-
ton. Then actuate the manual brake valve. (No pres-
sure must be in the piston chamber).
6. The bank of cup springs is now completely depressur-
ized.
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7. Unscrew the pressure hose and remove the brake.

8. Release the circlip and remove the pressure ring of the
housing.
9. Release the bank of cup springs and the piston.
NOTICE: Pay attention to the mounting direction of the seal
rings, otherwise leaks can occur.
NOTICE: Use for mounting the new seal rings a suitable
mounting needle with rounded edge. Use caution.
10. Change all seals and mount the parts of the brake in
other way round order.
11. When mounting the piston, the sliding and sealing sur-
faces must be greased lightly using lubricating grease
to DIN 51825.
12. The dust protection cap is fitted with a vulcanized-in
steel ring which is used to press it through the locat-
ing hole. For exchanging, “lever out” the ring using
a suitable tool. The new dust protection cap must be
pressed in with the aid of a suitable mounting ring and
screw clamps or a lever press.
13. Fit the brake, following the procedures described
above, in the machine/shaft.
NOTE: Any discovered defects or damage to parts not
listed here must naturally be repaired or replaced using
original parts.
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Parking brake caliper - Remove

1. Remove the linch pin (A).

2. Remove the adjusting nut (B).
3. Remove the operating lever (C).
LAIL11MG1679A0A 1
LAIL11MG1680A0A 2
4. Remove the bolts from the cup (D).
LAIL11MG1681A0A 3
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5. Lift the spring (F) over the brake assembly.

6. Remove the bolt from the cup (E).
LAIL11MG1682A0A 4
7. Swing the brake assembly (G) away from the brake

disc.
LAIL11MG1963A0A 5
8. Remove the adjusting pins (H).

9. Remove the brake pads (I).
LAIL11MG1461A0A 6
10. Move the spring (J) in front of the brake assembly.

11. Lift the brake pads (K) and remove them.
LAIL11MG1462A0A 7
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Parking brake caliper - Install

NOTE: There are two pins located in the lower brake pad
area (A) of the brake assembly. Brake pads have two holes
that locate on pins.
LAIL11MG1463A0A 1
1. Install brake pad spring (B) behind the brake assembly.

2. Install the brake pads (C) with a spring behind the
threaded shaft of the brake assembly.
3. Install the actuating pins (D) to position the top of the
brake pads.
LAIL11MG1964A0A 2
4. Swing brake assembly onto disk brake.

5. Install the cap screws.
6. Tighten the cap screw with a torque of 87 N·m (64 lb
ft).
LAIL11MG2011A0A 3
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7. Install the cam and lever (G).

8. Install the adjusting nut (F).
9. Install the cotter pin (E).
LAIL11MG1683A0A 4
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Index

Parking brake or parking lock - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Parking brake caliper - Adjust (FSG 75 model) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Parking brake caliper - Adjust (Models FSG 90/FSG 110 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Parking brake caliper - Assemble (FSG 75 model) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Parking brake caliper - Assemble (Model M90) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Parking brake caliper - Assemble (Models FSG 90/FSG 110 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Parking brake caliper - Cleaning /Inspection (M90 Model) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Parking brake caliper - Disassemble (Model M90) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Parking brake caliper - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Parking brake caliper - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Parking brake caliper - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Parking brake caliper - Replace (Models FSG 90 and FSG 110) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Parking brake caliper - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Parking brake caliper - Sectional view (Models FSG 90/FSG 110) (*) . . . . . . . . . . . . . . . . . . . . . . . . . 10
Parking brake caliper - Service instruction (FSG 75 model) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Parking brake caliper - Service instruction (FSG 75 model) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Parking brake caliper - Service instruction (Model M90) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Parking brake caliper - Service instruction (Models FSG 90/FSG 110 (*) . . . . . . . . . . . . . . . . . . . . . . . 45
Parking brake caliper - Service instruction (Models FSG 90/FSG 110) (*) . . . . . . . . . . . . . . . . . . . . . . 39
Parking brake caliper Lining - Replace (FSG 75 model) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Parking brake caliper Shoe - Replace (Model M90) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Parking brake caliper Shoe - Replace (Models FSG 90/FSG 110) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Parking brake or parking lock - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Parking brake or parking lock - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Parking brake or parking lock - Service instruction (Models FSG 90 and FSG 110) (*) . . . . . . . . . . . 12
Parking brake or parking lock - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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PRINTED IN BRAZIL
48050419D 06/10/2017
EN
SERVICE MANUAL
Hydraulic systems

48050419D 06/10/2017
35
Contents
Hydraulic systems - 35
[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1
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Contents
FUNCTIONAL DATA
Hydraulic systems
Hydraulic symbol - Schematic components (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic symbol - Pressure control (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic symbol - Directional control (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydraulic symbol - Composite (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hydraulic symbol - Flow control (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hydraulic symbol - Table of symbols (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydraulic schema (Models equipped with Tier 3 engine and “Torque Converter” transmission) (*) . . . . 20
Hydraulic schema - (Models equipped with Tier 3 engine and “Direct Drive” transmission) (*) . . . . . . . . 37
Hydraulic schema (Models equipped with Tier 3 engine, “Direct Drive” transmission, and “AWD”) (*) . 49
Hydraulic schema (Models equipped with Tier 3 engine, “Direct Drive” transmission, and “AWD”) (*) . 53
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Hydraulic systems - Hydraulic systems
Hydraulic systems - Hydraulic symbol - Schematic components

845B Direct drive transmission, Tier 3, made in Brazil
[HBZN0845VBAF00184 - ]
845B Torque converter transmission, Tier 3, made in Brazil
[HBZN0845VCAF01093 - ]
865B Direct drive transmission, Tier 3, made in Brazil [NBAF15000 - ]
865B Torque converter transmission, Tier 3,made in Brazil [NBAF14004 - ]
885B Direct drive transmission, Tier 3, made in Brazil [HBZN0885LBAF00098
-]
[HBZN0885PCAF00871 - ]
Accurate diagrams of hydraulic circuits are essential to the technician who must repair them. The diagram shows
how the components interact. The diagram shows how the system works, what each component should be doing and
where the oil should be going so the technician can diagnose and repair the system.
There are two types of circuit diagrams:

• Cutaway circuit diagrams show the internal construction of the components as well as the flow paths. Using colors,
shades or various patterns in the lines and passages, they show many different conditions of flow and pressure.
Cutaway diagrams take considerably longer to produce because of their complexity.
• Schematic circuit diagrams, the “shorthand” system of the industry, are usually preferred for troubleshooting. A
schematic diagram is made up of simple geometric symbols for the components and their controls and connections.
There are several systems of symbols used when making schematic diagrams:
• ISO – International Standards Organization
• ANSI – American National Standards Institute
• ASA – American Standards Association
• JIC – Joint Industry Conference
A combination of symbols from these systems are shown. There are differences between the symbol systems. There
is enough similarity, however, so if you understand the symbols shown, you will be able to interpret other symbols as
well.
Reservoirs
A rectangle with the top removed represents a vented
reservoir (A). A rectangle with the top in place represents
a pressurized reservoir (B).
RCIL07CCH025AAA 1
There are other schematic diagrams that show a slightly

different version of a pressurized reservoir, but the sym-
bols are similar and easily recognized. An oval with a
short line on top or a rectangle with curved sides repre-
sents a reservoir that is pressurized.
RCIL07CCH027AAA 2
Lines connected to the reservoir usually are drawn from

the top, regardless of where the actual connection is. This
symbol shows a line which returns fluid above the level in
the reservoir.
RCIL07CCH030AAA 3
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If the hydraulic line returns fluid below the level in the

reservoir, it is drawn all the way to the bottom of the sym-
bol.
RCIL07CCH032AAA 4
A hydraulic line connected to the bottom of the reservoir

may be drawn from the bottom of the symbol if the bottom
connection is essential to the systems operation.
RCIL07CCH033AAA 5
If the pump inlet (B) must be charged or flooded with fluid

above the inlet port, the reservoir symbol (A) appears
above the pump symbol, and the suction line is drawn out
of the bottom of the reservoir symbol.
Every system reservoir has at least two hydraulic lines

connected to it, and some may have many more. Often
the components that are connected to the reservoir are
spread all over the schematic. Rather than multiplying
lines all over the schematic, individual reservoir symbols
are drawn close to the components. The reservoir is usu-
ally the only component symbol pictured more than once
on a diagram.
RCIL07CCH124AAA 6
Lines, tubes and hoses

A hydraulic line, tube, hose or any conductor that carries
the fluid between components is shown as a line. A work-
ing line, such as an inlet pressure or return, is shown as
a solid line.
RCIL07CCH034AAA 7
Working lines with arrows show direction of flow. In the

first example (A), fluid flows in one direction only; in the
second example (B), fluid can flow in both directions.
RCIL07CCH035AAA 8
Pilot or control lines (A) are broken into long dashes.

Drain lines (B) for leakage oil are broken into short
dashes.
RCIL07CCH036AAA 9
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A flexible line is shown as an arc between two dots and is

always represented by a solid line.
RCIL07CCH026AAA 10
An enclosure outline indicates that there are several sym-

bols that make up a component assembly such as a valve
or a valve stack. The enclosure outline is rectangular and
is broken with dashes on all sides.
RCIL07CCH028AAA 11
Lines between components are drawn differently when

they are crossing or connected. There are lines that cross
other lines but are not connected. There are several ways
to show crossing lines which are not connected.
RCIL07CCH038AAA 12
Lines that are connected are shown with a dot that repre-
sents the connection or shown as a tee connection. The
dot connection is the most commonly used when drawing
schematic diagrams.
RCIL07CCH047AAA 13
Pumps
There are many basic pump designs. A simple fixed dis-
placement pump (A) is shown as a circle with a solid ar-
row that pointing outward. The arrow points in the direc-
tion that the fluid flows. If the pump is reversible (B) or
designed to pump in either direction, the symbol has two
arrows which point in opposite directions. The pump nor-
mally has a pressure port and line (1) from which pressur-
ized fluid is discharged and a suction port and line (2) into
which fluid is drawn from the reservoir.
RCIL07CCH048AAA 14
A variable displacement pump (A) is shown by an arrow

drawn through the pump symbol at a 45 degree angle. A
variable displacement, pressure compensated pump (B)
is shown by a small box with an arrow, added to the side
of the pump symbol.
RCIL07CCH040AAA 15
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If the pump is controlled by a lever (A) or a pedal (B), the

appropriate symbol is added to the side of the pump.
RCIL07CCH041AAA 16
A drive shaft is shown as two short parallel lines extending

from the side of the pump. A curved arrow, if present, on
the drive shaft indicates the direction of rotation.
RCIL07CCH049AAA 17
Motors
Motor symbols are circles with solid black arrows, which
point in the opposite direction of a pump’s arrow, to show
the motor as a receiver of fluid. One arrow is used for
non-reversible motors (A); and two arrows are used for
reversible motors (B).
RCIL07CCH051AAA 18
A simple schematic diagram is shown of a hydraulic motor

(A) connected to a hydraulic pump (B).
RCIL07CCH046AAA 19
Cylinders
A cylinder is a simple rectangle (A) representing the bar-
rel. The piston and rod are represented by a tee (B), in-
serted into the rectangle. The symbol can be drawn in any
position.
RCIL07CCH055AAA 20
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If the cylinder is single-acting (A), there is only one port

shown on the end of the cylinder that receives pressurized
fluid. The opposite end of the cylinder is left open. Both
ends are closed on a double-acting cylinder (B), and two
ports are shown.
RCIL07CCH054AAA 21
A double rod end cylinder has a rod extending from each

end of the rectangle.
RCIL07CCH057AAA 22
Some cylinders have cushions built into them. The cush-

ion slows the movement of the piston as it nears the end of
its stroke. Cylinder cushions are shown as a smaller rec-
tangle (A) on the piston. If the cushion has an adjustable
orifice, a slanted arrow is drawn at 45 degrees (B) across
the symbol.
RCIL07CCH126AAA 23
Accessories
Filters, strainers and heat exchangers are represented as
squares that are turned 45 degrees and have the port
connections at the corners.
A dotted line perpendicular to the flow line represent a

filter, strainer or screen.
RCIL07CCH080AAA 24
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A solid line perpendicular to the flow with solid arrows

pointing outward represents a cooler.
RCIL07CCH081AAA 25
The symbol for a heater is like the symbol for a cooler,

except the solid arrows point inward.
RCIL07CCH118AAA 26
Two sets of arrows pointing inward and outward repre-

sents a temperature control unit
The solid arrows point in the direction that heat is dissi-

pated. Or in the case of the control unit, they show that
heat can be regulated.
RCIL07CCH119AAA 27
An oval with details inside represents an accumulator.

The details explain what type of accumulator it is: spring
loaded (A), gas charged (B), or other features.
The divider line indicates there is a separator between the

charge and the fluid. A hollow arrow indicates gas.
A spring indicates that the accumulator is spring-loaded.
RCIL07CCH130AAA 28
Reference: Hydraulic systems - Hydraulic symbol - Pressure control (35.000)

Hydraulic systems - Hydraulic symbol - Directional control (35.000)
Hydraulic systems - Hydraulic symbol - Composite (35.000)
Hydraulic systems - Hydraulic symbol - Flow control (35.000)
Hydraulic systems - Hydraulic symbol - Table of symbols (35.000)
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Hydraulic systems - Hydraulic symbol - Pressure control

[HBZN0845VBAF00184 - ]
[HBZN0845VCAF01093 - ]
-]
[HBZN0885PCAF00871 - ]
The basic valve symbol is a square (which is called an

envelope) with external port connections and an arrow
inside to show the fluid passage and direction of flow. The
valve usually operates by balancing fluid pressure against
a spring, so a spring is shown on one side of the symbol
and a pilot pressure line on the other side.
Normally closed valve

A normally closed valve, such as a relief or sequence
valve, is shown with an arrow offset from the ports [in-
let (A), outlet (B)] toward the pilot pressure line (C) side
of the square. The spring (D) holds the valve closed until
the pilot line pressure is greater than the spring pressure.
Mentally visualize a build up of pressure in the pilot line
and the envelope moving over, compressing the spring.
Fluid can now flow through the valve.
RCIL07CCH059AAA 1
Normally open valve

A normally open valve is shown with the arrow connecting
the inlet and outlet ports. It closes when pressure over-
comes spring force. Mentally visualize a build up of pres-
sure in the pilot line and the envelope moving over, com-
pressing the spring. Fluid flow through the valve is now
blocked.
RCIL07CCH060AAA 2
Relief valve
A relief valve is shown as a normally closed symbol con-
nected between the pressure line (A) and the reservoir
(B). The flow direction arrow points away from the pres-
sure line port and toward the reservoir. This graphically
represents how a relief valve operates. When pressure in
the system overcomes the valve spring (C), flow is from
the pressure line through the relief valve to the reservoir.
RCIL07CCH061AAA 3
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Pressure reducing valve

A pressure reducing valve is shown as a normally open
symbol in a pressure line. This valve works opposite of
a relief valve, since it senses outlet pressure (A) versus
inlet pressure (B). As the outlet pressure builds, it works
against a predetermined spring force. As the spring force
is overcome, flow through the valve is reduced or shut off.
RCIL07CCH063AAA 4
Sequence valve
The normally closed symbol is also used for a sequence
valve (A). The inlet port is connected to a primary cylin-
der (B) and the outlet port to the secondary cylinder line
(C). When the piston in the primary cylinder reaches the
end of its stroke, the pressure in the supply line increases.
The sequence valve is also connected to the supply line
and also feels the increase in pressure. As pressure in-
creases, the envelope and directional flow arrow move
over, connecting the inlet and outlet ports allowing fluid to
flow to the secondary cylinder.
RCIL07CCH062AAA 5
Reference: Hydraulic systems - Hydraulic symbol - Directional control (35.000)

Hydraulic systems - Hydraulic symbol - Composite (35.000)
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Hydraulic systems - Hydraulic symbol - Directional control

[HBZN0845VBAF00184 - ]
[HBZN0845VCAF01093 - ]
-]
[HBZN0885PCAF00871 - ]
One way valve

A simple ball check valve is shown. When fluid pressure
is exerted on the left side of the ball, the ball is forced into
the “V” and no fluid can flow though the valve. When fluid
pressure is applied to the right side of the ball, the ball
moves away from the “V” and fluid can flow through the
valve.
RCIL07CCH066AAA 1
Bypass valve
A bypass valve is shown as a one-way valve with a spring
on the ball end of the symbol. Pressurized flow is neces-
sary to overcome the spring force and allow flow around
the ball.
RCIL07CCH067AAA 2
Reference: Hydraulic systems - Hydraulic symbol - Composite (35.000)

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Hydraulic systems - Hydraulic symbol - Composite

[HBZN0845VBAF00184 - ]
[HBZN0845VCAF01093 - ]
-]
[HBZN0885PCAF00871 - ]
One way valve

A more complex one-way valve is shown. This directional
control symbol uses multiple envelopes with a separate
envelope for each valve position. Within each envelope,
arrows show the flow paths when the valve is shifted to
that position.
NOTE: All port connections are made to the envelope
which shows the neutral condition of the valve.
The left symbol (A) a one-way valve in the closed position.

Mentally visualize a build up of pressure on the right side
of the valve symbol (B) to enable free flow through the
valve.
RCIL07CCH072AAA 1
Two position valve

Two envelopes (representing the spool) indicate a two po-
sition valve. Each envelopes shows the flow conditions for
its position. This simple schematic shows fluid supplied to
the rod end of the cylinder (A) from the control valve (B).
Return flow is from the piston end of the cylinder through
the control valve to tank.
RCIL07CCH073AAA 2
Mentally visualize the directional control valve shifted to

the other position. Pressurized fluid is supplied to the pis-
ton end of the cylinder (A) from the control valve (B), and
return fluid flows from the rod end of the cylinder through
the control valve to tank.
RCIL07CCH074AAA 3
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Three position valve

Three position valves have a centered (neutral) position.
The centered position can be either open or closed to flow.
The open center (A) is usually used with a fixed displace-
ment pump, while the closed center (B) is usually used
with a variable displacement pump.
RCIL07CCH068AAA 4
RCIL07CCH069AAA 5
Actuating controls
Valve spools are controlled by pedals (A), levers (B), pilot
fluid (C), electric solenoids (D), etc., which are called ac-
tuating controls. These actuating controls are shown by
symbols placed on the ends of the envelopes.
This symbol (E) is used when a solenoid is controlled with

internal pilot assist pressure.
RCIL07CCH017BAA 6
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To show that a valve is spring-centered, a spring symbol is

placed at each end of the envelope. This symbol shows
that a solenoid and pilot pressure assist are required to
overcome spring force to move the valve spool.
RCIL07CCH070AAA 7
Reference: Hydraulic systems - Hydraulic symbol - Flow control (35.000)

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Hydraulic systems - Hydraulic symbol - Flow control

[HBZN0845VBAF00184 - ]
[HBZN0845VCAF01093 - ]
-]
[HBZN0885PCAF00871 - ]
Restrictors
The basic flow control symbol is a restrictor. If the restric-
tor is adjustable, a slanted arrow is drawn across the sym-
bol. The restrictor could be a special fitting with a small
hole in it or a small drilled passageway within a valve. An
adjustable restrictor acts like a faucet: adjusting the re-
striction regulates flow. Restrictors are used to meter and
bleed circuits. RCIL07CCH075AAA 1
Adjustable restrictors can be pressure-compensated:

the size of the opening in the restrictor changes with
increases and decreases in pressure. A perpendicular
arrow indicates pressure compensation. If the restrictor
has both pressure and temperature compensation, the
symbol for a thermometer is added.
RCIL07CCH078AAA 2
Reference: Hydraulic systems - Hydraulic symbol - Table of symbols (35.000)
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Hydraulic systems - Hydraulic symbol - Table of symbols

[HBZN0845VBAF00184 - ]
[HBZN0845VCAF01093 - ]
-]
[HBZN0885PCAF00871 - ]
Line and line functions

Solid line - main line Dotted line - exhaust or
drain line
Dashed line - pilot line Enclosure outline
Lines crossing Lines joining
Lines crossing Liquid direction of flow
Gaseous direction of flow Flexible line
Mechanical devices
Connections (two parallel Variable component (arrow
lines) for shafts, levers, etc. intersects symbol at 45°)
Spring
Pumps and motors

Pump, fixed displacement Pump, variable
displacement
Pressure compensated, Fixed displacement pump

variable displacement (bidirectional flow)
pump
Motor, fixed displacement Motor, variable

displacement
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Oscillator
Reservoirs
Reservoir, open to Pressurized reservoir
atmosphere
Return line to reservoir Return line to reservoir

below fluid level above fluid level
Cylinders
Single acting Double acting, single rod
end
Double acting. double rod Single rod end, fixed

end cushion both ends
Single rod end, adjustable Differential cylinder

cushion, rod end only
Valves
Check valve Pilot-operated check valve
On/Off manual shut off Regulating or selector

valve valves
2 position, 2 way valve 2 position, 3 way valve
2 position, 4 way valve 3 position, 4 way valve
2 position, 4 way open Valve capable of infinite

center, crossover valve positioning (indicated by
horizontal lines parallel to
the envelope)
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Pressure relief valve Pressure reducing valve
Non-adjustable restrictor Adjustable restrictor valve

valve
Adjustable restrictor, Adjustable restrictor,

pressure compensated temperature and pressure
compensated
Valve actuators
Solenoid Detent
Spring Manual
Push button Lever
Pedal Mechanical
Pressure compensated Pilot pressure, remote

supply
Liquid supply
Accessories
Filter Cooler
Heater Temperature controller
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Accumulator (hydro- Reversing motor

pneumatic
Station or test point Pressure indicator
Temperature indicator Pressure switch
Quick disconnect Quick disconnect

(disconnected) (connected)
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Hydraulic systems - Hydraulic schema (Models equipped with Tier

3 engine and “Torque Converter” transmission)
[HBZN0845VCAF01093 - ]
845B models
Item Quantity PN Description
1 1 75323556 Main hydraulic pump with variable volume pistons
2 1 84212195 Control Valve Assembly
3 3 84238181 Float electrovalve
4 2 73160850 Anti-shock electrovalve
5 3 47751043 Accumulator
6 8 84207595 Dual balance valve
7 1 84325078 Left-hand blade lift cylinder
8 2 75255849 Solenoid valve
9 1 75269337 Ripper cylinder
10 2 75270223 Scarifier/dozer blade cylinder
11 1 75270176 Blade side shift cylinder
12 1 84325067 Blade tilt cylinder
13 1 391859A1 Anti-return valve
14 1 87389984 Motor hydraulic
15 1 75269499 Circle side shift cylinder
16 1 84324694 Right-hand articulation cylinder
17 1 84324699 Left-hand articulation cylinder
18 1 75252292 Dual anti-return valve
19 1 47508202 Front wheel tilt cylinder
20 1 84325073 Right-hand blade lift cylinder
21 1 87521643 Pressure-reducing valve
23 1 75267168 Saddle lock right-hand cylinder
24 1 75268406 Saddle lock left-hand cylinder
25 1 84149453 Hydraulic Reservoir
26 1 73161153 Filter
27 1 73125853 Filter element
28 1 73045861 Relief valve
29 1 87471428 Brake pedal valve – ZR Transmission
30 2 76028575 Brake Accumulators
31 1 87682047 Graziano shaft brake
32 1 87471441 Differential Lock Valve
33 1 48068347 Steering Control Unit
34 2 47507733 Steering Cylinders
35 1 84561804 Brake/steering gear pump
36 1 87382507 Fan hydraulic fluid cooler
37 1 401430A1 Transmission heat exchanger
38 1 87625375 Differential Lock
39 1 73163844 Load sensor priority valve
41 1 79104494 Cap with filter and pressurizer valve
42 1 73162805 Fan Drive Motor
43 1 75326838 Fan drive reversible hydraulic motor
44 1 8500563 Fan drive valve
45 1 84261959 Engine water radiator
46 1 73159101 Fan thermal shutdown bypass
47 1 8500209 Parking Brake Accumulator
48 1 87747168 3-way hydraulic valve
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49 1 84523397 Thermostat valve
50
50
50
51
52 Inlet pressure quick coupling
53 Steering pressure quick coupling
54 Quick coupling of the left-hand brake accumulator
55 Quick coupling of the right-hand brake accumulator
56 Quick coupling of the left-hand brake pressure
57 Quick coupling of the right-hand brake pressure
58 Quick coupling of the right-hand blade lift pressure
59 Quick coupling of the left-hand blade lift pressure
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84392235FTC01JA 1
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865B models
item Quantity PN Description
26 1 73161153 Filter
37 1 401430A1 Transmission heat exchanger
49 1 84523397 Thermostat valve
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item Quantity PN Description

50
50
50
51
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84392234GTC01JA 1
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[HBZN0885PCAF00871 - ]
885B models
26 1 73161153 Filter
28 1 73045861 Relief valeve
37 1 87751052 Transmission heat exchanger
43 1 8500565 Fan reverser and rotation control valve
47 1 84138750 Transmission thermal bypass valve
48
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48
48
49
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84392232HTC01JA 1
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A1 Valve block
A2 Control circuit
A3 Main fluid circuit
15 Connection for pressure at the radiator fluid inlet

16 Connection for pressure at the radiator fluid outlet
19 Connection for pressure after the fluid filter
35 Connection for pressure before the fluid filter
51 Measurement point of the fluid pressure at the converter inlet
52 Measurement point of the fluid pressure/temperature at the converter outlet
53 Measurement point of the fluid pressure for the KV clutch
55 Measurement point of the fluid pressure for the KR clutch
56 Measurement point of the fluid pressure for the K1 clutch
65 Connection for system pressure
T/C Torque converter

BLn Orifice n
Dn Damping n
NFSn Booster valve n
Yn Pilot pressure valve n
RV-9 Pressure-reducing valve
TEMP Temp sensor
HDV Main pressurization valve
MSV Torque converter relief valve
WGV Torque converter counter-pressure valve
WT Torque converter heat exchanger
LUB Lubrication
TANK Crankcase
WKV Lock-up clutch valve of the torque converter
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84392232HTC02JA 2
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Hydraulic systems - Hydraulic schema - (Models equipped with Tier

3 engine and “Direct Drive” transmission)
[HBZN0845VBAF00184 - ]
854B models
25 1 73161153 Filter
28 1 87673477 Brake pedal valve – FUNK Transmission
46
46
46
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47
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84392235FDD01JA 1
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865B models
25 1 73161153 Filter
46
46
46
47
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84392234GDD01JA 1
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-]
885B models
24 1 84149453 Hydraulic reservoir
25 1 73161153 Filter
46
46
46
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47
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84392232HDD01JA 1
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3 engine, “Direct Drive” transmission, and “AWD”)
865B AWD models

25 1 73161153 Filter
44 1 87668596 Hydraulic piston pump 55 cm3/rev
45 2 87612637 Hydraulic motor 75.9 CM3/rev
46 1 4532278 Flow divider
47 1 84213820 Bypass valve
48
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48
48
49
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84392234GDDA1JA 1
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3 engine, “Direct Drive” transmission, and “AWD”)
885B AWD models

25 1 73161153 Filter
44 1 87668596 Hydraulic piston pump 55 cm3/rev
45 1 4532278 Flow divider
46 2 87612637 Hydraulic motor 75.9 CM3/rev
47 1 84213820 Bypass valve
48
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48
48
49
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84392232HDDA1JA 1
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Index

Hydraulic systems - Hydraulic schema (Models equipped with Tier 3 engine and “Torque Converter”
transmission) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
transmission) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
transmission) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Hydraulic systems - Hydraulic schema (Models equipped with Tier 3 engine, “Direct Drive” transmis-
sion, and “AWD”) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Hydraulic systems - Hydraulic schema (Models equipped with Tier 3 engine, “Direct Drive” transmis-
sion, and “AWD”) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Hydraulic systems - Hydraulic schema - (Models equipped with Tier 3 engine and “Direct Drive”
transmission) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
transmission) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
transmission) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Hydraulic systems - Hydraulic symbol - Composite (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hydraulic systems - Hydraulic symbol - Directional control (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydraulic systems - Hydraulic symbol - Flow control (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hydraulic systems - Hydraulic symbol - Pressure control (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic systems - Hydraulic symbol - Schematic components (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic systems - Hydraulic symbol - Table of symbols (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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PRINTED IN BRAZIL
48050419D 06/10/2017
EN
SERVICE MANUAL
Frames and ballasting

48050419D 06/10/2017
39
Contents
Frames and ballasting - 39
[39.100] Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1
[39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.2
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39
Frame - 100

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Contents
Frame - 100
TECHNICAL DATA
Frame
Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Articulation frame pivot

Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Frame
Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Articulation frame pivot
Moldboard drawbar and circle
Remove - (Drawbar) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disassemble - (Turning circle) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassemble - (Turning circle gear reducer) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Assemble - (Turning circle gear reducer) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Assemble - (Turning circle) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Install - (Drawbar) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Moldboard saddle
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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Frames and ballasting - Frame
Frame - Torque
845B
865B
885B
LAIL11MG0203F0A 1
A. 8.8 – 9.6 N·m (6.5 – 7.1 lb ft)

B. 8.8 – 9.6 N·m (6.5 – 7.1 lb ft)
C. 3.8 – 4.2 N·m (2.8 – 3.1 lb ft)
D. 3.8 – 4.2 N·m (2.8 – 3.1 lb ft)
E. 30.4 – 33.2 N·m (22.4 – 24.5 lb ft)
F. 8.8 – 9.6 N·m (6.5 – 7.1 lb ft)
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Articulation frame pivot - Sectional view

845B
865B
885B
LAIL11MG0658F0A 1
A. E.D. of pin 66.7133 – 66.725 mm (2.627 – 2.627 in)

I.D. of the bearing cone 66.675 – 66.888 mm (2.625 – 2.633 in)
B. I.D. of the articulation support 66.7133 – 66.725 mm (2.627 – 2.627 in)
E.D. of the bearing cap 66.675 – 66.888 mm (2.625 – 2.633 in)
C. Screw torque 13.5 – 15.7 Nm (100 – 116 ft.lbs)
D. Screw torque 12.3 – 13.5 Nm (90 – 100 ft.lbs)
E. E.D. of the pin 66.7133 – 66.725 mm (2.627 – 2.627 in)
I.D. of the bush 66.890 – 67.160 mm (2.633 – 2.644 in)
F. E.D. of the pin 66.713 – 66.725 mm (2.626 – 2.627 in)
G. E.D. of the pin 66.7133 – 66.725 mm (2.627 – 2.627 in)
H. E.D. of the pin 66.7133 – 66.725 mm (2.627 – 2.627 in)
I.D. of the bush 66.8909 – 67.160 mm (2.633 – 2.644 in)
I. Screw torque 66.7133 – 66.725 mm (2.627 – 2.627 in)
J. Screw torque 66.7133 – 66.725 mm (2.627 – 2.627 in)
K. E.D. of the pin 66.7133 – 66.725 mm (2.627 – 2.627 in)
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Frame - Service instruction

845B
865B
885B
Drawbar and Turning Circle
LAIL11MG0506F0A 1
1. Adjust the shims (A) to obtain a vertical play of 1.5 mm

(0.06 in) between the wear plates and the circle guides.
2. With the circle against its guide, adjust the bolts (B) to
a play of 8 – 15 mm (0.31 – 0.59 in) between the circle
and each one of its guides.
3. Tighten the bolts (B) with a torque of 1085 N·m (800 lb
ft).
4. Adjust the rear guides (C) to obtain a maximum hori-
zontal play of 0.7 mm (0.03 in) between the circle and
each of its rear guides.
5. Tighten the bolts (D) with a torque of 1085 N·m (800 lb
ft).
NOTE: Rotate the circle 360 degrees to check for free
clearance.
6. Tighten the bolts (E) with a torque of 122 – 136 N·m (90
– 100 lb ft).
7. Tighten the bolts (F) with a torque of 569 – 583 N·m
(420 – 430 lb ft).
8. Adjust the shims (G) to obtain an end play of 0.00 –
0.25 mm (0.000 – 0.010 in) between the ball and the
socket.
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9. Tighten the nuts (H) at the torque of 813 N·m (600 lb

ft).
NOTE: Do not apply lubricant to the circle guide shoe liners
or wear surfaces of the circle.
10. Tighten the bolts (I) with a torque of 244 – 325 N·m
(180 – 240 lb ft).
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845B
865B
885B
Moldboard saddle
LAIL11MG1013F0A 1
A. Install shims to obtain a free clearance of 0 – 1.207 mm (0 – 0.048 in) for the ball.
E. Apply a light coat of Molykote “G” lubricant paste to the surface indicated.
Torques
B. 407 – 447 N·m (300 – 330 lb ft)
C. 230 – 254 N·m (170 – 187 lb ft)
D. 312 – 339 N·m (230 – 250 lb ft)
H. 47 – 53 N·m (35 – 39 lb ft)
Dimension
F. E.D. of Pin 47.752 – 47.803 mm (1.880 – 1.882 in)
E.D. of trunnion bushing – 47.904 – 47.995 mm (1.886 – 1.890 in)
G. E.D. of trunnion bushing – 37.993 – 38.040 mm (1.496 – 1.498 in)
E.D. of trunnion bushing – 37.846 – 37.871 mm (1.490 – 1.491 in)
I. With the grader on a level floor, measure the vertical distance from the floor to the center of each one of
the left and right lifting cylinder trunnion wishbones. For every 13 mm (0.5 in) difference between the two
dimensions, add two shims to the side with the lowest pivot. Do not add more than four shims.
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LAIL11MG0510G0A 2
A. I.D. of gudgeon hole (NOTES 1 and 2 )– 82.5590 – 82.575 mm (3.250 – 3.251 in)
NOTE: 1 – Install the inner bearing 0.77 mm (0.03 in) below the surface of the recessed hole.
NOTE: 2 – Install the outer bearing 10.2 mm (0.40 in) inside the gudgeon hole.
E.D. of gudgeon hole – 82.5590 – 82.575 mm (3.250 – 3.251 in)
I.D. of gudgeon hole – 76.302 – 76.752 mm (3.004 – 3.022 in)
E.D. of gudgeon hole – 76.175 – 76.200 mm (2.999 – 3.000 in)
B. Lubricate the seals with no. 1 grease.
C. Install the shims to obtain an end play of 0.025 – 0.076 mm (0.001 – 0.003 in)
D. torque the bolts to 122 – 136 N·m (90 – 100 lb ft)
E. torque the bolts to 949 – 1044 N·m (700 – 770 lb ft)
F. Install the shims to obtain a clearance of 0.000 – 0.127 mm (0.000 – 0.005 in) between the bench support
and the bench assembly.
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845B
865B
885B
Turning Circle Assembly
LAIL11MG0511G0A 1
A. Install the shims as required to obtain a clearance at the end of 0.0 – 3.3 mm (0.00 – 0.13 in). Do not apply
a pre-load.
B. With the worm gear removed, install shims to obtain a rotation torque of 9.4 – 0.9 N·m (6.9 – 0.7 lb ft) on
the bearings.
Torques
1. One position – 12.20 – 13.65 daN ( 90 – 100 lb ft)
Five positions – 15.60 – 17.60 daN ( 115 – 130 lb ft)
2. 4.70 – 5.40 daN ( 35 – 40 lb ft )
3. 47.40 – 50.80 daN ( 350 – 375 lb ft )
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Articulation frame pivot - Service instruction

1. The articulation joint consists of tapered roller bearings.

The joint allows for a total of 50 degrees articulation.
LAIL11MG1980A0A 1
2. Support the two main frames on jack stands during re-

build.
NOTE: Do not work with linkages, parts, or machines that
are not blocked or supported.
Clean bearing bores.
Never use gasoline or other inflammable fluids to clean the
elements. Use authorized, commercial, non-flammable,
non-toxic solvents. Watch out for people in the vicinity.
LAIL11MG1483A0A 2
3. Measure the bearing height of the outer races plus the

height of the spacer. Record these dimensions. Keep
the bearing pieces matched. Repeat the measurement
for the other bearing.
LAIL11MG2031A0A 3
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39.1 [39.100] / 10
4. Measure the thickness of frame boss at the bore.

Record these dimensions and repeat the measuring
process at the other frame boss. Select shims to build
the provided. Watch out for people in the vicinity.
LAIL11MG2032A0A 4
5. Use driver P/N 75300850 to install the bearing cup into

the frame bore. Install the bearing retainer in place.
NOTE: It is not safe to tap tempered steel parts with any
object other than a soft or non-ferrous material hammer.
When installing or removing these parts, wear safety
glasses with side shields and heavy gloves, etc., to reduce
the possibility of injury.
LAIL11MG1925A0A 5
6. Install the bearing in its housing. Prior to installing the

bearing retainers onto the frame, install the seal into
the retainer. Clean the joining surfaces of the seal
and retainer with P/N 775213760. Apply sealant P/N
75213776 to the retainer. Remove the lower saddle
plate cap screws and the plate.
LAIL11MG1708A0A 6
7. Install the bearing into the bore. Level the two frames
prior to installation. Install pins. Install the bushing and
inner tie-rod on the bottom joint pin. Install the plates
and tighten the cap screws to the specified torque.
NOTE: Lift and handle all heavy parts with a suitable ca-
pacity lifting device. Be sure parts are supported by proper
slings and hooks. Use lifting eyes if provided. Watch out
for people in the vicinity.
LAIL11MG2110A0A 7
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Moldboard drawbar and circle - Remove - (Drawbar)

865B AWD NA
885B AWD NA
1. Lower the blade so that the blade touches the ground.

2. Turn the Master disconnect Switch OFF.
NOTICE: Turn off the master switch before you perform
cleaning, repair or service tasks, and after you park the
machine. Failure to comply with this recommendation may
result in serious injuries or death.
COIL16GRD0045BA 1
3. Disconnect the lower ball terminals of the right-hand (1)

and left-hand (2) lift cylinders.
4. Keep the shims in position so that you can carry out the
assembly but not change the quantity.
COIL16GRD0065AB 2
48050419D 06/10/2017
39.1 [39.100] / 12
5. Disconnect the ball terminal from the lateral displace-

ment cylinder rod of the turning circle (3).
6. Keep the shims in position so that you can carry out the
assembly but not change the quantity.
7. Observe the contact surface of the ball terminals.
NOTE: If there is excessive wear or scratches on the sur-
face, replace the terminals.
COIL16GRD0043BA 3
8. To remove the ball terminals, loosen the fastening cas-

tle nuts (4), but do not fully remove the castle nuts.
9. Use a rubber mallet to tap the threaded end by hand to
loosen the terminals.
10. After the terminals are loose, completely remove the
nuts, the washers, and the ball terminals.
COIL16GRD0047AA 4
11. Disconnect the hoses (5) of the metal tubing at the

front of the circle frame.
COIL16GRD0064AA 5
48050419D 06/10/2017
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12. Remove the bolts (6) that secure the ball bearing
housing of the drawbar to the front chassis of the
grader.
NOTE: There are 8 bolts in total. The assembly of the two
lower bolts takes place via the front of the machine.
13. You can remove the drawbar from the machine
COIL16GRD0066AB 6
14. Loosen the nut (7) that secures the traction ball termi-
nal, but do not fully remove the nut.
15. Use a rubber mallet to tap the threaded end by hand
to loosen the terminal.
16. After the terminal is loose, completely remove the nuts
and the terminal.
COIL16GRD0041AA 7
17. Observe the contact surface of the traction ball termi-

nal.
NOTE: If there is excessive wear or scratches on the sur-
face, replace the terminal.
COIL16GRD0040AB 8
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Moldboard drawbar and circle - Disassemble - (Turning circle)

865B AWD NA
885B AWD NA

3. Loosen the 6 bolts (1) that secure the turning circle gear
reducer to the frame of the drawbar.
COIL16GRD0044AB 1
4. Loosen the nuts (2) that secure the turning circle wear
shoes (3).
NOTE: Loosen every other nut, one shoe at a time.
NOTICE: The wear shoe will drop after you remove the
second nut if the blade has proper support on the ground.
The figure shows the assembly with the circle upside down.
COIL16GRD0061AA 2
5. Note the condition of the celeron shoes (4).

NOTE: If the shoes have damage or are severely worn,
replace the shoes.
6. Note the condition of the wear shoes (3)
NOTE: If the shoes have damage or are severely worn,
replace the shoes.
7. Maintain the thickness of the shims (5) when you as-
semble the system.
COIL16GRD0055AA 3
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Moldboard drawbar and circle - Disassemble - (Turning circle gear

reducer)
865B AWD NA
885B AWD NA

3. Loosen the 6 bolts (1) that secure the turning circle gear
reducer to the frame of the drawbar.
COIL16GRD0044AB 1
4. In the workshop, properly position the assembly and

maintenance device of the turning circle gear reducer.
5. Attach the gear reducer onto the support.
COIL16GRD0001AA 2
6. Loosen the bolts (2) that secure the hydraulic motor.

7. Remove the engine.
COIL16GRD0033AA 3
48050419D 06/10/2017
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8. Loosen the bolts (3) that secure the engine coupling

flange.
9. Remove the flange.
NOTE: The flange is the housing of the tapered roller bear-
ing cup of the auger shaft.
10. Check the condition of the tapered roller bearing cup.
NOTE: If there are scratches or excessive wear, replace
the bearing.
11. Remove the seal O-ring.
12. Check the condition of seal O-ring. COIL16GRD0037AA 4
NOTE: If necessary, replace the O-ring.

13. Pull the auger shaft out through the bearing cone at
the same time as you turn the output shaft pinion.
14. Remove the auger shaft.
NOTE: It is necessary to rotate the inner ring gear so that
the auger comes out freely.
15. Check the condition of the tapered roller bearing cup
the bearing.
COIL16GRD0035AA 5
16. Remove the 4 bolts (4) that secure the closing cover
of the output shaft journal.
17. Remove the cover and the shims.
COIL16GRD0023AA 6
18. Remove the seal O-ring.

19. Check the condition of seal O-ring.
20. Remove the 3 bolts (5) that secure the axial journal of
the output shaft.
21. Keep the shims in place so as not to alter the number
during assembly.
COIL16GRD0029AA 7
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39.1 [39.100] / 17
22. Remove the thrust washer (6).
COIL16GRD0027AA 8
23. Loosen the 6 bolts (7) that secure the support cover
of the output shaft journal.
24. Remove the support cover and the seal O-ring.
25. Check the condition of seal O-ring.
26. Check the condition of the output shaft journal bush-
ing.
the journal bushing.
COIL16GRD0026AA 9
27. Remove the other thrust washer (6).
COIL16GRD0022AA 10
28. Slide the assembly onto the spline of the output shaft
to remove the ring gear and the ring gear hub.
29. Loosen the 10 bolts and nuts (8) that secure the ring
gear on the hub.
30. Observe the condition of the teeth of the ring gear and
of the auger.
NOTE: If there is excessive wear or damage, replace the
pair as a set.
COIL16GRD0015AA 11
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31. Remove the snap ring from the output shaft.

32. Remove shaft.
33. Observe the condition of the journals.
NOTE: If there is any damage or excessive wear, replace
the output shaft.
COIL16GRD0019AB 12
COIL16GRD0018AA 13
34. Observe the condition of the output shaft retainer.

NOTE: If there is damage or any oil leak, replace the re-
tainer.
COIL16GRD0006AA 14
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Moldboard drawbar and circle - Assemble - (Turning circle gear

reducer)
865B AWD NA
885B AWD NA
1. Clean the housing of the turning circle gear reducer.

Position the housing. Secure the housing on the as-
sembly device.
COIL16GRD0001AA 1
2. Cool the bushings of the output shaft of the turning

circle gear reducer in liquid nitrogen.
3. Assemble the bushing (1) of the gear reducer housing
and the bushing (2) of the housing cover as shown in
the figures.
COIL16GRD0002AA 2
COIL16GRD0024AA 3
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4. Cool the cups of the auger shaft tapered bearings in

liquid nitrogen.
5. Assemble the bearing cup (3) on the housing of the
gear reducer and the bearing cap (4) on the hydraulic
motor coupling flange as shown in the figures.
COIL16GRD0003AA 4
6. Install the seal O-ring (5) on the hydraulic motor cou-

pling flange.
COIL16GRD0010AB 5
7. Cool the guide pins of the auger ring gear hub in liquid
nitrogen.
8. Position the ring gear hub on the pressing device. With
the help of a hydraulic press, install the guide pins on
the hub.
COIL16GRD0011AA 6
COIL16GRD0012AA 7
48050419D 06/10/2017
39.1 [39.100] / 21
9. Use ten bolts, nuts, and washers to assemble the auger

ring gear on the hub.
NOTE: Use Threebond 1134B on the threads of the bolts.
10. Place the assembly in a vise. Use a 3/4 in socket
and a torque wrench to apply a torque of 490 N·m
(50 kgf.m).
COIL16GRD0015AA 8
11. Use an inductive heater to heat the cones of the auger

shaft tapered bearings to 120 °C (248 °F).
12. Assemble the bearing cones in their respective seats
on the auger shaft.
COIL16GRD0016AA 9
13. Install the output shaft retainer (6) in the gear reducer
housing.
COIL16GRD0004AA 10
14. Lubricate the pinion output shaft with grease.

15. Insert the output shaft through the face of the retainer
in the gear reducer housing.
COIL16GRD0017AA 11
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39.1 [39.100] / 22
16. From inside the housing, install the thrust snap ring of
the ring gear hub.
COIL16GRD0019AB 12
COIL16GRD0018AA 13
17. Lubricate the splines of the shaft with Tutela MR-3.

18. Assemble the hub assembly and ring gear (7) on the
pinion output shaft.
19. Assemble the flat thrust washer (8) of the hub.
COIL16GRD0022AA 14
20. Assemble the seal O-ring of the gear reducer housing

cover.
COIL16GRD0024AA 15
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39.1 [39.100] / 23
21. Lubricate the end of the shaft with Tutela MR-3.

22. Assemble the gear reducer housing cover.
23. Apply THREEBOND TB 1215 to the bores of the threads
of the bolts that secure the cover.
COIL16GRD0025AA 16
24. Install the 6 bolts and lock washers that secure the
cover.
25. With a torque wrench, torque the bolts to 124 –
138 N·m (12,6 – 14,0 kgf.m).
COIL16GRD0026AA 17
26. Install the second thrust washer. Lubricate with

grease.
COIL16GRD0027AA 18
27. Use 3 bolts and washers to assemble the thrust flange

of the pinion output shaft.
28. Select an adequate quantity of shims to make sure
that the output shaft rotates freely.
COIL16GRD0028AA 19
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39.1 [39.100] / 24
29. Tighten the bolts (9) to a torque of 49 – 59 N·m (5 –

6 kgf.m).
30. Rotate the input shaft to check whether the reducer
turns freely.
31. With the help of the grease, attach the seal O-ring on
chamfer of the housing cover seat.
COIL16GRD0029AA 20
32. Use 4 bolts (10) to assemble the housing cover.

33. Tighten the bolts 49 – 59 N·m to a torque of (5 –
6 kgf.m).
COIL16GRD0023AA 21
34. Insert the auger shaft in its housing.

35. Turn the pinion by hand to allow/ease the entry of the
auger shaft, due to contact with the teeth of the ring
gear.
36. The notched side of the hydraulic motor must face the
side of the flange that secures the motor.
COIL16GRD0035AA 22
37. Choose a number of shims to place on the flange that

secures the hydraulic motor in order to ensure zero
end play on the auger shaft.
COIL16GRD0036AA 23
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39.1 [39.100] / 25
38. Secure the flange with the 4 bolts. Torque to 49 –

59 N·m (5 – 6 kgf.m).
39. The correct thickness of the shims is determined by
the swing torque on the auger shaft.
COIL16GRD0037AA 24
40. Attach the shaft drive tool (11). Rotate about 35 turns.
41. Use a torque meter to help measure the swing torque.
42. The swing torque should be 6,9 – 9,3 N·m (0,70 –
0,95 kgf.m).
NOTE: If the torque is below this value, remove the flange,
reduce the thickness of the shim, and reassemble the as-
sembly.
43. Measure the swing torque.
COIL16GRD0039AA 25
44. Place the hydraulic motor on the workbench. Apply a

layer of THREEBOND TB 1215 as shown in the figure.
COIL16GRD0031AA 26
45. Install the hydraulic motor on the flange with 2 fasten-

ing bolts.
46. Use a torque meter to help you torque the bolts to 139
– 153 N·m (14,0 – 15,5 kgf.m).
COIL16GRD0033AA 27
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39.1 [39.100] / 26
47. Install the drain plug. Apply a layer of ThreeBond 1104

on the thread of the housing.
COIL16GRD0004AA 28
48. Install the fill plug. Apply a layer of ThreeBond 1104

on the thread of the housing.
COIL16GRD0005AA 29
49. Install the valve on the cover of the gear reducer hous-
ing. Apply a layer of ThreeBond 1104 on the thread of
the cover.
50. You can now install the assembly on the drawbar
frame.
COIL16GRD0007AA 30
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Moldboard drawbar and circle - Assemble - (Turning circle)

865B AWD NA
885B AWD NA
1. Use 6 bolts (1) and 6 flat washers to attach the turning

circle gear reducer on the drawbar frame.
2. Tighten the bolts 133 N·m to a torque of (13,5 kgf.m).
COIL16GRD0053AA 1
3. Install the 8 bolts (2) and 8 adjustment nuts for the

position of the wear shoes.
NOTE: Do not thread the bolts very much so as not to limit
the shoe assembly.
COIL16GRD0052AA 2
COIL16GRD0050AA 3
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4. Use the 8 fastening bolts of the shoes to position the 4

celeron shoes (3) and the 4 shims (4) on the drawbar
frame.
NOTE: The purpose of this operation is to keep the shoes
and shims in position so that you can place the base of
the turning circle over the assembly. There is no need to
tighten the bolts with nuts.
COIL16GRD0055AA 4
5. Position the base of the turning circle on the contact

surface of the celeron shoes.
NOTE: Try to center the base on the drawbar.
6. Remove the bolts (5) that were used only to position
the shoes.
7. Keep the bolts near the location of each shoe, as you
will use the bolts later.
COIL16GRD0056AA 5
8. Assemble the 2 thrust pads on each of the 4 cast iron

wear shoes.
9. Tighten the bolts (6) to a torque of 150 N·m
(15,3 kgf.m).
COIL16GRD0057AA 6
10. Position each of the wear shoes on their respective

attachment locations.
COIL16GRD0059AA 7
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11. Insert the fastening bolts from the bottom up as shown

in the figure.
NOTE: Insert the bolts from the side of the drawbar.
12. Assemble the washers and the fastening nuts (7).
NOTE: Thread the nuts loosely to allow adjustment of the
radial position of the wear shoes.
COIL16GRD0061AA 8
13. At this point, measure the vertical clearance between

each wear shoe and the guide of the turning circle
base.
NOTE: The clearance should be a maximum of 1,5 mm.
Change the thickness of the shims to ensure this clear-
ance. Fit the fastening nuts again.
14. Turn the base of the turning circle 360°. Recheck the
clearance of each wear shoe and the turning circle
guide.
15. Use the shoe positioning bolts (2) to adjust the radial
position of the wear shoes.
COIL16GRD0061AA 9
16. Try to center the base of the turning circle but do not
zero the clearance with the guide.
NOTE: Keep the gear clearance of the swing pinion on the
rack between 0,8 – 1,5 mm.
COIL16GRD0063AA 10
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17. After you obtain the gear clearance, tighten the lock
nuts of the shoe adjustment bolts.
COIL16GRD0062AA 11
18. Torque the 8 fastening bolts of the wear shoes to

1400 N·m (142,7 kgf.m).
COIL16GRD0061AA 12
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Moldboard drawbar and circle - Install - (Drawbar)

865B AWD NA
885B AWD NA
1. Place the assembled drawbar assembly under the front

chassis of the machine.
2. Support the blade on the ground.
NOTICE: Turn off the master switch before you perform cleaning, repair or service tasks, and after you park the
machine. Failure to comply with this recommendation may result in serious injuries or death.
4. Insert the ball terminal into its housing on the drawbar.
5. Position the fastening nut (1). Torque to 830 N·m
(84,6 kgf.m).
COIL16GRD0041AA 1
COIL16GRD0040AB 2
6. During installation of the ball bearing housing, ensure a

clearance of 0 – 0,25 mm millimeters between the ball
and the spherical bushings of the bearing.
7. Install the bearing housing without the shims (2).
Tighten the 8 fastening bolts to a final torque of
320 N·m (32,6 kgf.m). Measure the clearance be-
tween the front of the chassis and the bearing housing.
8. Place a quantity of shims equivalent to at least the
clearance measurement found and at most the clear-
ance measurement plus 0,25 mm.
LAIL11MG2037A0A 3
48050419D 06/10/2017
39.1 [39.100] / 32
9. Assemble the ball terminals (3) of the right-hand and

left-hand lift cylinders and of the lateral displacement
cylinder.
COIL16GRD0049AA 4
10. Insert the ball terminals (3) in each of the mounting

holes of the drawbar.
11. Position the washers. Tighten the castle nuts (4) until
the assembly is in a fully seated state.
12. Once the assembly is in a seated state, rotate the
castle nuts (4) far enough clockwise to assemble the
lock pin.
COIL16GRD0047AA 5
13. Use the same number of shims as each bearing con-

tains to assemble the ball bearings (5) and (6) of the
lift cylinders and of the lateral displacement cylinder.
14. If you replaced the ball terminals, you may need to
adjust the number of shims again.
COIL16GRD0043BA 6
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39.1 [39.100] / 33
15. Connect the hoses (7) of the metal tubing at the front
of the circle frame.
COIL16GRD0064AA 7
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39.1 [39.100] / 34
Moldboard saddle - Disassemble

865B AWD NA
885B AWD NA

2. Turn off the master electrical switch.
NOTICE: Always disconnect the master switch before
cleaning, repairing, maintaining, or parking the machine to
avoid injuries.
LAIL11MG2038A0A 1
3. Remove the bolts and the lower plate from the saddle.
LAIL11MG2040A0A 2
4. Disconnect the light wires.
LAIL11MG2041A0A 3
48050419D 06/10/2017
39.1 [39.100] / 35
5. Disconnect the moldboard blade lift cylinders at the

yoke.
LAIL11MG1981A0A 4
6. Disconnect the shift cylinder where the cylinder con-

nects to the saddle, as well as the hose bracket.
LAIL11MG2042A0A 5
7. Disconnect the lock pins from the saddle hydraulic

lines.
LAIL11MG1982A0A 6
8. Support the saddle. Remove the bolts that secure the

thrust plate to the saddle.
9. Lift the saddle from the machine's frame.
NOTICE: Lift and handle all heavy parts with a suitable ca-
pacity lifting device. Make sure that the parts have support
from proper chains and hooks. Use lifting eyes if available.
Watch out for people in the vicinity.
LAIL11MG1983A0A 7
48050419D 06/10/2017
39.1 [39.100] / 36
10. Remove the bolts that secure the saddle support to

the frame.
NOTE: Keep the shims in position.
NOTICE: Lift and handle all heavy parts with a suitable ca-
pacity lifting device. Make sure that the parts have support
from proper chains and hooks. Use lifting eyes if available.
Watch out for people in the vicinity.
LAIL11MG2109A0A 8
48050419D 06/10/2017
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Index
Frame - 100
Articulation frame pivot - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Articulation frame pivot - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Frame - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Frame - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Moldboard drawbar and circle - Assemble - (Turning circle gear reducer) (*) . . . . . . . . . . . . . . . . . . . 20
Moldboard drawbar and circle - Assemble - (Turning circle) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Moldboard drawbar and circle - Disassemble - (Turning circle gear reducer) (*) . . . . . . . . . . . . . . . . . 16
Moldboard drawbar and circle - Disassemble - (Turning circle) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Moldboard drawbar and circle - Install - (Drawbar) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Moldboard drawbar and circle - Remove - (Drawbar) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Moldboard saddle - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
48050419D 06/10/2017
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Ballasts and supports - 140

48050419D 06/10/2017
39.2 [39.140] / 1
Contents
FUNCTIONAL DATA
Front ballast
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Front ballast
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
48050419D 06/10/2017
39.2 [39.140] / 2
Frames and ballasting - Ballasts and supports
Front ballast - Exploded view

845B
865B
885B
LAIL11MG0659F0A 1
48050419D 06/10/2017
39.2 [39.140] / 3
Frames and ballasting - Ballasts and supports
Front ballast - Assemble

845B
865B
885B
To mount the front counterweight, put the front plate into

place and tighten the nuts.
LAIL11MG1929A0A 1
LAIL11MG0659F0A 2
48050419D 06/10/2017
39.2 [39.140] / 4
Index

Front ballast - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Front ballast - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48050419D 06/10/2017
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PRINTED IN BRAZIL
48050419D 06/10/2017
EN
SERVICE MANUAL
Steering

48050419D 06/10/2017
41
Contents
Steering - 41
[41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1
48050419D 06/10/2017
41
Steering - 41
Hydraulic control components - 200

48050419D 06/10/2017
41.1 [41.200] / 1
Contents
Steering - 41
TECHNICAL DATA
Power steering control valve

Power steering control valve - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Steering circuit relief valve
Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA

Power steering control valve - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE

Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Auxiliary steering priority valve
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DIAGNOSTIC

Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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Steering - Hydraulic control components
Power steering control valve - Torque

845B
865B
885B
End cover screws

31 N·m (274 lb in)
Power steering control valve - Special tools

845B
865B
885B
600057
Eaton spring installer
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Steering circuit relief valve - Torque

845B
865B
885B
Spool bore screws

7.3 – 9.6 N·m (65 – 85 lb in)
Spool bore screws
33.9 – 54.2 N·m (300 – 480 lb in)
Adapter
8.1 – 9.5 N·m (72 – 85 lb in)
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Power steering control valve - Exploded view

845B
865B
885B
LAIL11MG1354G0A 1
1. Screw 13. Needle thrust bearing

2. End Cover 14. Bearing races
3. O-Ring 15. O-Ring
4. Gerotor 16. O-Ring
5. Spacer plate 17. Seal gland bushing
6. Drive Shaft 18. Circlip
7. Steering control housing 19. Dust cover
8. Coupling 20. Ball check
9. Spool 21. Roll pin
10. Spacer 22. Roll pin
11. Pin 23. Ball check
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12. Centering springs
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Power steering control valve - Disassemble

1. Clean the port area of the steering control valve hous-

ing before disconnecting the hydraulic lines.
2. Drain the oil, and plug the ports. Clean the exterior
of the steering control valve housing. Protect the ma-
chines surfaces during repair.
3. Secure the steering control valve in a vise (1) so that
the end cap (2) is facing upwards, see illustration 1.
Component description:
(1) Vise
(2) End cap
(3) Anti-cavitation valves LAIL11MG1351A0A 1
Check valve (4)

4. Remove the seven screws (1), the end cap (2), the
O-ring (3), the gerotor (4), the O-ring (3), the spacer
plate (5), and the O-ring (3), see illustration 4.
5. Remove the star of the gerotor (4), see illustration 4.
6. Remove the drive shaft (6), see illustration 4.
7. Remove housing from vise. Place housing on a clean
soft cloth to protect surface finish. Use a fine-blade
screwdriver to remove the retaining ring from the hous-
ing, as shown in illustration 2.
LAIL11MG1352A0A 2
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8. Rotate spool and sleeve until pin is horizontal. Push

the spool and sleeve assembly forward with your thumb
enough to free the seal gland bushing (1) from the
housing, see illustration 3. Remove the bushing.
LAIL11MG1353A0A 3
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LAIL11MG1354G0A 4
Steering control valve

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9. Remove the quad ring seal (1) from the seal gland
bushing (2).
10. Use a thin bladed screwdriver to pry dust seal from
seal gland bushing. Do not damage the bushing.
(1) Quad seal ring
(2) Seal gland bushing
(3) Dust boot
LAIL11MG1355A0A 5
11. Remove the two bearing races (1) and (3) and the
needle thrust bearing (2) from the spool and sleeve
assembly.
LAIL11MG1356A0A 6
12. Remove the spool and sleeve assembly from the

14-bore end of the housing, see illustration 7.
NOTICE: Do not push the spool and sleeve into the hous-
ing. Rotate spool slowly when removing from sleeve.
13. Push the pin (1) out of the spool and sleeve assembly.
LAIL11MG1357A0A 7
14. Partially push the spool from the control end of the
sleeve, then carefully remove the six spool centering
springs by hand, see illustration 8.
15. Push the spool back through and out of the sleeve,
see illustration 8. Slowly rotate the spool while remov-
ing it from the sleeve.
LAIL11MG1358A0A 8
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16. Remove the O-ring from the housing, see illustration

9, and the two shock valves from the cylinder bore
(adjustment screw, O-ring, spring, and check ball).
(1) O-Ring
(2) Adjustment screw
(3) O-Ring
(4) Spring
(5) Check ball
LAIL11MG1359A0A 9
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Section Drawing and Integral Valves

NOTE: The housing (7) of the steering control valve,
(shown in illustration 4), has two internal anti-cavitation
valves (EE) and one check valve (CC). Before removing
these valves, verify their positions.
17. To disassemble these valves, insert a soda straw (3)
in each end of the threaded holes, see illustration 11.
Remove the steering control valve housing from the
vise and tilt the housing until the bore face (4) is facing
upwards. Continue turning it until the roll pins (2) and
the check balls (1) slide through the straw.
LAIL11MG1360F0A 10
AA. Inlet check valve

CC. Internal check valve for limited steering
DD. Cylinder bore shock valves
EE. Anti-cavitation valves for the cylinder bores
18. Disassembly of the anti-cavitation valve.

(1) Check ball.
(2) Roll pin.
(3) Straw.
(4) Bore face.
(5) Anti-cavitation valves.
(6) Check valve.
LAIL11MG1361A0A 11
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Power steering control valve - Inspect

1. Clean all parts in cleaning solvent and air dry on paper

towels. Do not use cloths to wipe parts dry, as it may
leave lint on the parts.
2. Check all machined surfaces for wear or damage. If
there are rough points on the ends of the gerotor star or
on the gerotor (4), on the housing of the steering control
valve (7), on its end cap (2), or on the spacer plate
(5), use 600 sandpaper to smooth the surfaces, see
illustration 1. Place the emery cloth on a flat surface. If
the emery cloth is new, rub a piece of steel across the
emery cloth six times to remove the sharp pieces of grit.
Make sure that the part is held flat on the emery cloth.
Rub each part across the cloth six times. Check to
see if the rough places are removed. Use this method
until all rough places are removed. Clean the parts in
cleaning solvent to remove any grit.
3. If the spool (9) and sleeve (8) or if the bore in the steer-
ing control valve housing (7) are damaged or worn, re-
place the steering control valve with a new one, see
illustration 1.
4. Inspect the screws (1), the pin (11), the recoil washer
(15), the seal ring (16), the O-ring (17), the needle
thrust bearing (13), and the bearing races (14). Re-
place the parts as necessary, see illustration 1.
5. If your steering control valve has anti-cavitation and
check valves, inspect check balls (20) and (23) and roll
pins (21) and (22) for damage or wear. Replace the
parts as necessary, see illustration 1.
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LAIL11MG1354G0A 1
Steering control valve

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Power steering control valve - Assemble

NOTE: During reassembly of the steering control valve,

use new seals (3), (16), and (19).
NOTICE: Lubricate all of the new seals (except the new
quad seal) with petroleum jelly such as Vaseline. Do not
use excess lubricant on the seals for the meter section.
When ordering spare parts, consult the parts list that covers
your steering control unit. A good maintenance technique
is to replace all of the old seals for new seals.
1. Use a straw (3) as a guide. See illustration 1. Drop the
straw (3) to the bottom of the bore of the anti-cavitation
valves (5) and of the check valve (6). Drop the check
ball (2) through the straw (3). Pull the straw (3) out and
use the same procedure for the other ball seats.
2. Use a small flashlight and check each bore in order to
make sure that each check ball (2) is in the right place.
Add the roll pin (1) to each bore.
(1) Roll Pin
(2) Check ball
LAIL11MG0615A0A 1
(3) Straw
(4) Bore face
(5) Anti-cavitation valves
Check valve (6)
3. Assemble spool and sleeve carefully so that the spring
slots line up at the same end. Rotate spool while slid-
ing parts together. Some spool and sleeve sets have
identification marks. Align these marks as shown in il-
lustration 2. Test for free rotation. Spool should ro-
tate smoothly in sleeve with finger tip force applied at
splined end.
LAIL11MG0616A0A 2
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4. Bring spring slots of both parts in line and stand parts

on end of bench. Insert spring installation tool through
spring slots of both parts. The tool is available as part
number 600057. Position 3 pairs of centering springs
(or 2 sets of 3 each) on bench so that extended edge
is down and arched center section is together. In this
position, insert one end of the entire spring set into the
installation tool, see illustration 3.
5. Compress extended end of centering spring set and
push into spool sleeve assembly with drawing instal-
lation tool at the same time.
LAIL11MG0617A0A 3
6. Center the spring set in the parts so that they push

down evenly and flush with the upper surface of the
spool and sleeve.
7. Install the pin (1) through the spool and sleeve assem-
bly until the pin becomes flush on both sides of the
sleeve.
LAIL11MG0618A0A 4
8. Position the spool and sleeve assembly so that the

splined end of the spool enters the 14-bore end of the
housing first, see illustration 5.
NOTICE: Take great care to ensure that the parts do not
bend out of position during insertion. Push parts gently into
place with slight rotating action, keep pin nearly horizontal.
Bring the spool assembly entirely within the housing bore
until the parts are flush at the meter end or 14-bore end of
the housing. Do not pull the spool assembly beyond this
point to prevent the cross pin from dropping into the dis-
charge groove of the housing. With the spool assembly in
this flush position, check for free rotation within the housing
by turning with light finger tip force at the splined end.
LAIL11MG0619A0A 5
9. Place housing on clean, lint free cloth. Install the seal

in the housing, see illustration 6.
(1) Needle thrust bearing
(2) Seal
(3) Bearing races
LAIL11MG0620A0A 6
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10. Fit the needle bearings and two races in the order
shown in the illustration 6.
11. Install the dust shield in the seal gland bushing. The
flat or smooth side of the dust shield should be facing
down toward the bushing, see illustration 8.
12. Install the quad seal ring dry in the seal gland bushing.
Level the seal in place with your finger. Do not use
any seal that falls freely in the bushing cavity, see
illustration 11.
(1) Seal gland bushing (with seals)
LAIL11MG0621A0A 7
Retaing ring (2)
13. Install seal gland bushing over the spool end with a
twisting motion. Tap the bushing in place with a rubber
hammer. Make sure the bushing is flush against the
bearing race.
14. Install the retaining ring in the housing (see illustra-
tions 7 and 8). After installing ring, tap on ring end
to pry with screwdriver around entire circumference of
ring to property seat ring in groove.
(1) Screwdriver
(2) Dust boot
LAIL11MG0622A0A 8
Retaing ring (3)
(4) Seal gland bushing
(5) Quad seal ring
(6) Seal
15. Secure the housing in a vise, as shown in illustration
9. Clamp lightly on edges of mounting area. Do not
over tighten jaws.
NOTE: Make sure that the spool and sleeve assembly are
flush or slightly below the 14-bore surface of the housing.
NOTICE: Clean the upper surface of the housing by wiping
with the palm of clean hand. Clean each of the flat surfaces
of the meter section parts in a similar way when ready for
reassembly. Do not use cloth or paper to clean surfaces.
LAIL11MG0623A0A 9
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16. Install the seal in the housing, see illustration 10.

17. Install the spacer plate. AIign bolts holes in spacer
plate with tapped holes in housing.
LAIL11MG0624A0A 10
18. Rotate the spool and sleeve assembly until the pin is
parallel with the bore face, see illustration 11. Install
the drive shaft, making sure that it has engaged with
the pin. To ensure the correct alignment, mark the
drive shaft as shown in illustration 13 (B). Note rela-
tionship between slotted end of drive to splined end of
drive when marking.
(1) Bore face
(2) Drive shaft
(3) Pin parallel with the bore face
11
(4) Pin LAIL11MG0625A0A
19. Install the seal on the meter.

(1) Meter (gerotor)
(2) Seal
LAIL11MG0626A0A 12
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20. With seat side of meter toward spacer plate, align star
valleys (ref. A) on the drive shaft (B). Note the parallel
relationship of the reference lines (A), (B), (C), and (D)
in illustration 13. Align bolt holes without disengaging
meter from drive.
(1) Star valley of the meter (gerotor)
(2) Drive shaft (marked)
(3) Pin
(4) Bore face
LAIL11MG0653B0A 13
21. If used, install the drive shaft spacer in the meter, see
illustration 14.
22. Install seal in end cap.
23. Install end cap on gerotor, align holes.
(1) Drive shaft spacer
(2) Seal
(3) End cap
Bolt (4)
LAIL11MG0627A0A 14
24. Install 7 dry cap screws in end cap. Pre-tighten the

screws to a torque of 17 N·m (150 lb in), then tighten
them to a torque of 31 N·m (274 lb in), in the se-
quence shown in illustration 15.
LAIL11MG0628A0A 15
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Auxiliary steering priority valve - Disassemble

1. Put the steering priority valve in a soft jawed vise.

2. Remove the relief valve (1). Remove the relief valve
and discard the O-ring (2).
3. Remove plug (3). Remove and discard the O-ring from
the plug (4).
4. Remove spring (5).
5. Remove the spool (6).
6. Remove plug (7). Remove and discard the O-ring from
the plug (8).
LAIL11MG1011F0A 1
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1. Reliefvalve 6. Spool
2. O-Ring 7. Plug
3. Plug 8. O-Ring
4. O-Ring 9. Casing
5. Spring
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Auxiliary steering priority valve - Cleaning

ATTENTION: Wear eye protection when using com-

pressed air.
1. Clean all parts in cleaning solvent. Immerse the hous-
ing (9) in cleaning solvent and shake the solvent. Use
compressed air to remove foreign matter from the in-
side of the valve housing and to ensure that all of the
orifices and bores are clear.
2. Inspect the spool (6) and housing bores for deep
scratches, gouges, and other damage. Replace steer-
ing priority valve if any of these conditions are seen.
3. Check that the orifice screws in each end of spool (6)
are free and clear of foreign matter. If necessary, re-
move the orifice screws and use compressed air to re-
move foreign matter from inside the spool (6) and ori-
fice screws. Install the orifice screws in the ends of the
spool (6). Torque screws to 7.3 – 9.6 N·m (65 – 85 lb
in).
4. Check the spring (5) for cracks, breaks, or signs of per-
manent deformation. Replace if any of these conditions
are seen.
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LAIL11MG1011F0A 1
2. O-Ring 7. Plug
3. Plug 8. O-Ring
4. O-Ring 9. Casing
5. Spring
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Auxiliary steering priority valve - Assemble

1. Install a new O-ring (8) on the plug (7). Install plug and
O-ring. Tighten the plug to a torque of 33.9 – 54.2 N·m
(25 – 40 lb ft).
2. Install the spindle (6) and spring (5).
3. Install a new O-ring (4) on the plug (3). Install plug and
O-ring. Tighten the plug to a torque of 33.9 – 54.2 N·m
(25 – 40 lb ft).
4. Install a new O-ring (2) on the relief valve (1). Install
relief valve and O-ring. Tighten the plug to a torque of
33.9 – 54.2 N·m (25 – 40 lb ft).
LAIL11MG1011F0A 1
2. O-Ring 7. Plug
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3. Plug 8. O-Ring
4. O-Ring 9. Casing
5. Spring
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Power steering control valve - Troubleshooting

845B
865B
885B
NOTE: Steering problems can be corrected if the problem is properly defined. The entire steering system should be
evaluated before removing any components. The steering control unit is generally not the cause of most steering
problems. The following is a list of steering problems along with possible causes and suggested corrections.
NOTE: Thermal shock - A condition caused when the hydraulic system is operated for some time without turning
the steering wheel so that the fluid in the reservoir and system is hot and the steering control unit is relatively cool
[more than a 10 °C (50 °F) temperature differential]. When the steering wheel is turned quickly the result is temporary
seizure and possible damage to internal parts of the steering control unit. The temporary seizure may be followed by
total free wheeling.
Slow steering, hard Worn or malfunctioning pump Replace the pump
steering, or loss of power
assist
Stuck flow divider plunger Replace the flow divider
Worn pump compensator allowing the sys- Replace the pump and the compensator
tem pressure to be less than that specified
Malfunctioning relief valve allowing the sys- Replace relief valve
tem pressure to be less than that specified
Overloaded steering axle Reduce the load
If the load sensing system: Fix:
a. Is leaking or the load sensing signal line a. Check spring and sticking piston. Check
is kinked the damping orifices in both ends of the
b. Malfunctioning priority valve main bore
b. Check system pressure at SCU inlet for
proper system pressure. If it is not correct,
replace the priority valve relief cartridge
Deviation – The vehicle Air in the system due to a low oil level, cav- Correct
will not stay in a straight itating pump, leaky fittings, pinched hose,
line etc.
Worn mechanical articulation Repair or replace
Bending of the articulation or cylinder rod Repair or replace
Loose cylinder piston Repair or replace
Leaky crossover relief or anti-cavitation Repair or replace the accessory valve
valve in the cylinder lines
Severe wear in the steering control unit Replace the steering control unit
Drift – The vehicle veers The single rod end cylinder slowly extends A low extension rate may be normal on a
slowly in one direction without turning the steering wheel closed center system
Worn or damaged steering articulation Replace the articulation and align the front
Slip – A small movement Leakage of the cylinder piston seals or the Replace the seals or the accessory valve
of the steering wheel fails accessory valve between the cylinder lines
to cause any movement or cylinder bores
by the steered wheels
Worn steering control unit meter Replace the steering control unit
Temporary hard steering Thermal shock (see note) Check that the unit is working correctly and
or interruption the cause of the thermal shock
Erratic steering Air in system due to low level of oil, cavitat- Correct the problem and top up the fluid
ing pump, leaky fitting, pinched hose, etc. level
Loose cylinder piston Replace cylinder
Thermal shock damage (see note) Replace the steering control unit
Sticking flow control spool Replace the flow control valve
"Spongy" or soft steering Air in hydraulic system. Most probably air Bleed the air out of the system. Placing the
trapped in the cylinders or in the lines bores on top of the cylinder will help prevent
air from becoming trapped
Low fluid level Add fluid and check for leaks
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Free wheeling - The The steering column upper shaft is loose or Tighten the steering wheel nut
steering wheel turns damaged
freely with no feeling of
pressure and no action on
the steered wheels
The lower splines of the column may be Repair or replace the column
disengaged or broken
Steering control unit meter has a lack of oil. Usually, starting the engine will cure the
This can happen on start-up, after repairs, problem
or after long periods without use
No flow to steering unit can be caused by: Correct:
a. Low fluid level a. Add fluid and check for leaks
b. Ruptured hose b. Replace the hose
Tractors with turbocharged engines Inter- Tractors with turbocharged engines Re-
nal steering control unit damaged due to place the unit
thermal shock (see note)
Free wheeling - The Leaky crossover relief or anti-cavitation Repair or replace the accessory valve
steering wheel turns valve in the cylinder lines
with slight resistance
but results in little or no
action on the steered
wheels
Damaged plunger seal Determine cause. Correct and replace the
seal
The steering wheel has The steering wheel nut is loose Repair or replace the steering wheel con-
excessive play nection or column
Steering column shaft worn or damaged. Repair or replace the steering wheel con-
There should be very little free play in the nection or column
unit itself
The steering wheel has Broken or worn articulation between the Check for loose anchor points and bearing
excessive play cylinder and the steered wheels fittings in the steering articulation between
the cylinder and the steered wheels
Leaky cylinder seals Replace the cylinder seals
Steering wheel crooked Binding or misalignment in the steering col- Align the column pilot and spline to the
or not centralized umn or splined input connection steering control unit
High back pressure in tank line can cause Review the circuit return line
slow return to center. Must not exceed
300 psi.
Large particles can cause binding between Clean the unit and filter the oil. If another
the spool and the sleeve component has failed, generating contami-
nants, flush the system while bypassing the
steering control unit
The steering control unit Large particles in meter section. Clean the unit.
locks up
Insufficient hydraulic force Check hydraulic power supply.
[units above 245.8 cm³ (15 in³)].
Severe wear and/or broken pin. Replace the unit.
Thermal shock (see note) Replace the unit.
The steering wheel Parts assembled wrong. Correct.
oscillates or turns by
itself
Steering unit improperly timed. Correct timing.
Lines connected to wrong ports. Reconnect lines correctly.
The steered wheels turn Lines connected to wrong cylinder ports. Reconnect the lines to the correct ports.
in the wrong direction
when the operator turns
the steering wheel
The steering wheel kicks No inlet check valve on steering control Install a check valve.
at the start of steering unit.
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Index
Steering - 41

Auxiliary steering priority valve - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Auxiliary steering priority valve - Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Auxiliary steering priority valve - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Power steering control valve - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Power steering control valve - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Power steering control valve - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Power steering control valve - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Power steering control valve - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Power steering control valve - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Power steering control valve - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Steering circuit relief valve - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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PRINTED IN BRAZIL
48050419D 06/10/2017
EN
SERVICE MANUAL
Cab climate control

48050419D 06/10/2017
50
Contents
Cab climate control - 50
[50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1
[50.104] Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2
[50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.3
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Heating - 100

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Contents
Heating - 100
SERVICE
Heater core
Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Heater control valve
Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Heater coolant return lines
- Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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Cab climate control - Heating
Heater core - Replace

1. Close hot water taps (1) and (2) in the engine compart-
ment.
LAIL11MG1703A0A 1
LAIL11MG1918A0A 2
LAIL11MG1967A0A 3
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2. Using a 13 mm wrench, loosen and remove the bolts

(3) and the right protective cover from the chassis.
LAIL11MG1697A0A 4
3. Locate spring clamps (4) and (5) that hold the heating
hose to the floor of the machine and, using suitable
pliers, move the clamps onto the body of the heating
hose.
4. Without using the wrench, remove the heating hoses
from the heater pipes.
5. Using a 13 mm wrench (some models use an 8 mm
Allen key), loosen and remove the bolts that hold the
driver's seat to the cover of the evaporator box, remov-
ing the seat.
6. Using a 13 mm wrench, loosen the bolts that fix the
cover of the evaporator box, removing the cover. LAIL11MG1471A0A 5
7. Remove the seal mass from the heater and evapora-

tor tubes, thermostat bulb and disconnect the electrical
terminals from the thermostat, see figure 6.
LAIL11MG1877A0A 6
8. Using a Philips screwdriver, loosen and remove the two

screws (6) that hold the evaporator casings.
LAIL11MG2017A0A 7
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9. Locate and loosen, using a 10 mm wrench, the four

bolts (7) that hold the evaporator box side finish, see
figures 8 and 9, removing the finish. Access to these
four bolts is via the right maintenance cover and from
the inside of the cab, see figures 10 and 11.
LAIL11MG2018A0A 8
LAIL11MG2019A0A 9
LAIL11MG1472A0A 10
LAIL11MG2020A0A 11
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10. Using a 10 mm wrench, loosen the two nuts (8) that

hold the heater/evaporator assembly.
LAIL11MG1968A0A 12
11. Without using any tools, remove the heater.

12. After the replacement, follow the previous stages in
reverse order to install the component.
NOTE: If water is lost from the engine cooling system, use
the recommended quantity to top up the level.
LAIL11MG1878A0A 13
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Heater core - Replace

865B ANZ (8 x 8 direct drive) OR (6 x 3 torque converter) OR (Tier 3-VHP) OR
(AWD) --- APAC (8 x 8 direct drive) OR (6 x 3 torque converter) OR (Tier
3-VHP) OR (AWD) --- LA (8 x 8 direct drive) OR (6 x 3 torque converter)
OR (Tier 3-VHP) OR (AWD) --- MEA (8 x 8 direct drive) OR (6 x 3 torque
converter) OR (Tier 3-VHP) OR (AWD) --- NA (8 x 8 direct drive) OR (6 x
3 torque converter) OR (Tier 3-VHP) OR (AWD)
ment.
LAIL11MG2077A0A 1
LAIL11MG1476A0A 2
LAIL11MG1972A0A 3
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LAIL11MG1697A0A 4
3. Locate spring clamps (4) and (5) that hold the heating
pliers, move the clamps onto the body of the heating
hose.
4. Without using the wrench, remove the heating hoses
from the heater pipes.
LAIL11MG1471A0A 5

operator's seat to the cover of the evaporator box, re-
moving the seat.
cover of the evaporator box, removing the cover.
7. Remove the seal mass from the heater and evapora-
tor tubes, thermostat bulb and disconnect the electrical
terminals from thermostat, see figure 6.
LAIL11MG1877A0A 6
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screws (6) that hold the evaporator casings.
LAIL11MG2017A0A 7
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9. Locate and loosen, using a 10 mm wrench, the four

bolts (7) that hold the evaporator box side finish, see
figures 8 and 9, removing the finish. Access to these
four bolts is via the right maintenance cover and from
the inside of the cab, see figures 10 and 11.
LAIL11MG2018A0A 8
LAIL11MG2019A0A 9
LAIL11MG1472A0A 10
LAIL11MG2020A0A 11
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10. Using a 10 mm wrench, loosen the two nuts (8) that

hold the heater/evaporator assembly.
LAIL11MG1968A0A 12
11. Without using any tools, remove the heater.
LAIL11MG1878A0A 13
12. After the replacement, follow the previous stages in

reverse order to install the component.
NOTE: If water is lost from the engine cooling system, use
the recommended quantity to top up the level.
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Heater control valve - Replace

ment.
LAIL11MG1703A0A 1
LAIL11MG1918A0A 2
LAIL11MG1967A0A 3
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LAIL11MG1697A0A 4
3. Using a 1/4 in wrench, loosen the valve screw (4) that

secures the steel cable to the valve body and remove
the steel cable and the valve.
screws that fix the valve on the support on the ma-
chine's chassis.
LAIL11MG2016A0A 5
5. Locate the spring-type clamps (5) and (6) that secure

the heating hoses to the hot water valve under the
floor of the machine and, using suitable pliers, move
the clamps toward the body of the hose, removing the
valve.
NOTE: To fit and adjust the cable, check that the heater
selector on the control panel is in the maximum cold posi-
tion (lower left blue region) and that the valve is completely
closed. Failure to adjust the cable will result in the air con-
ditioning not working properly.
If water is lost from the engine cooling system, use the
recommended quantity to top up the level.
LAIL11MG1475A0A 6
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Heater control valve - Replace

ment.
BRCE12GRCCM017A 1
LAIL11MG1476A0A 2
BRCE12GRCCM018B 3
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LAIL11MG1697A0A 4
3. Using a 1/4 in wrench, loosen the valve screw (4) that

secures the steel cable to the valve body and remove
the steel cable and the valve.
screws that fix the valve on the support on the ma-
chine's chassis.
LAIL11MG2016A0A 5
5. Locate the spring-type clamps (5) and (6) that secure

the heating hoses to the hot water valve under the
floor of the machine and, using suitable pliers, move
the clamps toward the body of the hose, removing the
valve.
closed. If the cable is not adjusted, the air conditioning will
not function correctly.
LAIL11MG1475A0A 6
In case of loss of water from the engine cooling system,

use the recommended amount to top up the level.
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Heater coolant return lines - Replace

Stages 1 and 2 apply to the replacement of all heating

hoses. If water is lost from the engine cooling system,
follow the machine manufacturer's recommendations to
top up the level. Use the same path for the replaced
hose in each case.
ment.
LAIL11MG1703A0A 1
LAIL11MG1918A0A 2
LAIL11MG1967A0A 3
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LAIL11MG2063A0A 4
3. Replacing the heater valve heating hose:

A. Locate the spring clamp (4) that holds the heating
pliers, move the clamp onto the body of the hose.
B. Without using the wrench, remove the heating
hose from the heater pipe.
C. Using a Philips screwdriver, loosen and remove
the two screws that fix the valve on the support on
the machine's chassis.
D. Locate the spring clamp (5) that holds the heating
pliers, move the clamp onto the body of the hose. LAIL11MG2064A0A 5
E. Without using the wrench, remove the heating

hose from the heat valve and remove the hose.
F. After the replacement, follow the previous stages
in reverse order to install the component.
LAIL11MG1475A0A 6
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4. Replace the hose from the heat valve to the hot water
tap on the engine:
A. After carrying out Stages 1 and 2, using a Philips
screwdriver, loosen and remove the two screws
that fix the valve on the support on the machine's
chassis.
B. Locate the spring clamp (6) that holds the heating
C. Without using the wrench, remove the heating
hose from the heat valve.
D. Locate the spring clamp (7) that holds the hot water LAIL11MG2065A0A 7
tap heating hose to the machine engine and, using
suitable pliers, move the clamp onto the body of
the hose.
hose from the hot water tap and remove the hose.
LAIL11MG2066A0A 8
5. Replacing the hose on the hot water tap from the en-
gine to the heater:
A. After following Steps 1 and 2, locate the spring
clamp (8) that holds the hot water tap heating hose
to the machine engine and, using suitable pliers,
move the clamp onto the body of the hose.
hose from the hot water tap.
C. Locate the spring clamp (9) that holds the heating
hose and, using suitable pliers, move the clamp
onto the body of the hose.
D. Without using the wrench, remove the heating LAIL11MG2067A0A 9
hose from the heater pipe and remove the hose.
E. After the replacement, follow the previous stages
LAIL11MG2068A0A 10
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Heater coolant return lines - Replace

Stages 1 and 2 apply to the replacement of all heating

hoses. If water is lost from the engine cooling system,
follow the machine manufacturer's recommendations to
top up the level. Use the same path for the replaced
hose in each case.
ment.
LAIL11MG2077A0A 1
LAIL11MG1476A0A 2
LAIL11MG1972A0A 3
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LAIL11MG1697A0A 4
3. Replacing the heater valve heating hose:

A. Locate the spring clamp (4) that holds the heating
hose from the heater pipe.
C. Using a Philips screwdriver, loosen and remove
the two screws that fix the valve on the support on
the machine's chassis.
D. Locate the spring clamp (5) that holds the heating
pliers, move the clamp onto the body of the hose. LAIL11MG1471A0A 5

hose from the heat valve and remove the hose.
LAIL11MG1475A0A 6
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4. Replace the hose from the heat valve to the hot water
tap on the engine:
A. After carrying out Stages 1 and 2, using a Philips
screwdriver, loosen and remove the two screws
that fix the valve on the support on the machine's
chassis.
B. Locate the spring clamp (6) that holds the heating
C. Without using the wrench, remove the heating
hose from the heat valve.
D. Locate the spring clamp (7) that holds the hot water LAIL11MG1475A0A 7
tap heating hose to the machine engine and, using
suitable pliers, move the clamp onto the body of
the hose.
hose from the hot water tap and remove the hose.
LAIL11MG1476A0A 8
5. Replacing the hose on the hot water tap from the en-
gine to the heater:
A. After following Steps 1 and 2, locate the spring
clamp (8) that holds the hot water tap heating hose
to the machine engine and, using suitable pliers,
move the clamp onto the body of the hose.
hose from the hot water tap.
C. Locate the spring clamp (9) that holds the heating
hose and, using suitable pliers, move the clamp
onto the body of the hose.
D. Without using the wrench, remove the heating LAIL11MG1471A0A 9
hose from the heater pipe and remove the hose.
E. After the replacement, follow the previous stages
LAIL11MG1973A0A 10
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Index
Heating - 100
Heater control valve - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Heater control valve - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Heater coolant return lines - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Heater coolant return lines - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Heater core - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Heater core - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Ventilation - 104

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Contents
Ventilation - 104
SERVICE
Air filter
Replace /Clean (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Recirculation filter - Replace /Clean (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Cab climate control - Ventilation
Air filter - Replace /Clean

1. Open the access cover (1) to the filter on the outer

left-hand side of the cab.
LAIL11MG1689A0A 1
2. Loosen the knob (2) for the external air filter cover with-
out using a wrench.
LAIL11MG1690A0A 2
3. Remove the cylindrical air filter (3) and clean/replace.

NOTE: To clean, use a jet of air in a direction counter to
the flow, i.e. position the jet at the center of the filter.
LAIL11MG1691A0A 3
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4. Before fitting the filter, the filter housing has to be

cleaned.
LAIL11MG1692A0A 4
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Air filter Recirculation filter - Replace /Clean

1. Position the operator's seat (1) to its maximum forward

adjustment.
LAIL11MG1965A0A 1
2. Locate and loosen the two fixing handles (2) and (3)
of the internal air filter located in the rear part of the
evaporator box without needing to use a wrench.
LAIL11MG1966A0A 2
LAIL11MG1693A0A 3
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3. Remove the air filter (4) and clean/replace it.

NOTE: To clean, use water or a jet of air against the flow,
i.e. position the jet on the inner face of the filter.
4. Before fitting the filter, the filter housing has to be
cleaned.
LAIL11MG1694A0A 4
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Index
Ventilation - 104
Air filter - Replace /Clean (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Air filter Recirculation filter - Replace /Clean (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Air conditioning - 200

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Contents
TECHNICAL DATA
Air conditioning
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
Air conditioning
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Overview (Refrigerant recycling and recovery station - 294048) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Overview (Refrigerant charge and vacuum station - 380000315) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SERVICE
Air conditioning
Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Service instruction (Air-conditioning system update - Introduction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Service instruction (Air-conditioning system update - Safety procedures) . . . . . . . . . . . . . . . . . . . . . . . . . 14
Prepare (Air-conditioning system update - Preparation of the system before an update) . . . . . . . . . . . . 15
Inspect (Air-conditioning system update - Inspection of the system before an update) . . . . . . . . . . . . . . 17
Service instruction (Air-conditioning system update - General refrigerant update procedure) . . . . . . . . . 19
Install (Air-conditioning system update - Low pressure switch installation) . . . . . . . . . . . . . . . . . . . . . . . . . 23
Service instruction (Air-conditioning system update - General care in the system update) . . . . . . . . . . . 24
Tool description (Refrigerant recycling and recovery station - 294048) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Replace (Refrigerant recycling and recovery station - 294048) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Replace (Refrigerant recycling and recovery station - 294048) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Recover (Refrigerant recycling and recovery station - 294048) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Tool description (Refrigerant charge and vacuum station - 380000315) . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Check (Refrigerant charge and vacuum station - 380000315) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Charging (Refrigerant charge and vacuum station - 380000315) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Install (Heating and air-conditioning system performance improvement kit) . . . . . . . . . . . . . . . . . . . . . . . . 43
Test (Heating and air-conditioning system performance improvement kit) . . . . . . . . . . . . . . . . . . . . . . . . . 54
Air-conditioning compressor
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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Receiver-dryer
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Air-conditioning compressor lines
Air-conditioning compressor lines - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Air-conditioning condenser
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Air-conditioning evaporator
- Replace (Evaporator, expansion valve and thermostat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Replace (Blowers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
DIAGNOSTIC
Air conditioning
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
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Cab climate control - Air conditioning
Air conditioning - General specification

Normal operating conditions for the air conditioning system
There is specific operating data for each type of system
for a determined condition tested in the laboratory or field,
which will be difficult to obtain on a day-to-day basis from
technical assistance. The information below is somewhat
generic, but will help to diagnose possible problems in the
system.
• Suction pressure (low): 6 – 30 psi

• Discharge pressure (high): as in the table (these values
may vary around 30 psi or more above or below the
recommended bands).
• Air outlet temperature in the diffusers: 2 – 14 °C.
Pressure Pressure
Ambient recommended recommended
temperature minimum maximum
discharge discharge
21 °C 126 psi 166 psi
22 °C 129 psi 169 psi
23 °C 133 psi 173 psi
24 °C 137 psi 177 psi
25 °C 140 psi 180 psi
26 °C 143 psi 183 psi
27 °C 147 psi 187 psi
28 °C 151 psi 191 psi
29 °C 155 psi 195 psi
30 °C 159 psi 199 psi
31 °C 164 psi 204 psi
32 °C 168 psi 208 psi
33 °C 173 psi 213 psi
34 °C 177 psi 217 psi
35 °C 182 psi 222 psi
36 °C 186 psi 226 psi
37 °C 190 psi 230 psi
38 °C 195 psi 235 psi
39 °C 200 psi 240 psi
40 °C 205 psi 245 psi
41 °C 210 psi 250 psi
42 °C 215 psi 255 psi
43 °C 220 psi 260 psi
44 °C 225 psi 265 psi
45 °C 230 psi 270 psi
46 °C 236 psi 276 psi
47 °C 242 psi 282 psi
48 °C 248 psi 288 psi
49 °C 254 psi 294 psi
50 °C 260 psi 300 psi
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Recommendations
Aggressor agents (chemical products used to clean the
engine) may attack the belt and cause noise.
When the system has to be cleaned (oil contamination),

suitable equipment and fluids must be used. The com-
pressor and the expansion valve need to be removed.
NOTICE: The coolant gas or fluid used to clean the air
conditioner must never be released into the atmosphere.
Suitable equipment must be used to collect these agents.
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Air conditioning - Exploded view
LAIL11MG1595H0A 1
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LAIL11MG1583F0A 2
1. Compressor assembly 24 V 23. Evaporator/compressor hose

2. Compressor 24. O-ring # 6 (7.65 x 1.78)
3. Compressor connection 25. O-ring # 8 (10.82 x 1.78)
5. Box assembly HVAC 26. O-ring # 10 (14.00 x 1.78)
6. Motor actuator 24 V with wiring harness 27. Liquid reservoir assembly
7. Centrifuge electro fan 24 V 28. Liquid reservoir
8. Heating 29. Binary high/low female pressure switch
9. Rounded diffuser 4 in 30. Clamp assembly
10. Plastic knob, M6 x 13 31. Air conditioning control panel assembly
11. PVC hose, crystal, 1/2 x 2.0 for drain 32. HVAC Panel
12. Box electric wiring harness HVAC 33. Panel frame
13. Motor actuator wiring harness 34. Panel electric wiring harness
14. Universal auxiliary relay 24 V – 40 A 35. Cable with doubled conduit
15. Recirculating filter 36. Plastic heating valve with support
16. Termostat/Thermostat 37. Heating hose 5/8 in x 250 mm
17. Evaporator 38. Heating hose 5/8 in x 2400 mm
18. Expansion valve 39. Heating hose 5/8 in x 2550 mm
19. Mounted condenser 40. Transparent polyurethane flexible tube 4 in x 60 mm
20. Compressor/condenser hose 41. PVC flexible tube, 2 1/2 in x 1200 mm
21. Condenser/reservoir hose 42. Worm gear bolt clamp 2.5 in
22. Reservoir/evaporator hose 43. Worm gear bolt clamp 4 in
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Air conditioning - Exploded view
BRCE12GRCCM019A 1
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LAIL11MG0887F0A 2
1 Compressor assembly 24 V 23 Evaporator/compressor hose

2 Compressor 24 O-ring # 6 (7.65 x 1.78)
3 Compressor connection 25 O-ring # 8 (10.82 x 1.78)
4 Belt, 13AV 1300 26 O-ring # 10 (14.00 x 1.78)
5 Box assembly HVAC 27 Liquid reservoir assembly
6 Motor actuator 24 V with wiring harness 28 Liquid reservoir
7 Centrifuge electro fan 24 V 29 Binary high/low female pressure switch
8 Heating 30 Clamp assembly
9 Rounded diffuser 4 in 31 Air conditioning control panel assembly
10 Plastic knob, M6 x 13 32 HVAC Panel
11 PVC hose, crystal, 1/2 x 2.0 for drain 33 Panel frame
12 Box electric wiring harness HVAC 34 Panel electric wiring harness
13 Motor actuator wiring harness 35 Cable with doubled conduit
14 Universal auxiliary relay 24 V – 40 A 36 Plastic heating valve with support
15 Recirculating filter 37 Heating hose 5/8 in x 250 mm
16 Termostat/Thermostat 38 Heating hose 5/8 in x 2400 mm
17 Evaporator 39 Heating hose 5/8 in x 2550 mm
18 Expansion valve 40 Transparent polyurethane flexible tube 4 in x 60 mm
19 Mounted condenser 41 PVC flexible tube, 2 1/2 in x 1200 mm
20 Compressor/condenser hose 42 Worm gear bolt clamp 2.5 in
21 Condenser/reservoir hose 43 Worm gear bolt clamp 4 in
22 Reservoir/evaporator hose
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Air conditioning - Overview (Refrigerant recycling and recovery

station - 294048)
COIL15GRD0121FA 1
Refrigerant recycling and recovery station
1. Cylinder pressure gauge 12. Red service tubing for connection with the
2. Recovery pressure control manometer compressor (discharge side).
3. Anti-acid and decontamination filter 13. Oil discharge valve of the recovery compressor
4. Recovered refrigerant/oil distillation cylinder 14. Recovery compressor service valve (suction).
5. Switch
6. Control valve of the refrigerant gas inlet (LOW) 15. Humidity indicator
7. Recovered oil discharge valve (yellow) 16. Yellow service tubing for refrigerant transfer
17. Connection for refrigerant transfer
8. Recovered oil discharge tubing 18. Refrigerant transfer valve (REF)
9. Oil return-to-compressor control valve (yellow) 19. Refrigerant gas cylinder
20. Safety valve
10. Quick hitch mount connectors 21. Yellow cylinder discharge valve (gas phase)
11. Blue service tubing for connection with the
compressor (suction side)
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Air conditioning - Overview (Refrigerant charge and vacuum station

- 380000315)
COIL15GRD0122FA 1
Refrigerant charge and vacuum station
1. Safety valve 17. Blue service tubing for connection with the side of
2. Cylinder pressure gauge the compressor connection
3. Refrigerant charge valve 18. Oil drain plug
4. Low pressure side valve (LOW) 19. ON/OFF switch (I), heater (II)
5. Low pressure switch 20. Oil meter connector
6. High pressure gauge (red) 21. Vacuum pump
7. 5-way pressure gauge manifold 22. High pressure side valve (HIGH)
8. Vacuum meter 23. Sight glass
9. Vacuum test valve (Vac) 24. Yellow service tubing
10. Vacuum meter test valve 25. Cylinder heater
11. Vacuum meter safety valve 26. Outer ring
12. Oil charge valve 27. Refrigerant transfer valve (REF)
13. Oil fill cap 28. Connector for refrigerant transfer
14. Sight glass 29. Glass dipstick
15. Red service tubing for connection with the 30. Outer housing (acrylic)
discharge side of the compressor 31. Refrigerant charge valve
16. Quick hitch mount connectors
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Air conditioning - Service instruction

Before carrying out maintenance work or repairing the air-conditioning system, it is important to observe the
following items:
1. Make that the machine is shut down. Place a notice on the panel that says that the machine is under
maintenance. If possible, the maintenance mechanic should retain the master key so that no one can start the
machine at the wrong time. When you service the electrical part, you should disconnect the battery negative
cable to prevent electric shock.
2. Wait the necessary time for the condenser, compressor, and engine parts to cool, if working on these parts.
3. When the coolant charge has to be removed from the system, use suitable equipment to collect it. Do not
release coolant gas into the atmosphere. Charging the system with coolant gas:
a. Run an integrity test on all system components that were replaced and repaired.
Option 1: charge the system with 50 g of gas R134a and inject nitrogen up to a pressure of 150 psi. Use an
electronic leak detector. Correct the leak (if there is one).
Option 2: pressurize the system with nitrogen to 250 psi. Wait 15 min, confirm that the pressure has
remained stable at 250 psi, and apply water with detergent to the connection points between the
components, principally those that were repaired or replaced. Correct the leak (if there is one).
Option 3: if the pressurization equipment required in the previous options is not available, the vacuum
creation step can be used. After doing this, wait 20 min and check that the pressure has changed. If
there have been significant leaks, the pressure will be close to 0 psi. NOTE: This procedure does not
detect small leaks.
b. Add the correct amount of synthetic lubricating oil PAG 46 for the components repaired or replaced.
Compressor: if the compressor is replaced (before removing it, connect the air conditioning with the engine
idling for 5 min), drain the oil from the used compressor, and measure the amount. Drain the oil from the
new compressor and replace the same amount measured in the used compressor. If the used compressor
has been damaged due to a lack of oil (no oil drains out), refill 60 ml of oil in the new compressor. Other
components: Evaporator ( 40 ml), Condenser ( 50 ml), Liquid reservoir ( 30 ml), and Hose ( 20 ml).
If there has been wear to any air conditioning component (normally the compressor) with the release of
solid contaminants, after it is replaced and before charging the system, the components must be cleaned
internally using suitable liquid (for example R141b). The system also needs to be cleaned if the oil has been
contaminated. In these two cases, the liquid reservoir must be replaced.
c. Create a vacuum for at least 30 min (minimum of 26 in Hg). Never carry out a coolant charge without
producing a vacuum, and never produce a vacuum without the suitable equipment (vacuum pump of at
least 2 cfm or machine). In some circumstances the air-conditioning compressor itself may be used to
produce the vacuum.
d. Using the appropriate equipment (charging machines, balances, dosage bottles) charge the system with
1650 – 1750 g of coolant gas R134a . If the charge is via the liquid line, the compressor shaft must be turned
by hand (by the magnetic clutch plate) at least 3 complete turns.
NOTICE: Both coolant gas R134a and liquid R141b, when in contact with the skin or eyes, can cause frostbite.
Contact with the eyes: wash immediately with copious amount of water for 15 min and contact a doctor immediately
Contact with the skin: wash with water and apply treatment for burning, if necessary. Contact a doctor.
Excessive inhalation: keep calm. Remove personnel to a ventilated location. If they are not breathing, give artificial
respiration. If they are having difficulty breathing, give oxygen. Contact a doctor.
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Air conditioning - Service instruction (Air-conditioning system

update - Introduction)
The air-conditioning system update kit is compatible
with HFC 134A refrigerant.
If the machine on which you are installing the kit has
been updated from R-12 to HFC 134A refrigerant,
you only need to install the compressor, the mounting
bracket, and the service connection adapters. How-
ever, it is a good service practice to also replace the
receiver-drier, the pressure switch, and the sealing
O-rings when you install a new compressor.
If the machine is still equipped with R-12 refrigerant, it
should be updated to HFC 134A. The compressor in the
kit is only compatible with HFC 134A refrigerant. In this
case, see the machine model-specific table of R-12 to
HFC 134A replacement parts, with regard to the list of
components that must be replaced.
It is extremely important that the safety procedures are
followed to protect your eyes and skin from contact with
the refrigerant gas. See the safety procedures below.
Before you install the update kit, carefully inspect the
machine's air-conditioning system.
See "Preparation of the air-conditioning system before
an update" in Air conditioning - Prepare (Air-condi-
tioning system update - Preparation of the system
before an update) (50.200). See "Inspection of the
air-conditioning system before an update" in Air condi-
tioning - Inspect (Air-conditioning system update -
Inspection of the system before an update) (50.200)
A proper inspection, repair, and/or replacement of worn
or failed components ensures that the system operates
correctly once updated.
After you inspect the system, follow the update pro-
cedure of this installation instruction. Note the list of
original air-conditioning system components for the ma-
chine. This information should provide enough data to
perform the installation. You can also see the Machine
Repair Manual to obtain additional information about re-
covery techniques and refrigerant charge procedures.
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update - Safety procedures)
ATTENTION: See the following important safety information and instructions. Carefully read the following guidelines.
Be alert to the possibility of personal injury or death. Only certified technicians trained in the procedures for operation
of refrigerant recovery devices are qualified to perform the following upgrade operations.
1. Always wear safety goggles when you perform any ser-
vice or maintenance work near an air-conditioning sys-
tem. The refrigerant gas may cause serious injuries if
it comes into contact with your eyes. If the refrigerant
comes in contact with your eyes or the areas around
your eyes:
A. Flush your eyes with water for 15 min.
B. See a doctor immediately.
2. Refrigerant can cause frostbite. If the coolant comes
into contact with your skin, treat the injury as frostbite
or see a doctor.
3. Keep refrigerant containers in the upright position. Al-
ways keep refrigerant containers away from heat and
sunlight. The pressure in a container will increase with
heat.
4. Before you perform any welding or steam cleaning in
the areas near the air-conditioning system, recover the
refrigerant from the system.
5. Always check the temperature and the static pressure
of the air-conditioning system before you recover refrig-
erant, or when you test the system.
6. Poisonous gas may form when refrigerant comes in
contact with an open flame or an extremely hot surface.
Never inhale these fumes.
7. Never check for leaks with compressed air or with a
flame. Tests have shown that compressed mixtures of
air and HFC 134A can form a combustible gas.
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Air conditioning - Prepare (Air-conditioning system update -

Preparation of the system before an update)
NOTE: For the best results, the update procedures should be performed in covered workshops, at an ambient tem-
perature above 22 °C.
1. Use a refrigerant identifier to determine the type and
quality of refrigerant gas in the system.
ATTENTION: Refrigerant contamination has become an is-
sue since the introduction of HFC 134A as a replacement
for the R-12 refrigerant. Contamination refers to a mixture
of refrigerants and/or a mixture of alternative refrigerants
with HFC 134A. Contamination also refers to an excessive
amount of non-condensables (air) in the system. If you find
a contamination level of 2% or greater, do not recover the
refrigerant from the system into a reservoir that contains
pure HFC 134A refrigerant. Recover the contaminated re-
frigerant into a tank reserved for this.
NOTE: Check with your local environmental agency for
regulations on the proper disposal of contaminated refrig-
erant.
NOTE: To ensure the purity of the different refrigerants
used in vehicular air-conditioning systems, use separate
service equipment for HFC 134A refrigerant and R-12 re-
frigerant.
2. Repair any issues or leaks before you update the sys-
tem. If you require spare parts in addition to those spec-
ified in the update procedures, see the list of original
parts of the air-conditioning system of your machine.
Use parts compatible with HFC-134A, whenever pos-
sible. See the Repair Manual for additional information
about the procedures.
Make sure that your machine is updated. Take into
account all of the Service Bulletins issued for the air
conditioning system.
If the air-conditioning system has suffered a cata-
strophic failure, clean the system completely with a
flushing procedure.
3. Check the cab recirculation and fresh air filters. For
optimum cooling performance of the air-conditioning
system, clean or replace the dirty or damaged filters.
Check the heater and evaporator core. Clean the cores
if they are excessively dirty or clogged.
4. Start the machine's engine. Allow the engine to idle.
Turn on the air-conditioning system fan at the highest
speed for 10 minutes to maximize the amount of oil
in the compressor. If you perform the update in cold
weather (see the note at the beginning of the prepa-
ration instructions), turn on the heater and wait for the
heater to produce warm/hot air before you operate the
air-conditioning system. Then set the air conditioning
controls to recirculation mode. This will produce an ap-
propriate heat load for the evaporator.
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5. Use service equipment for R-12 to recover all of the

R-12 refrigerant (when possible) from the air-condition-
ing system of the machine. Excess levels of R-12 can
cause contamination or damage to the system. Make
a minimum vacuum of 750.0 mm (29.5 in) of mercury
in the air-conditioning system for at least 1.5 hours to
remove as much R-12 as possible from the mineral oil
residue.
6. Remove all of the R-12 service equipment.
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Air conditioning - Inspect (Air-conditioning system update -

Inspection of the system before an update)
ATTENTION: Read "General procedure to update from R-12 refrigerant to HFC 134A refrigerant" in Air conditioning
- Service instruction (Air-conditioning system update - General refrigerant update procedure) (50.200) before
you carry out the inspection. Some components in this list must be replaced during the machine update. Unless
otherwise specified in the procedures, replace any components that are not in good condition with a new part of the
same number.
ATTENTION: Make sure to use only recommended CASE CONSTRUCTION components in the maintenance of the
machines. Other components may not be compatible with the CASE CONSTRUCTION system. Those components
may not work reliably. Please see the list of original parts of the air-conditioning system to obtain the correct part
numbers.
NOTE: Any leak in the system must be repaired before you assemble the update kit.
1. Inspect the compressor belt.
Make sure that the belt is properly tensioned. If neces-
sary, replace the belt. If you install a new compressor
that is compatible with HFC 134A, you may also need
a new compressor belt. This is due to the difference in
diameter of the clutches between the new compressor
and the original R-12 compressor.
2. Inspect the heat exchangers.
Check the condition of the air-conditioning condenser,
hydraulic fluid and transmission fluid radiators, and the
engine water radiator. Make sure that no dirt, dust, or
other material clogs the fins. Straighten any fins that
are bent. This will improve the air flow and the cooling
performance of the system. Check for corrosion.
3. Inspect the receiver-drier.
A new receiver-drier must be installed in all updates.
Also install a new receiver-drier each time the ma-
chine's air-conditioning system is serviced. Make sure
that the replacement receiver-drier has a yellow or light
blue label. This label indicates that the receiver-drier
is compatible with HFC 134A.
4. Inspect the hoses.
If a hose is spliced, damaged, extremely old, worn, or
in poor condition, replace the hose with a new part of
the same number. Check the hose terminals and con-
nections for corrosion or damage. If the hoses are in
good condition, you will not need to replace them. If
a new hose is requested, make sure that the hose is
equipped with the green O-ring (HNBR) (where appli-
cable). Be careful not to kink the new hose during in-
stallation. The nylon inner liner is a hard material and
can break if kinked. This causes the hose to leak.
NOTE: If no system connections are opened, then the seal
O-ring of the connection does not need to be replaced dur-
ing the update. Only the O-rings of connections that are
disassembled must be replaced. Check the condition of
the clamps used to secure the hose in its routing. If neces-
sary, replace the clamps.
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5. Inspect the evaporator.

Make sure that no dirt, dust, or other material clogs the
fins. Older machines tend to build up more dirt or other
materials that may clog the evaporator. Straighten any
fins that are bent or damaged. This will improve the air
flow and the cooling performance of the system. Check
for corrosion.
6. Inspect seals.
Make sure that all of the seals around the fan and
around the evaporator are in good condition. Deteri-
orated seals may cause the evaporator to clog. This
makes the air go around the fins of the core.
7. Inspect the thermal expansion valve.
Replace the valve if the valve is corroded or damaged,
or if your performance is compromised. Check the
O-rings of the valve. If the valves must be replaced,
install new rings of the same part number. Although
the new rings are black, they are compatible with the
HFC 134A refrigerant.
For systems without valve block.
Check the contact between temperature sensor bulb
and the surface of the evaporator hose tube. Make sure
that the surface is not corroded, oxidized, or dirty.
NOTE: The sensor should have good contact with the sur-
face to control the flow of refrigerant correctly. The sensor
must be in contact with the surface of the top half of the
hose/tube. Excess mineral oil and/or waste in the system
can accumulate at the bottom of the tube and insulate the
surface of the refrigerant tube. This changes the tempera-
ture reading of the fluid. Make sure to cover the expansion
valve and tube with clay insulation or insulation of a similar
material.
8. Inspect the thermostat switch.
Check if the capillary tube of the thermostat switch is
located in the specified area on the evaporator and has
good contact with the fins and tubes. See the repair
manual of the machine for the correct location.
9. Inspect the heater control valve.
Make sure that the heater control valve works correctly.
Even a small leak in the valve when closed (temper-
ature selector outside the red region) will significantly
reduce the air conditioning performance.
10. Inspect the air and outside air recirculation filters.
Clean the filters. If the filters are in poor condition or
very dirty, the filters must be replaced.
11. Inspect the cab fan.
Make sure that the cab fan operates satisfactorily at
all speeds.
12. Inspect the cab air vents.
Make sure that all of the vents can be opened or
closed. Replace if required.
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update - General refrigerant update procedure)
Update from R-12 refrigerant to HFC 134A refrigerant
NOTE: For best results, do not execute the update procedures at an ambient temperature below 22 °C.
ATTENTION: If genuine CASE CONSTRUCTION replacement parts are not used, other procedures may be needed
for installation. See the list of original parts of your machine's air-conditioning system.
ATTENTION: Replace the seal O-rings for R-12 refrigerant of any connection that has been disassembled (opened)
during the update with O-rings compatible with HFC 134A refrigerant (green).
NOTICE: Always wear safety goggles when you work with refrigerant.
NOTE: If the end of the hose or orifice is exposed for more than 5 minutes, it is good practice to install a plug or cap
on the connection to prevent contamination by dirt or moisture.
1. Remove the oil plug from the original compressor.
Drain all of the mineral oil from the compressor body.
Be sure to measure the amount of mineral oil drained
in cubic centimeters (cm³) or milliliters (ml)
• 1 cm³ = 1 mL
• 1 mL = 0,034 oz
• 1 oz = 29,5 cm³
NOTE: Make sure to install a plug or cap on the exposed
ends of the hoses to prevent contamination by dirt or air.
2. Drain the mineral oil through the suction and discharge
orifices of the compressor poppet. Use a socket
wrench on the retaining nut of the clutch hub to make
the axle rotate.
ATTENTION: Be sure to measure the amount of mineral
oil drained from the compressor cylinder poppet.
A typical air-conditioning system will contain approxi-
mately 250 cm³ of oil. Each component will contain the
following approximate volumes:
• Condenser = 1,7 oz or 50 cm³
• Evaporator = 1,4 oz = 40 cm³
• Receiver-drier = 0,85 oz = 25 cm³
• Each hose = 0,34 oz = 10 cm³
NOTE: For each hose drained, you will lose approximately
10 cm³ of oil. In the replacement of the receiver-drier,
you will lose approximately 25 cm³. The new Sanden®
compressor for HFC 134A holds approximately 200 cm³ of
SANDEN SP-10 LUBRICANT oil. The total capacity of the sys-
tem is 250 cm³ of SANDEN SP-10 LUBRICANT oil. Add the
volume of oil drained from the original York compressor,
hoses, receiver-drier, and other important components that
were replaced from the list above. Subtract from 250 cm³
the total volume drained from the system. Add to 200 cm³
( 200 cm³ of oil is the amount in the new Sanden® com-
pressor) to determine if the total system volume is greater
or lower than 250 cm³. If you get more than 250 cm³, then
a small amount of SANDEN SP-10 LUBRICANT oil from the
new Sanden® compressor must be removed to bring the
total amount of the system to 250 cm³. If the total is less
than 250 cm³, SANDEN SP-10 LUBRICANT oil must be added
to the system.
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3. Reinstall the compressor oil plug on the original com-

pressor. Disconnect the discharge and suction hoses
and the electrical connections from the original com-
pressor. Remove the hoses and connections from the
machine.
4. Install the mounting bracket for the Sanden® compres-
sor on the machine. Use the appropriate fasteners.
5. Install the hose connection manifold onto the Sanden®
compressor. Use the instructions and the appropriate
components.
6. Install the new Sanden® compressor onto the mount-
ing bracket. Assemble so as to guarantee a sufficient
clearance for the alignment and belt tensioning. To
accomplish this, use the oblong holes at the base of
adapter. Place washers between the lugs of the com-
pressor and the curved adapters of the assembly arms.
The combination should allow enough flexibility to align
the belt and the clearance properly.
7. Connect the suction and discharge hoses and the ser-
vice valves.
8. Remove the receiver-drier for R-12 from the machine.
Discard the receiver-drier. Allow as much as possi-
ble of the oil contained in the air conditioning hoses to
drain.
Make sure that the receiver-drier you install has a light
blue or yellow decal. This means that the receiver-drier
is compatible with HFC 134A. (See the table for re-
placement of R-12 components with HFC 134A com-
ponents for your machine, contained within this instal-
lation instruction. The table shows the list of parts that
need to be replaced in the update to HFC 134A).
NOTE: If the end of the hose or orifice are exposed for
more than five minutes, a plug or cap should be placed on
the connection to prevent contamination by dirt or moisture.
9. Replace the O-rings (black) of the connections of the
receiver-drier with O-rings approved for HFC 134A
(green). See a table of O-rings compatible with HFC
134A. Check and replace any other O-rings of connec-
tions that have been disassembled (opened).
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10. Convert the orifices of the service valves of the R-12

system so they are compatible with HFC 134A. To do
so, use the service orifice adapters from the update
kit. Thread the adaptors on the original service ori-
fices for R-12. (Top adapter – red cap, bottom adapter
– blue cap) Two types of adapters are available –
straight adapters and 90° T-adapters. Use whichever
type is more convenient for installation and removal
of the charge connections. These adapters have an
adhesive lock, so they are difficult to remove after
installation. Update adapters can be installed incor-
rectly! (See warning below). Before you install the
new adapters, the existing fittings for R-12 must be
cleaned with a solvent to remove all traces of dirt and
oil. Install and tighten the steel fittings with a torque of
14 – 16 N·m (10 – 12 lb ft).
NOTICE: Update adapters can be installed incorrectly! Ex-
treme caution: The larger adapter (red cap) is installed on
the discharge hose. The smaller adapter (blue cap) is in-
stalled on the suction hose.
NOTICE: It is very important to remove the Schrader valve
from the service orifice of the hose prior to the installation
of the adapters. The orifice will not work if the Schrader
valve is not removed!
11. For some specific models, replacement of the high
or low pressure switch with a new switch with power
drive settings compatible with a HFC 134A system is
recommended. In this case, see a machine model-
specific table of R-12 to HFC 134A replacement parts.
NOTE: Some machines require the installation of a T-fit-
ting and the addition of an electric wire when you replace
the low pressure switch. The installation procedure for the
low pressure switch is described in the section "Low pres-
sure switch installation (update to HFC 134A)" in Air condi-
tioning - Install (Air-conditioning system update - Low
pressure switch installation) (50.200).
12. Connect the HFC 134A service hoses and other
equipment. Make a minimum vacuum of 750.0 mm
(29.5 in) of mercury in the air-conditioning system for
at least 1,5 h.
13. Charge the system with HFC 134A refrigerant. The
amount of HFC 134A refrigerant required is 800 g.
14. Check the performance of the air-conditioning system
after the update. See the pressure-temperature ta-
ble for HFC 134A for the machine updated in "HVAC
system performance test procedure" in Air condition-
ing - Install (Heating and air-conditioning system
performance improvement kit) (50.200). Make sure
that the system works correctly.
NOTE: The discharge pressures in a system updated with
HFC 134A tend to be in the upper limit of the ranges spec-
ified in the troubleshooting tables. This is because the ta-
bles show the pressures for machines designed for R-12
refrigerant. HFC 134A refrigerant has higher discharge
pressures and lower suction pressures than R-12.
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15. Replace all of the informational decals for R-12 with

information about the update with HFC 134A that was
just performed. Install the update with HFC 134A de-
cal 139638A1. Make sure that the update decal is in
an obvious place to prevent future mixture of the re-
frigerants.
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Air conditioning - Install (Air-conditioning system update - Low

pressure switch installation)
Update for HFC 134A
The low pressure switch for R-12 is not sufficient for the
detection of loss of refrigerant with HFC 134A. There-
fore, a new low pressure switch should be installed.
The low pressure switch should be incorporated into the
system near the evaporator core outlet. When the sys-
tem refrigerant charge is low, the pressure in the evap-
orator falls below the acceptable level. This activates
the low pressure switch. With HFC 134A it is very im-
portant to incorporate this safety switch in the system,
especially in an update. This is so that the compressor
does not operate continuously in a vacuum, which can
cause a fault.
For installation of the low pressure switch, see Air con-
ditioning - Install (Heating and air-conditioning sys-
tem performance improvement kit) (50.200).
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update - General care in the system update)
NOTE: See figures Air conditioning - Overview (Refrigerant recycling and recovery station - 294048) (50.200)
and Air conditioning - Overview (Refrigerant charge and vacuum station - 380000315) (50.200) for the proce-
dures to follow.
Recycling of the refrigerant

ATTENTION: Carefully follow the safety instructions and the instructions for use during these operations.
Handle all parts with care. Wear safety clothing, including protective goggles, gloves, and safety footwear.
Take care in refrigerant recovery and recycling and with the vacuum stations and charging
system
ATTENTION: Do not use a recovery/recycling system or vacuum/charge system that was designed for use with a
refrigerant type other than that used in the system of the machine. Different types of refrigerant have different chemical
compositions and are incompatible.
Connection of the tubing on the recovery and charging station

NOTE: When you connect the recharging stations on the system service valves, always connect the low pressure
tubes (blue) [item (11) in Air conditioning - Overview (Refrigerant recycling and recovery station - 294048)
(50.200) or item (17) in Air conditioning - Overview (Refrigerant charge and vacuum station - 380000315)
(50.200)] on the service valve of the suction side of the compressor (S – suction). Always connect the high pressure
tubing (red) [item (12) in Air conditioning - Overview (Refrigerant recycling and recovery station - 294048)
(50.200) or item (15) in Air conditioning - Overview (Refrigerant charge and vacuum station - 380000315)
(50.200)] on the service valve of the discharge side of the compressor (D – discharge).
ATTENTION: Check the seals of the joints of the tubing [items (11), (12), and (16) in Air conditioning - Overview
(Refrigerant recycling and recovery station - 294048) (50.200) or items (15), (17), and (16) in Air conditioning
- Overview (Refrigerant charge and vacuum station - 380000315) (50.200)]. Replace the seals if they are faulty.
Remember that the sealed tubing connections should be tightened only by hand. Do not force the connections. Oth-
erwise, the seal may be damaged.
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Air conditioning - Tool description (Refrigerant recycling and

recovery station - 294048)
COIL15GRD0121FA 1
Refrigerant recycling and recovery station
1. Cylinder pressure gauge 12. Red service tubing for connection with the
2. Recovery pressure control manometer compressor (discharge side).
3. Anti-acid and decontamination filter 13. Oil discharge valve of the recovery compressor
4. Recovered refrigerant/oil distillation cylinder 14. Recovery compressor service valve (suction).
5. Switch
6. Control valve of the refrigerant gas inlet (LOW) 15. Humidity indicator
7. Recovered oil discharge valve (yellow) 16. Yellow service tubing for refrigerant transfer
17. Connection for refrigerant transfer
8. Recovered oil discharge tubing 18. Refrigerant transfer valve (REF)
9. Oil return-to-compressor control valve (yellow) 19. Refrigerant gas cylinder
20. Safety valve
10. Quick hitch mount connectors 21. Yellow cylinder discharge valve (gas phase)
11. Blue service tubing for connection with the
compressor (suction side)
Description
NOTE: The machine is designed to recover and recycle the refrigerant used in air-conditioning systems. The recov-
ered refrigerant is first subjected to an evaporation process in a special chamber to remove any traces of oil. In the
filter section, the acidity is neutralized, the moisture is absorbed, and solid particles are removed. The decontami-
nated refrigerant is then stored in the metering cylinder.
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Technical features
• Recovery compressor equipped with oil level indica-
tor, discharge valve and service connection.
• A decontamination anti-acid filter (3), with high mois-
ture absorption capacity.
• A refrigerant/oil distillation cylinder (4) with a heating
element, an automatic device for oil recovery in the
recovery station compressor, and an automatic flow
control valve for refrigerant that enters the station.
• A graduated cylinder (19) for recovered refrigerant
with a capacity of 2,2 kg, with a heater and a safety
valve.
• A 2-way pressure gauge unit, with refrigerant flow
and pressure indicator (1) and (2) for control of the
pressure in the cylinder and at the inlet.
• A humidity indicator (15) to check the decontami-
nated refrigerant.
• A low pressure switch for automatic activation of the
compressor.
• Graduated container for the discharge of recovered
contaminated oil.
• Switch (5) 1 - 0 - 2 for recovery and heating of the
cylinder.
• Operation indicator lights.
• Flexible service tubes (11), (12), and (16) with safety
valves.
• Recovery capacity: 200 g per minute.
• Supply source: 220 V ( 50 Hz).
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Air conditioning - Replace (Refrigerant recycling and recovery

station - 294048)
NOTE: See figure Air conditioning - Overview (Refrigerant recycling and recovery station - 294048) (50.200)
for the procedures to follow.
Replacement of the refrigerant decontamination filter

ATTENTION: Replace the filter (3) every 12 months. Replace the filter more frequently if the humidity indicator (15)
turns yellow (and remains this color) during the recovery/recirculation phase.
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1. Close all of the valves, including the yellow service

valve (9) installed below the distillation cylinder (4).
2. If the refrigerant is in the circuit, press the push but-
ton (5) to position “1”. Carry out the refrigerant recov-
ery operation. The compressor will stop automatically
when the pressure on the pressure gauge (2) drops to
0,3 bar.
3. Remove and replace the contaminated filter (3).
4. Perform the vacuum operation normally for approxi-
mately 30 minutes. Use the 380000315 recycling, vac-
uum, and charge system. Connect the tube (17) of
figure A Air conditioning - Overview (Refrigerant
charge and vacuum station - 380000315) (50.200) to
service valve (14). Open the valve of the tube and the
valves (4), (9), and (10) in the figure Air conditioning
- Overview (Refrigerant charge and vacuum station
- 380000315) (50.200).
Upon completion of the vacuum operation, close the
valves (4), (9), and (10) of the figure Air conditioning
- Overview (Refrigerant charge and vacuum station
- 380000315) (50.200), and the valve assembled on the
tube (17). Disconnect the tube (17).
Filter connections leak check

5. To check for leaks in the connections of the previously
replaced filter (3), open the yellow service valve (9) on
the distillation cylinder (4).
6. Perform a brief recycling operation on the refrigerant
contained in the cylinder (19). Proceed as described
in the operations 18 to 21 in Air conditioning - Re-
cover (Refrigerant recycling and recovery station
- 294048) (50.200). Use a leak detector to check for
leaks at the connections of the new filter.
7. Record the operation on the appropriate service report.
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Air conditioning - Replace (Refrigerant recycling and recovery

station - 294048)
Replacement of the compressor oil in the recovery and recycling station

ATTENTION: The oil from the compressor should be replaced with new oil every 12 months, in the recovery and
recycling station. This is to maintain the treatment capacity of the refrigerant gas and to protect the compressor.
1. Open the valve (13). Drain the oil into a container to be
disposed of in accordance with local regulations for the
disposal of oil waste.
2. Close the valve (13).
3. Remove the covers from the service valves (14) on the
side of the compressor and (13) on the sight glass.
4. Connect the service tube of the vacuum station to valve
(14). Connect a suction tube to valve (13) on the sight
glass.
5. Perform the vacuum operation with the pump in oper-
ation. The new oil can be aspirated from an external
container through the suction tube.
6. Once the compressor has been filled with the correct
quantity of oil (half the height of the sight glass) (13),
disconnect the tubing. Put the cover back on the ser-
vice valve (13). Continue to perform the vacuum oper-
ation for about 30 minutes.
7. To finish the operation, close the valves, shut down the
pump, disconnect the service tube, and put the cover
back on the service valve (14).
8. Record the operation on the appropriate service report.
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Air conditioning - Recover (Refrigerant recycling and recovery

station - 294048)
Recovery of the cab air-conditioning system refrigerant
ATTENTION: During this operation, follow the safety instructions and instructions for use described in this manual.
Handle the components with care. Wear safety clothing, including protective goggles, gloves, and safety footwear.
NOTE: The recovery operation can be performed more quickly and completely if the system is previously heated. The
heat will help the evaporation of the refrigerant and facilitate the system vacuum process.
1. If possible, run the air-conditioning system for a few
minutes with the machine engine turned on and the en-
gine hood closed. This is so that the heat produced is
gradually transferred to the various components of the
system. This allows all pockets of cold, liquid refriger-
ant within the system to evaporate.
2. Shut down the engine.
ATTENTION: Only perform the recovery operation when
the machine's engine is shut down.
3. If the charge cylinder (19) already contains a small
amount of refrigerant, check if there is still sufficient
free volume to hold all of the refrigerant in the system
(the maximum capacity is 2 kg). If not, transfer the ex-
cess refrigerant to an external cylinder, as described in
"Transfer of decontaminated refrigerant from the cylin-
der (19) to an external cylinder".
4. Connect the station's electrical plug to an electrical out-
let.
5. Make sure that all of the valves are closed except for
the service valve (9).
6. Remove the covers from the service valves installed on
the suction and discharge line of the compressor.
7. Connect the blue service tube (11) to the valve, on the
suction side (low pressure) of the compressor (marked
“S”).
8. Connect the red service tube (12) to the valve, on
the discharge side (high pressure) of the compressor
(marked “D”).
9. Turn on the cab ventilation fan at maximum speed to
assist the transfer of heat between the ambient air and
the evaporator core.
10. Open the valves (10), installed on the piping (11) and
(12).
11. Slowly open the valve (6) (low) on the pressure gauge
manifold. The pressure gauge (2) will show the pres-
sure of the refrigerant in the system. If the needle is
near "0", the system is empty.
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12. Set the switch (5) to position "1" (Recovery). The

green indicator light will illuminate. The recovery unit
compressor will be activated.
During the recovery operation, the refrigerant passes
through the distillation chamber (where the oil is sepa-
rated), the purification filter (where the majority of im-
purities are filtered), and then reaches the graduated
cylinder. The compressor will stop automatically when
the pressure on the pressure gauge (2) is at 0,3 bar.
13. Wait a few minutes to allow all of the refrigerant
residue in the system to evaporate and be removed.
14. Check the pressure (2). If the pressure rises above
the previous absolute value of 0,3 bar, the station will
automatically start a second recovery operation. If the
pressure is maintained near the value obtained during
the first recovery operation, all of the refrigerant has
been recovered and the operation is complete.
NOTE: If the station has not recovered more than 1 kg of
refrigerant after 10 minutes of operation, check the pres-
sure gauge (1). If the pressure reading is above 10 bar,
open the valve (21) and discharge the air. Make sure that
the pressure on the pressure gauge (1) does not exceed a
maximum of 10 bar throughout the recovery operation.
15. Close all of the valves except the valve (9). Discon-
nect the service tubes (11) and (12) from the air-con-
ditioning system compressor. Shut down the station.
16. Switch off the cab ventilation fan.
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Recycling of recovered refrigerant

NOTE: After completion of the recovery operation, the refrigerant must be completely purified.
ATTENTION: Recovered refrigerant must be completely purified before you can reuse it.
17. All the valves must be closed, with the exception of
valve (9). The station must be shut down. Switch (5)
must be in position "0". The green light on the indicator
must be off.
18. Connect the end of the yellow service tube (16) onto
the free connector (17) that is located on the left-hand
side of the pressure gauge manifold.
19. Connect the two ends of the yellow tube (16) and the
blue (11) tube with the connector supplied.
20. Slowly open the valve (18) (REF) and the blue valve
(6) (low) on the pressure gauge manifold. Open the
valves of the two servicing tubes that were previously
connected, (16) and (11).
21. Set the switch (5) to position "1" (Recovery). The
green indicator light will illuminate. The recovery com-
pressor will start to operate. The refrigerant will pass
from the graduated cylinder to the recovery circuit (dis-
tillation cylinder, filter, and compressor) and then re-
turn to the graduated cylinder.
22. Continue the operation until the circular sector of the
humidity indicator (15) turns green. If the circular sec-
tor of the humidity indicator (15) is still not green after
15 minutes, replace the filter (3). Follow the procedure
described in "Replacement of the refrigerant decon-
tamination filter" in Air conditioning - Replace (Re-
frigerant recycling and recovery station - 294048)
(50.200).
NOTE: The circular sector of the humidity indicator (15)
must remain green throughout the recycling operation. If
the color of the sector varies between yellow and green, or
turns completely yellow, this means that the filter is satu-
rated with moisture and must be replaced.
23. After completion of the decontamination operation,
close the yellow valve (18) (REF). Continue to recover
the refrigerant. The compressor will stop automati-
cally when the pressure on the pressure gauge (2)
indicates 0,3 bar.
24. Close the valve (6) (low pressure), the two valves at
the ends of the blue service line (11) and yellow ser-
vice line (16). Disconnect the tubing (16) and (11).
Shut down the station. Place the switch (5) in position
"0".
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Discharge of recovered oil

NOTE: After completion of the recovery operation, the contaminated oil will be visible in the distillation chamber (4).
This oil must be discharged and disposed of (in accordance with applicable local regulations for the disposal of used
oil).
25. Slowly open the yellow valve (7). Discharge the re-
covered oil into the graduated container.
26. If no refrigerant leaks of any kind were detected in the
system during the recharge procedure, replace the
contaminated oil with the same quantity of new oil.
This procedure is described in "Charge of the cab air-
conditioning system with new oil" in Air conditioning -
Charging (Refrigerant charge and vacuum station
- 380000315) (50.200).
Transfer of decontaminated refrigerant from the cylinder to an external cylinder

NOTE: If the decontaminated refrigerant will not be immediately returned to the air-conditioning system, transfer the
decontaminated refrigerant from the cylinder (19) to an approved refillable gas container for safety reasons.
27. Check that all of the valves are closed, except for the
valve (9). Check that the station is shut down. Check
that the container (cylinder) is large enough to contain
all the refrigerant to be transferred without exceeding
the permitted safety level.
28. Connect the end of the yellow service tube (16)
without the valve to the free connector (17) on the
left-hand side, on the manifold pressure gauges side.
Connect the other end (with the valve) to the red
connector of the external cylinder.
29. Set the switch (5) to position "2" (Cylinder Heating) to
turn on the refrigerant heater in the cylinder (19). This
is to facilitate the transfer of the refrigerant from the
internal cylinder to the external cylinder.
30. Open the yellow valve (18) (REF), the yellow valve on
the service tubing, and the red valve on the external
cylinder.
31. After completion of the transfer, close all of the valves.
Shut down the station. Place the switch (5) in position
0.
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Air conditioning - Tool description (Refrigerant charge and vacuum

station - 380000315)
COIL15GRD0122FA 1
Refrigerant charge and vacuum station
1. Safety valve 17. Blue service tubing for connection with the side of
2. Cylinder pressure gauge the compressor connection
3. Refrigerant charge valve 18. Oil drain plug
4. Low pressure side valve (LOW) 19. ON/OFF switch (I), heater (II)
5. Low pressure switch 20. Oil meter connector
6. High pressure gauge (red) 21. Vacuum pump
7. 5-way pressure gauge manifold 22. High pressure side valve (HIGH)
8. Vacuum meter 23. Sight glass
9. Vacuum test valve (Vac) 24. Yellow service tubing
10. Vacuum meter test valve 25. Cylinder heater
11. Vacuum meter safety valve 26. Outer ring
12. Oil charge valve 27. Refrigerant transfer valve (REF)
13. Oil fill cap 28. Connector for refrigerant transfer
14. Sight glass 29. Glass dipstick
15. Red service tubing for connection with the 30. Outer housing (acrylic)
discharge side of the compressor 31. Refrigerant charge valve
16. Quick hitch mount connectors
Description
NOTE: The machine is designed to empty and charge air-conditioning systems with the refrigerant gas. The emptying
stage is necessary to remove any moisture and impurities from the system. The refrigerant removed from the system
is transferred to a graduated cylinder. The refrigerant is then pumped to the air-conditioning system.
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Technical features
• A dual-action rotary vacuum pump (21) in oil bath.
• A charge cylinder (31) with maximum level indicator
and graduated scale for measurement of the quantity
of refrigerant
• A 5-way pressure gauge manifold with two pressure
gauges (5) and (6), and a vacuum gauge (8).
• Flexible service tubes (15), (17), and (24) with safety
valves.
• Supply source: 220 V ( 50 Hz).
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Air conditioning - Check (Refrigerant charge and vacuum station -

380000315)
Level check and replacement of the oil of the charge and vacuum station pump (periodic
check)
NOTE: See figure Air conditioning - Overview (Refrigerant charge and vacuum station - 380000315) (50.200)
Periodically check the level and condition of the oil.
If necessary, drain the old oil through the plug (18).
The used oil must always be discarded in accordance
with applicable local regulations.
Remove the cap (13). Fill the vacuum pump (21) with
oil up to the midpoint of the sight glass (14). Use new
oil of the type indicated by the pump manufacturer.
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Air conditioning - Charging (Refrigerant charge and vacuum station

- 380000315)
Vacuum and charge of the cab air-conditioning system
NOTE: See figure Air conditioning - Overview (Refrigerant charge and vacuum station - 380000315) (50.200)
NOTE: Operations 1 to 3 should only be performed if there is no refrigerant in the graduated cylinder (31).
1. Close the valves (4), (22), and (27).
2. Open the valves (3), (9), and (10).
3. Start the pump. Place the switch (19) in position "1" to
create a vacuum in the cylinder (31). After 5 minutes,
close the valves (3), (9), and (10). Shut down the pump.
Completion of the charge of the graduated cylinder

NOTE: If the decontaminated refrigerant in the recovery and recycling station is returned immediately into the air-
conditioning system of the machine, it must be transferred from the cylinder [item (19) of figure Air conditioning -
Overview (Refrigerant recycling and recovery station - 294048) (50.200)] to the cylinder (31) of the vacuum and
charge station. Follow the procedure described below:
4. Connect the end of the yellow service tube (24), without
the valve, to the free connector (28) on the left-hand
side, on the charge and vacuum pressure gauges side.
5. Connect the other end (with the valve) to the free
connector [item (17) of figure Air conditioning -
Overview (Refrigerant recycling and recovery sta-
tion - 294048) (50.200)] on the left-hand side of the
recovery and recycling station pressure gauge mani-
fold.
6. Use the figure Air conditioning - Overview (Re-
(50.200) as a reference. Check that all of the valves of
the recovery and recycling station are closed, except
for the valves (9) and (17) and the valve of the tubing
(16).
7. Check that all the valves of the charge and vacuum
station are closed, except for the valve (27).
8. Make sure that the station is shut down, with switches
(5) and (18) in position "0".
9. Use the figure Air conditioning - Overview (Re-
(50.200) as a reference. Place the heating cylinder
switch (5) in position "2" (Cylinder Heating) to turn
on the refrigerant heater installed on the cylinder
(19). This facilitates the transfer of the refrigerant to
the cylinder [item (31) of figure Air conditioning -
Overview (Refrigerant charge and vacuum station
- 380000315) (50.200)] of the charge and vacuum
station.
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10. After completion of the refrigerant transfer operation,

close all of the valves, except for the valve [item (9)
of figure Air conditioning - Overview (Refrigerant
recycling and recovery station - 294048) (50.200)].
Shut down the recovery and recycling station. Place
the switch [item (5) of figure Air conditioning -
Overview (Refrigerant recycling and recovery
station - 294048) (50.200)] in position "0".
11. Check the quantity of refrigerant in the graduated
cylinder (31).
12. Calculate the quantity of refrigerant that must be
added to the cylinder (31) to top up the total quantity
necessary in the air-conditioning system. Indicated in
the note of item 17.
13. Transfer the refrigerant from the external cylinder to
the graduated cylinder (31). Proceed as described
below.
14. Connect the yellow tube (24) to the connector (28) and
to the external cylinder that contains the refrigerant
(upside down if not equipped with an outlet valve).
15. Open the valve of the external cylinder, the valve on
the charge tube (24), and the valve (27).
16. Rotate the outer housing (30) so that pressure value
shown on the graduated scale corresponds to the
value shown on the pressure indicator (2).
17. When the refrigerant in the cylinder reaches the re-
quired level, as indicated on the glass rod (29) , close
the valve of the external cylinder, the valve on the
charge tube (24), and the valve (27).
NOTE: If an excessively long period of time is required
to transfer the refrigerant from the external cylinder to the
cylinder (31), open the valve (1) slightly. Discharge the air
from the cylinder (31). The reading on the pressure gauge
(2) should not exceed 5 bar.
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Creation of the vacuum in the cab air-conditioning system

NOTE: Previously discharged through the recovery and recycling station.
18. Remove the covers from the service valves of the suc-
tion and discharge line of the compressor.
19. Connect the blue service tube (17) to the valve, on
the suction side (low pressure) of the compressor
(marked “S”).
20. Connect the red service tube (15) to the valve, on
the discharge side (high pressure) of the compressor
(marked “D”).
21. Open the quick hitch mount valves (16).
22. Open the valves (4), (9), (10), and (22).
23. Place the switch (19) in position "I" to start the pump.
Make a vacuum in the system for at least 30 min. The
pressure gauges (5), (6), and (8) should show a nega-
tive reading. If the vacuum operation is not performed
correctly, check all of the connections.
24. Close the valve (9). Place the switch (19) in position
"0" to shut down the pump. Check the vacuum seal
for at least 5 minutes with the vacuum meter (8). Then
close all of the valves.
Charge of the cab air-conditioning system with new oil

(after the creation of the vacuum)
NOTE: If no refrigerant leaks of any kind were detected in the system during the recharge, replace the contaminated
oil previously recovered (operations 25 and 26) with new oil. If there have been significant leaks in the past, continue
with the procedure to check the compressor oil level.
25. Pour the oil into the graduated oil meter.
26. Connect the oil meter to the oil meter (20).
27. Close the valves (4) and (10).
28. Put the switch (19) in position "2" to turn on the refrig-
erant heater in the cylinder (31).
29. Open the valve (12) and the valve on the graduated
oil meter.
30. Check the quantity of oil that flows from the oil me-
ter. When the necessary amount is reached, close
the valve (12) and the valve of the oil meter. Remove
the graduated meter.
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Charge of the cab air-conditioning system with refrigerant

(after the creation of the vacuum)
NOTE: The quantity of refrigerant to be put into the system is 800 g ( HFC 134A refrigerant).
31. Keep the switch (19) in position 2, with the refrigerant
heater in the cylinder (31) turned on. Heat the refriger-
ant for 10 – 15 min to facilitate transfer from the cylin-
der to the air-conditioning system of the machine.
32. In accordance with the type of refrigerant, rotate the
outer housing (30) so that the graduated scale and
the pressure values correspond with the reading on
the pressure gauge (2).
33. Move the outer ring (26) along the glass cylinder to
mark the quantity of refrigerant to be charged.
34. Open the valve (22). Charge via the high pressure
side.
35. Open the valve (3). Charge about 300 g of refrigerant.
Close the valve (3). Check for leaks.
36. If there are no leaks, continue to charge up to the
recommended quantity.
37. After you complete the charge operations, put the
switch (19) in position "0". Close the valves (3) and
(22). Disconnect the tubes (15) and (17). Reinstall
the covers on the service valves.
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Summary of charge operations for the air-conditioning system

NOTE: Perform the operation tests with the system set to the maximum performance levels, as described below.
38. Pressure gauge readings after completion of the re-
frigerant recycling and recovery operation.
COIL15GRD0123AA 1
39. Pressure gauge readings with the valves (4), (9), (10),
and (22) open, cylinder (31), with 1100 g of refrigerant,
red and blue service tubing connected to the system of
the machine, valve (16) closed and compressor shut
down.
COIL15GRD0124AA 2
red and blue service tubing connected to the system
of the machine, valve (16) open, and compressor on
(initial vacuum stage).
COIL15GRD0125AA 3
red and blue service tubing connected to the system
of the machine, valve (16) open, and compressor on
(final vacuum stage, after 30 min).
COIL15GRD0126AA 4
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42. Pressure gauge readings with the valves (4), (10), and
(22) open, cylinder (31), with 1100 g of refrigerant, red
and blue service tubing connected to the system of
the machine, valve (16) open, compressor shut down,
and valve (9) closed (check on the vacuum meter (8)
that there is no pressure drop after a period of 5 min-
utes).
COIL15GRD0126AA 5
43. Pressure gauge reading (start of charge – end of

charge). All of the valves previously opened must be
closed, except for valves (3) and (4). Shut down the
compressor. You can see that the level of refrigerant
in the charge cylinder drops. Proceed until only 300 g
of refrigerant remains in the charge cylinder ( 800 g
grams transferred). The reading on the vacuum me-
ter (8) remains the same from the start to the end of
the charge operation.
COIL15GRD0127AA 6
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Air conditioning - Install (Heating and air-conditioning system

performance improvement kit)
NOTE: An improved Heating, Ventilation, and Air-Conditioning (HVAC) system has been developed. The following
describes the procedures for installation and update of machines with this kit.
DANGER
Avoid injury!
Observe ALL precautions listed below when servicing the air-conditioning system and handling re-
frigerant.
D0043A
WARNING
Pressurized system!
Refrigerant under pressure. Service, repair, or recharging must be performed only by trained service
technician.
W1180A
WARNING
Escaping refrigerant may cause frostbite!
If you get refrigerant on your skin:
-Warm the area with your hand or lukewarm water, 32 - 38 °C (90 - 100 °F).
-Cover the area loosely with a bandage to protect the area and the prevent infection.
-Seek medical assistance immediately.
W0341A
WARNING
Inhalation hazard!
Never leak test an air-conditioning system with an open flame or a flame-type detector. When re-
frigerant comes into contact with an open flame it forms phosgene gas, which is poisonous. Never
breathe these fumes.
W1342A
WARNING
Explosion hazard!
Air-conditioning refrigerant boils at -12 °C (10 °F)!
-NEVER expose any part of the air-conditioning system to a direct flame or excessive heat.
-NEVER disconnect or disassemble any part of the air-conditioning system.
Discharging refrigerant gas into the atmosphere is illegal in many countries.
W0340A
WARNING
Avoid injury!
Avoid breathing air-conditioning refrigerant, lubricant vapor or mist. If accidental system discharge
occurs, ventilate the work area before resuming service.
W1000B
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CAUTION
• The air-conditioning system contains a mixture of refrigerant and oil under high pressure. Under no
circumstances should you loosen the connections of the tubing of a charged air-conditioning system. Discharge
the air-conditioning system before you start any service activity.
• Never loosen the oil level plug of the air-conditioning system compressor when it is charged.
• Never heat the container of refrigerant gas. If the temperature of the refrigerant exceeds 50 °C (122 °F), the
pressure in the refrigerant container will increase very quickly.
• Always use approved refrigerant containers that have been safety valves when you transfer refrigerant from
one container to another.
• Never fill more than 80% of the maximum capacity of the containers with refrigerant.
• Never change the setting of the safety valves and/or control devices.
• Never connect the recovery and recycling stations or the charge and vacuum stations to electrical outlets with
voltages that are not the specified voltages. Do not leave the stations connected unless you use the stations
immediately.
NOTE: For machines that have a 25 cm³ cooling fan hydraulic pump (prior to the introduction of the 28 cm³ pump),
update the pump as per product improvement program M0113 (bulletin number 2014-009 CASE CONSTRUCTION N
PIP). Perform the update before you adjust the fan rotation speed as described in the following procedure. The new
28 cm³ fan hydraulic pump was introduced after serial number NCAF01666.
Procedure for installation of the system performance improvement kit

1. Disconnect the connector (1) from the wiring harness
of the operator seat (2).
BAIL15SBC0011AA 1
2. Remove the seat.
BAIL15SBC0012AA 2
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3. Release the parking brake (3).

4. Remove the bolts (4) that secure the guard.
BAIL15SBC0013AA 3
BAIL15SBC0014AA 4
5. Loosen the bolts (5) from the cover (6) of the HVAC
system box.
BAIL15SBC0015AA 5
6. Remove the cover of the HVAC system box.
BAIL15SBC0016AA 6
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7. Remove the left-hand side panel.
BAIL15SBC0017AA 7
8. Remove the bolts (7) from the right-hand side panel (8).
Remove the right-hand side panel (8).
BAIL15SBC0018AA 8
9. Remove the cab rear panel (9).
BAIL15SBC0019AA 9
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10. At the rear of the cab, remove the access covers (10)
and (11).
BAIL15SBC0020AA 10
BAIL15SBC0021AA 11
11. If necessary, use a knife to cut the seal between the

cover and the cab.
12. See Air-conditioning evaporator - Replace (Evap-
orator, expansion valve and thermostat) (50.200)
and Air-conditioning evaporator - Replace (Blow-
ers) (50.200) for reference.
13. Note the refrigerant recovery and recycling pro-
cedures in Air conditioning - Tool description
(Refrigerant recycling and recovery station -
294048) (50.200). Note the vacuum and refrigerant
charge procedures in Air conditioning - Tool de-
scription (Refrigerant charge and vacuum station
- 380000315) (50.200).
14. Discharge the refrigerant from the air-conditioning
system with an approved refrigerant recovery station.
15. Disconnect the hoses from the evaporator box.
16. Remove all of the “prestite” tape from the side of the
HVAC system box.
BAIL15SBC0022AA 12
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17. Remove the four bolts (12) that secure the side cover
of the HVAC system box (13).
BAIL15SBC0023AA 13
18. Remove the side cover (13) from the HVAC system
box.
BAIL15SBC0025AA 14
19. Remove the mounting bolts (14) from the expansion

valve (15).
BAIL15SBC0026AA 15
20. Disconnect the thermostat terminals.
BAIL15SBC0027AA 16
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21. Loosen the plastic clamp that secures the electrical

wiring harness to the top cover of the evaporator.
BAIL15SBC0028AA 17
22. Remove the ends of the upper seal.

23. Remove the two bolts at the top of the top cover of the
evaporator.
BAIL15SBC0029AA 18
BAIL15SBC0030AA 19
24. Remove the thermostat sensor from the evaporator.
BAIL15SBC0031AA 20
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25. Remove the top cover of the evaporator.
BAIL15SBC0032AA 21
26. Loosen the two fixing nuts from the evaporator/heater

assembly. Do not remove the nuts.
BAIL15SBC0033AA 22
BAIL15SBC0034AA 23
27. Remove the evaporator from the machine.
BAIL15SBC0035AA 24
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28. In the new evaporator, apply Prestite tape over the

expansion valve and the tubes. See the illustration.
BAIL15SBC0036AA 25
29. Install the new evaporator in the HVAC system box.

30. Assemble the components removed in steps 16 to 25
in the reverse order of the removal procedure.
31. Remove the plastic overlay. Mold the Prestite tape
around the tubes and the expansion valve.
BAIL15SBC0037AA 26
BAIL15SBC0038AA 27
32. Replace the cab air filter. Reinstall the new recircula-
tion filter 47724222 from the update kit.
BAIL15SBC0039AA 28
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33. Remove the bolts indicated to remove the lower shield

and the noise insulator from the engine compartment.
BAIL15SBC0041AA 29
BAIL15SBC0040AA 30
34. Remove the clamps from the air conditioning suction

hose.
35. Replace the suction hose 84304777 with the suction
hose 47710307 from the update kit. Keep the routing
of the new suction hose identical to the original rout-
ing.
36. Use tie straps to make sure that the new suction hose
is clear of the air conditioning compressor belt and
moving parts of the engine.
37. Replace the pressure switch 87674059 with the new
pressure sensor (16) 47710360 of the update kit.
BAIL15SBC0042AA 31
38. Reconnect the electrical wiring harnesses of the

HVAC system box.
39. Reconnect all of the hoses removed from the HVAC
system.
40. Assemble the components removed in steps 1 to 10
in the reverse order of the removal procedure.
41. Add lubricant oil to compensate for the replacement
of the hose and of the evaporator:
• Evaporator = 1,4 oz or 40 cm³
• Suction hose = 0,34 oz or 10 cm³.
42. Recharge the air-conditioning system with 1.45 kg
(3.20 lb) of refrigerant.
NOTE: The refrigerant charge should be 1.45 kg (3.20 lb)
rather than 1.75 kg (3.86 lb) to increase the performance
of the HVAC system and the life of the compressor.
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43. Check the speed of the engine cooling system fan.

NOTE: The fan speed should be 1725 – 1775 RPM with
the engine at 2200 RPM for the best performance of the
air-conditioning system.
44. Adjust the speed of the engine cooling system fan as
necessary.
45. Turn the engine on. Activate the air conditioning func-
tion. Test the air-conditioning system with regard to
its correct operation. Shut down the engine. Use the
appropriate test equipment to test the HVAC system
for refrigerant leaks or engine coolant leaks.
46. Check the oil level in the air-conditioning compressor.
Top up, if necessary. The unit is now ready to be put
back into service. Carry out the performance test.
See Air conditioning - Test (Heating and air-con-
ditioning system performance improvement kit)
(50.200).
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Air conditioning - Test (Heating and air-conditioning system

performance improvement kit)
HVAC system performance test procedure
1. With the fan rotation selector in the "OFF" position and
the air conditioning switch in the "OFF" position, start
the engine. Run the engine between 1400 – 1500 RPM
for at least 30 s.
2. Turn the air conditioning temperature selector to the
maximum cooling position.
3. Turn the fan control selector to the maximum rotation
position. The air-conditioning system should work.
4. Open all of the cab air vents. Position a temperature
gauge in the air flow.
5. Open both cab doors.
6. After 5 min of operation with the machine engine at
1500 RPM, measure:
A. The ambient temperature
B. The ambient relative humidity
C. The temperature of the air coming out of vents
D. The pressure on the low pressure side of the air-
conditioning system compressor (suction)
E. The pressure on the high pressure side of the air-
conditioning system compressor (discharge)
7. To confirm that the air-conditioning system provides the
minimum cooling specified, compare the values mea-
sured above with the values in the table below.
Normal suction pressure Normal discharge pressure Maximum temperature of

Ambient (low pressure) (high pressure) the air in the vents
temperature Low High
Low humidity High humidity Low humidity High humidity
humidity humidity
21 °C 120 – 139 kPa 147 – 171 kPa 937 – 1120 kPa 1041 – 1210 kPa 13 °C 17 °C
(70 °F) (17 – 20 psi) (21 – 0.0 psi) (136 – 162 psi) (151 – 175 psi) (55 °F) (63 °F)
(81 °F) (21 – 25 psi) (25 – 30 psi) (168 – 200 psi) (183 – 213 psi) (61 °F) (66 °F)
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Components of the HVAC system performance improvement kit

Description Quantity Part number
HVAC system performance improvement kit 1 47827915
Suction hose 1 47710307
Pressure switch 1 47710360
Evaporator 1 47724220
Recirculation vent 1 47724222
O-ring (10.83 x 1.78) 1 84315516
O-ring (7.65 x 1.78) 1 75310922
O-ring (14.00 x 1.78) 3 75310923
Expansion valve 1 87033212
Prestite tape 1 47724222
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Air-conditioning compressor - Replace

Compressor and belt
1. Remove the coolant charge from the system using suit-
able equipment to collect it. Do not release coolant gas
into the atmosphere.
2. Using two 17 mm wrenches, loosen screws (1) and (2)
that secure the compressor to the bracket, removing
the air conditioning belt. To replace the compressor it
will be necessary to remove the tensioner bolt (3).
LAIL11MG1970A0A 1
LAIL11MG1971A0A 2
3. Disconnect the electrical wire harness and, using a

29 mm wrench, loosen and disconnect the two nuts (4)
and (5) of the compressor hose fittings.
LAIL11MG1473A0A 3
4. Using two 17 mm wrenches, loosen and remove the

three screws (1) and (2) that secure the compressor to
the bracket, removing the compressor.
5. After the replacement, follow the previous stages in re-
verse order to install the components.
NOTE: After replacement/maintenance, check that the
compressor pulley is aligned with the drive pulley. If not,
loosen the screws that secure the compressor bracket to
the engine block. You can use a metal ruler or another
straight implement to align the pulley channels.
LAIL11MG1970A0A 4
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Air-conditioning compressor - Replace

Compressor and belt
2. Using a 19 mm wrench and a 13 mm wrench, loosen
screws (1) and (2) that secure the compressor bracket
and remove the air conditioning belt. To replace the
compressor it will be necessary to remove the tensioner
bolt (3).
LAIL11MG1879A0A 1
LAIL11MG1477A0A 2
3. Disconnect the electrical wire harness and, using a

29 mm wrench, loosen and disconnect the two nuts (4)
and (5) of the compressor hose fittings.
LAIL11MG1880A0A 3
4. Using a 13 mm wrench, loosen and remove the four

screws (6) and (7) that secure the compressor to the
bracket, removing the compressor.
NOTE: After replacement/maintenance, check that the
compressor pulley is aligned with the drive pulley. If not,
loosen the screws that secure the compressor bracket to
the engine block. You can use a metal ruler or another
straight implement to align the pulley channels.
LAIL11MG1478A0A 4
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Receiver-dryer - Replace
2. Using a 19 mm wrench, loosen and disconnect the two
nuts (1) and (2) from the liquid reservoir hose fittings.
bolts that fix the clamp to the machine's chassis, re-
moving the reservoir.
verse order to install the component.
NOTE: Always note the inlet position (IN) when fitting the
LAIL11MG2071A0A 1
reservoir. This is the connection that takes the hose from
the condenser.
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Receiver-dryer - Replace
2. Using a 19 mm wrench, loosen and disconnect the
two nuts (1) and (2) from the connections on the liq-
uid reservoir hose fittings.
bolts that fix the clamp to the machine's chassis, re-
moving the reservoir.
LAIL11MG1479A0A 1
NOTE: Always note the inlet position (IN) when fitting the
reservoir. This is the connection that takes the hose from
the condenser.
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Air-conditioning compressor lines - Replace

1. Remove the coolant charge from the system, using
suitable equipment to collect it. Do not release coolant
gas into the atmosphere.
2. Replacing the hose from the compressor to the con-
denser:
A. Using a 29 mm wrench, loosen and disconnect the
nut (1) from the compressor connection.
B. Using a 19 mm wrench and (fixing the condenser
nut) and a 22 mm wrench, loosen and disconnect
the nut (2) from the condenser connection, remov-
ing the hose. It is important to use two wrenches.
C. After the replacement, follow the previous stages LAIL11MG1473A0A 1
NOTE: Use the same path for the hose and replace the
O-rings.
LAIL11MG1919A0A 2
3. Replacing the hose from the condenser to the liquid

reservoir:
A. Using a 17 mm wrench (fixing the condenser nut)
and a 19 mm wrench, loosen and disconnect the
nut (3) from the condenser connection. It is impor-
tant to use two wrenches.
B. Using a 19 mm wrench, loosen and disconnect the
nut (4) from the liquid reservoir connection, remov-
ing the hose.
C. After the replacement, follow the previous stages
NOTE: Use the same path for the hose and replace the LAIL11MG2054A0A 3
O-rings.
LAIL11MG1474A0A 4
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4. Replacing the hose from the liquid reservoir to the

evaporator:
nut (5) from the liquid reservoir connection.
nut (6) from the evaporator connection, removing
the hose.
NOTE: Use the same path for the hose, taking care not to
remove the grommet from the hose path on the floor and
replace the O-ring sealing rings. LAIL11MG2055A0A 5
LAIL11MG2021A0A 6
5. Replacing the hose from the evaporator to the com-

pressor:
nut (7) from the evaporator connection.
nut (8) from the compressor connection, removing
the hose.
LAIL11MG2053A0A 8
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Air-conditioning compressor lines - Replace

1. Remove the coolant charge from the system, using
suitable equipment to collect it. Do not release coolant
2. Replacing the hose from the compressor to the con-
denser:
nut (1) from the compressor connection.
B. Using a 19 mm wrench and (fixing the condenser
nut) and a 22 mm wrench, loosen and disconnect
the nut (2) from the condenser connection, remov-
ing the hose. It is important to use two wrenches.
C. After the replacement, follow the previous stages LAIL11MG2057A0A 1
NOTE: Use the same path for the hose and replace the
O-rings.
LAIL11MG1919A0A 2
3. Replacing the hose from the condenser to the liquid

reservoir:
A. Using a 17 mm wrench (fixing the condenser nut)
and a 19 mm wrench, loosen and disconnect the
nut (3) from the condenser connection. It is impor-
tant to use two wrenches.
nut (4) from the liquid reservoir connection, remov-
ing the hose.
NOTE: Use the same path for the hose and replace the LAIL11MG2054A0A 3
O-rings.
LAIL11MG2059A0A 4
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4. Replacing the hose from the liquid reservoir to the

evaporator:
nut (5) from the liquid reservoir connection.
nut (6) from the evaporator connection, removing
the hose.
LAIL11MG2021A0A 6
5. Replacing the hose from the evaporator to the com-

pressor:
nut (7) from the evaporator connection.
nut (8) from the compressor connection, removing
the hose.
LAIL11MG2058A0A 8
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Air-conditioning condenser - Replace

2. Using a 17 mm and 19 mm wrench for the smaller fit-
ting and a 19 mm and 22 mm wrench for the larger fit-
ting, loosen and disconnect the two nuts (1) and (2)
from the condenser hose fittings. In each case, it is
necessary to use two wrenches each time.
screws (3) that secure the condenser to the radiator
and remove the condenser.
4. After the replacement, follow the previous stages in re- LAIL11MG1919A0A 1
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Air-conditioning condenser - Replace

2. Using a 17 mm and 19 mm wrench for the smaller fit-
ting and a 19 mm and 22 mm wrench for the larger fit-
ting, loosen and disconnect the two nuts (1) and (2)
from the condenser hose fittings. In each case, it is
necessary to use two wrenches each time.
screws (3) that secure the condenser to the radiator
and remove the condenser.
4. After the replacement, follow the previous stages in re- LAIL11MG2024A0A 1
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Air-conditioning evaporator - Replace (Evaporator, expansion valve

and thermostat)
1. Remove the coolant charge from the system. Use suit-
able equipment for collection. Do not release coolant
2. Using a 16 mm wrench and a 22 mm wrench, loosen
and disconnect the two nuts (1) from the hose connec-
tors of the evaporator housing.
3. To replace the evaporator, expansion valve and ther-
mostat, follow steps 5 to 10 of Heater core - Replace
(50.100).
LAIL11MG1969A0A 1
4. Using a special Philips screwdriver, loosen and remove

the two screws (2) supporting the expansion valve
bracket.
LAIL11MG1704A0A 2
5. Remove the evaporator without using any tools.
LAIL11MG1705A0A 3
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6. With the evaporator on a workbench and using a

Phillips screwdriver, loosen and remove the two screws
(3) that support the thermostat Remove the thermostat.
LAIL11MG1706A0A 4
7. Using a 19 mm and 26 mm wrench, loosen and re-

move the two evaporator nuts (4) that connect the ex-
pansion valve to the evaporator. Remove the expan-
sion valve. It is necessary to use two wrenches.
LAIL11MG1707A0A 5
8. Replace the components; after replacement, follow the

previous stages in reverse order to install the compo-
nents.
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Air-conditioning evaporator - Replace (Blowers)

operator's seat to the cover of the evaporator box, re-
moving the seat.
that fix the cover of the evaporator box, removing the
cover.
3. Using a Philips screwdriver, loosen the screw that holds
the fan fixing support (1), removing the support.
LAIL11MG1701A0A 1
4. Without using tools, remove the fan and disconnect its

electrical terminals to replace (2).
LAIL11MG1702A0A 2
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Air conditioning - Troubleshooting

NOTICE: All repairs that involve the coolant load being collected/applied must be carried out by technical assistance.
Low suction pressure Suction hose obstructed or blocked Check and replace hose
Pressure reading with:
Low suction and
Discharge normal
High suction pressure Low compressor performance Check and replace the compressor
High suction and
Discharge normal
High suction pressure Insufficient air flow through the condenser Clean and straighten the vanes
High suction and
Discharge high
Low discharge pressure Low air flow in the evaporator Clean and straighten the vanes
Pressure reading at:
Normal suction and
Low discharge
Low refrigerant charge Charge following good practices (until the
bubbles in the liquid reservoir disappear)
High discharge pressure Air in the system Load new coolant gas
Normal to high suction
and
Discharge high
Excess coolant gas Load new coolant gas
Insufficient cooling Humidity in the system Replace the liquid reservoir and add new
Pressure reading at: coolant charge
Suction normal to high
and
Discharge normal
Excess oil Remove the charge, clean the system, and
recharge. Add 150 ml of oil
Insufficient cooling Humidity in the system Replace the liquid reservoir and add new
Pressure reading with: coolant charge
Suction normal to high
and
Discharge normal
Excess oil Remove the charge, clean the system, and
recharge. Add 150 ml of oil
Insufficient cooling Insufficient refrigerant charge Check and eliminate any leaks. Install a
Pressure reading with: new refrigerant charge
Low suction and
Low discharge
Insufficient cooling Obstruction of the liquid reservoir Replace the liquid reservoir and add new
Pressure reading with: coolant charge
Low vacuum suction and
Low discharge
Insufficient cooling Obstructed expansion valve Replace the expansion valve
Zero vacuum suction and
Low discharge
Insufficient cooling The compressor does not shut down Replace the thermostat
Low suction and
Discharge normal
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Insufficient cooling Expansion valve locked open Replace the expansion valve
High suction and
Normal to low discharge
Insufficient cooling Mixture of hot and cold air Check the damper, control (electric/pneu-
Pressure reading with: matic), and heating valve
Normal suction and
Discharge normal
Insufficient cooling The compressor does not work or works Belt slipped
Pressure reading with: intermittently Correct the belt tension
Normal suction and
Discharge high
Belt coming off, slipping, Compressor support not aligned. Align or replace the compressor support
or over-worn
Belt coming off, slipping, Excess coolant gas. Load new coolant gas.
or over-worn
Pressure reading at:
Normal suction and
Discharge high
The compressor is not Gas coolant leak Check and eliminate any leaks. Install a
working new refrigerant charge
Clutch coil without any power • Check and replace the blown fuse
• Check and replace the A/C switch
• Check and replace the A/C relay
• Check and replace the A/C pressure
switch
• Check and replace the thermostat
• Check the clutch coil and replace the
compressor
The clutch plate does not engage with the Check the clearance between the plate and
pulley or there is slipping the pulley. Remove the shim washers. Re-
place the compressor
Poor ventilation Evaporator obstructed due to freezing Check and replace the thermostat
Low suction and
Discharge normal
Poor ventilation Fan motor without power • Check and replace the blown fuse
• Check and replace the fan switch
• Check and replace the resistor
• Check poor contact in the electrical wire
harness
Air filters blocked Clean or replace the filters
Faulty fan motor Check and replace the fan motor
Noise Belt loose or too tight Correct the belt tension
Noise Compressor damaged Replace the compressor
High suction and
Low discharge
Noise Excess coolant gas Load new coolant gas
High suction and
Low discharge
Noise Resonance of the tubing or other parts Assess the protection of the hoses and
other parts with rubber or the need for a
muffler
Pulley (engine, compressor, bypass) mis- Align or replace
aligned
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Clutch slipping (excess coolant gas or • Install a new refrigerant charge
clearance between the clutch plate and the
• Remove the shim washers or replace
pulley)
the compressor
Damaged pulley bearing Replace the bearing
Fixing bolts loose Re-tighten
WARNING: All repairs that involve the need
to collect/install a refrigerant charge must
be performed by technical assistance.
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Index

Air conditioning - Charging (Refrigerant charge and vacuum station - 380000315) . . . . . . . . . . . . . . 37
Air conditioning - Check (Refrigerant charge and vacuum station - 380000315) . . . . . . . . . . . . . . . . 36
Air conditioning - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air conditioning - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Air conditioning - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air conditioning - Inspect (Air-conditioning system update - Inspection of the system before an up-
date) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Air conditioning - Install (Air-conditioning system update - Low pressure switch installation) . . . . . . 23
Air conditioning - Install (Heating and air-conditioning system performance improvement kit) . . . . . 43
Air conditioning - Overview (Refrigerant charge and vacuum station - 380000315) . . . . . . . . . . . . . . 11
Air conditioning - Overview (Refrigerant recycling and recovery station - 294048) . . . . . . . . . . . . . . . 10
Air conditioning - Prepare (Air-conditioning system update - Preparation of the system before an
update) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Air conditioning - Recover (Refrigerant recycling and recovery station - 294048) . . . . . . . . . . . . . . . . 30
Air conditioning - Replace (Refrigerant recycling and recovery station - 294048) . . . . . . . . . . . . . . . . 27
Air conditioning - Replace (Refrigerant recycling and recovery station - 294048) . . . . . . . . . . . . . . . . 29
Air conditioning - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Air conditioning - Service instruction (Air-conditioning system update - General care in the system
update) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Air conditioning - Service instruction (Air-conditioning system update - General refrigerant update
procedure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Air conditioning - Service instruction (Air-conditioning system update - Introduction) . . . . . . . . . . . . 13
Air conditioning - Service instruction (Air-conditioning system update - Safety procedures) . . . . . . . 14
Air conditioning - Test (Heating and air-conditioning system performance improvement kit) . . . . . . 54
Air conditioning - Tool description (Refrigerant charge and vacuum station - 380000315) . . . . . . . . 34
Air conditioning - Tool description (Refrigerant recycling and recovery station - 294048) . . . . . . . . . 25
Air conditioning - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Air-conditioning compressor lines - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Air-conditioning compressor - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Air-conditioning compressor - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Air-conditioning compressor lines - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Air-conditioning condenser - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Air-conditioning condenser - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Air-conditioning evaporator - Replace (Evaporator, expansion valve and thermostat) . . . . . . . . . . . . 66
Air-conditioning evaporator - Replace (Blowers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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Receiver-dryer - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Receiver-dryer - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
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PRINTED IN BRAZIL
48050419D 06/10/2017
EN
SERVICE MANUAL
Electrical systems

48050419D 06/10/2017
55
Contents
Electrical systems - 55
[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1
[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
[55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5
[55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
[55.024] Transmission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7
[55.051] Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls. . . . . . . . . . . . . . . . . . . . . 55.8
[55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . . . . . 55.9
[55.020] Transmission speed sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10
[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11
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Electrical system - 000

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Contents
FUNCTIONAL DATA
Electrical system
Electrical schema index (Models with Tier 3 Engine) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical schematic sheet 03 (Models with Tier 3 Engine) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical schematic sheet 09 (Models equipped with Tier 3 engine and “Torque Converter” transmission)
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Electrical schematic sheet 09 - (Models equipped with Tier 3 engine and “Direct Drive” transmission) (*)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Component identification (Models with Tier 3 Engine) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
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Component identification (Models equipped with Tier 3 engine and “Torque Converter” transmission) (*)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Component identification - (Models equipped with Tier 3 engine and “Direct Drive” transmission) (*) . . 73
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Component identification (Models with Tier 3 Engine) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Electrical schema index (Models equipped with Tier 3 engine, “Direct Drive” transmission, and “AWD”) (*)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Electrical schematic sheet 03 (Models equipped with Tier 3 engine, “Direct Drive” transmission, and “AWD”)
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Electrical schematic sheet 07 (Models Equipped with Tier 3 engine, “Direct Drive” transmission and “AWD”
traction) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Electrical schematic sheet 08 (Models Equipped with Tier 3 engine, “Direct Drive” transmission and “AWD”
traction) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
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(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Component identification (Models equipped with Tier 3 engine, “Direct Drive” transmission, and “AWD”)
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
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Electrical systems - Electrical system
Electrical system - Electrical schema index (Models with Tier 3

Engine)
[HBZN0845VBAF00184 - ]
[HBZN0845VCAF01093 - ]
-]
[HBZN0885PCAF00871 - ]
Component list
Name Description Sheet
DB Electronic Throttle 23-6
AEB “Torque Converter” (ZF) Transmission Tool Connector 21-2
AIC Adv. Instrument Cluster 9-6/9a-6
AT Aerial, Antenna for Radio 22-3
BLD-C Blade Control (Optional) 12-1
CB1 105 A Circuit Breaker 2-3/3-4
CI1 Cylinder 1 Injector (Electro-valve) 24-6
D8 Diode for the Fan Drive On/Off System (Optional) 14-4
D12 Diode to the Electric Master Switch “ACC” 3-5
D13 Diode to the Electric Master Switch “IGN” 3-5
DB1 Diode Box for the Turn Signal 6-3
DB2 Diode Box for the Wipers and Demister Fans 17-4
Diode and Resistor Box for the Parking Brake Signals and “Come-Home” – “Direct
DR 25-7/25-8
Drive” (FUNK) Transmission
ECA Fuse Box on the Lateral Console 32 and 33
ECB Fuse and Relay Box on the Lateral Console 32 and 33
ECC Fuse and Relay Box on the Lateral Console 32 and 33
ECD Fuse and Relay Box on the Lateral Console 32 and 33
ECE Fuse and Relay Box on the Front Console 34
EDC7 Engine Data Controller on the Lateral Console 23 and 24
EM Electromagnetic Clutch for the Air Conditioning 19-1
EV2 Differential Lock Solenoid Valve (Optional) 11-1
EV4 Solenoid Valve for the Saddle Lock Pin 11-5
EV5 Left Solenoid Valve for the Ripper or Scarifier (Optional) 15-2
EV7 Right Solenoid Valve for the Ripper or Scarifier (Optional) 15-5
EV9 Left Float Solenoid Valve of the Blade (Optional) 12-2
EV11 Right Float Solenoid Valve of the Blade (Optional) 12-5
EV13 Anti-Impact Solenoid Valve of the Left Lift Cylinder (Optional) 13-2
EV17 Anti-Impact Solenoid Valve of the Right Lift Cylinder (Optional) 13-5
EV19 Float Solenoid Valve of the Front Blade (Optional) 14-1
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EV27 Drive Inverter Solenoid Valve of the Fan (Optional) 11-4
EV28 Fan Drive On/Off Solenoid (Optional) 14-6
EV28a Fan Control Solenoid Valve (Optional) 11-3
EV–LOCK–UP “Lock-Up” Solenoid – “Torque Converter” (ZF) Transmission 21-10
EV–P.BRAKE Parking Brake Solenoid – “Torque Converter” (ZF) Transmission 9-6
EVT1 Proportional Solenoid Valve 1 – Directional 25-9
EVTA Proportional Solenoid Valve A – Speed 25-9
EVTB Proportional Solenoid Valve B – Speed 25-10
EVTC Proportional Solenoid Valve C – Speed 25-10
EVTD Proportional Solenoid Valve D – Speed 25-11
EV–Y1 Clutch Proportional Solenoid K4 – “Torque Converter” (ZF) Transmission 21-10
EV–Y2 Clutch Proportional Solenoid KR – “Torque Converter” (ZF) Transmission 21-11
EV–Y5 Clutch Proportional Solenoid KV – “Torque Converter” (ZF) Transmission 21-11
FGH 125 A Mega Fuse – “Grid Heater” Intake Air Heater 23-4
FH Fuel Filter Heater 3-6
G1 12 V Battery – 1010 CCA 3-1
G3 28 V 90 A Alternator 3-2
GH Intake Air Heater “Grid Heater” 23-3
H1 Right-Hand Work Light in the Front of the Blade 5-2
H2 Left-Hand Work Light in the Front of the Blade 5-3
H3 Right-Hand Work Light Behind the Blade 5-3
H4 Left-Hand Work Light Behind the Blade 5-4
H5 Front Left Position Light 6-2
H6 Rear Right Position Light 6-2
H7 Right Fog Work Light 5-5
H8 Left Fog Work Light 5-6
H9 Front Right Turn Signal of the Cab – Reserve 6-5
H10 Rear Right Turn Signal Light 6-5
H11 Front Right Turn Signal Light 6-5
H12 Front Left Turn Signal Light 6-4
H13 Rear Left Turn Signal Light 6-4
H14 Front Left Turn Signal on the Cab – Reserve 6-4
H16 Left Headlight (High Beam) 7-1
H17 Right Headlight (High Beam) 7-2
H18 Left Headlight (Low Beam) 7-2
H19 Right Headlight (Low Beam) 7-3
H20 Front Right Position Light 7-3
H21 Rear Left Position Light 7-3
H22 License Plate Light (Optional) 7-4
H27 Rear Right Reflector (Cab) 7-6
H28 Rear Left Reflector (Cab) 7-6
H29 Left Cab Headlight (Optional) 8-1
H30 Right Cab Headlight (Optional) 8-2
H31 Left-Hand Light of the Front Blade (Optional) 8-2
H32 Right-Hand Light of the Front Blade (Optional) 8-3
H33 Left-Hand Brake Light 8-4
H34 Right-Hand Brake Light 8-4
H40 Front Right Beacon Light (Optional) 16-6
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HA1 Horn 6-1
HA2 Audible Signal (AIC) 9-3/9a-5
HA3 Reverse Alarm (Optional) 8-5
J1–J2–J3 ECU Connectors – “Direct Drive” (FUNK) Transmission 25
J4 Gear Selector Connector – “Direct Drive” (FUNK) Transmission 25-3
J6 Connector – “Direct Drive” (FUNK) Transmission 25-8
K15 Hazard Light Relay 6-3
KBLD Blade Control Unit 12-2
K C1 12 – 24 V Cigarette Lighter and Radio Voltage Converter 22-1
K ECU Transmission Electronic Control Unit – “Direct Drive” (FUNK) Transmission 25
KFH Heater Relay for the Fuel Filter and Water Separator 3-5
K IP “Direct Drive” (FUNK) Pedal – “Inching” Transmission 25-1
K PT Auxiliary Magnetic Switch for the Tire Inflator 22-6
KR Radio 22-4
KRD Demister Relay for the Rear Window and Side Mirrors 20-2
KRV1 Air Conditioning Fan – 1st Speed Relay 19-2
KRV2 Air Conditioning Fan – 2nd Speed Relay 19-3
KRV3 Air Conditioning Fan – 3rd Speed Relay 19-4
KSR Starter Relay 3-4
K TCU Transmission Control Unit – “Torque Converter” (ZF) Transmission 21
K TVP Transient Voltage Protection – “Direct Drive” (FUNK) Transmission 25-1
M1 Starter Motor 3-3
M2 Front Windshield Wiper 17-3
M3 Front Windshield Washer Pump 17-4
M4 Rear Windshield Wiper 17-6
M5 Rear Windshield Washer Pump 18-1
M6 Washer Pump for the Lower Front Windshield (Optional) 18-4
M7 Lower Front Windshield Wiper (Optional) 18-2
M8 Air Suspension Seat (Optional) 18-4
M9 Rear Demister Fan (Optional) 18-5
M10 Demister Fan for the Left-Hand Windshield (Optional) 18-5
M10a Demister Fan for the Right-Hand Door (Optional) 18-6
M11 Air Conditioning Mode Port 19-5
MLS Demister for the Left-Hand Side Mirror 20-4
MPT Tire Inflator Compressor 22-5
MRS Demister for the Right-Hand Side Mirror 20-4
M.T. Air-Conditioning Evaporator Unit (Optional) 19-4
PO1 Energy Socket 20-5
PRM A Power Relay Module A – Accessories 4-5
PRM B Power Relay Module B – Ignition 4-4
PRM C Power Relay Module C – Accessories 4-3
R3 12 V Cigarette Lighter 22-2
RWDR Rear Window Demister 20-2
S1 Electric Master Switch (General Switch) 3-1
S2 Ignition Switch 4-1
S3 Work Light Switch for the Front and Rear of the Blade 5-2
S4 Switch for the Headlights/Reflector Lights, Horn and Turn Signal 6-4
S5 Warning Lights Switch (Hazard Lights) 6-3
S6 Rear Reflector Switch 7-5
S7 Switch for the Cab Headlights and Fog Lights (Optional) 8-1
S8 Front Blade Switch (Optional) 8-2
S9 Brake Light Switch 8-4
S12 Function Keys Switch 10-2 to 3
S14 Fuel Level Sensor 9-1/9a-1
S15 Engine Coolant Temperature Switch 10-1
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S16 Air Filter Restriction Switch 10-3
S17 Restriction Switch for the Transmission Fluid Filter 9a-11
S18 Transmission Fluid Pressure Switch 9-10/9a-9
S20 Hydraulic Fluid Temperature Switch 9-2/9a-2
S21 Brake Low Pressure Switch 9-11/9a-11
S22a Output Speed Sensor – “Torque Converter” (ZF) Transmission (B4) 21-5
S23 Restriction Switch for the Hydraulic Fluid Filter 10-2
S24 Differential Lock Switch (Optional) 11-2
S26 Switch for the Saddle Lock Pin 11-6
S27 Switch for the Ripper or Scarifier (Optional) 15-3
S28 Left Float Switch of the Blade (Optional) 12-3
S29 Right Float Switch of the Blade (Optional) 12-5
S30 Lift Cylinder Damper Switch (Optional) 13-3
S31 Front Blade Float Switch (Optional) 14-1
S32 Switch for the Left-Hand Cab Dome Light (Next to the Left-Hand Door) 16-3
S33 Switch for the Right-Hand Cab Dome Light (Above the Console) 16-4
S34 Beacon Light Switch (Optional) 16-5
S35 Switch for the Front Windshield Wiper, Windshield Washer Pump and the Timer 17-1
S37 Rear Windshield Wiper Switch 17-5
S38 Switch for the Rear Windshield Washer Pump 18-1
S39 Switch for the Washer and Wiper of the Lower Front Windshield (Optional) 18-3
S40 Demister Fan Switch (Optional) 18-6
S40a Switch for the Rear Window and Mirror Demister (Optional) 18-6
S41 High Pressure Switch for the Air-Conditioning System (Optional) 19-2
S42 Switch for the Three-Speed Fans of the Air-Conditioning System (Optional) 19-3
S43 Air Conditioning On/Off Switch (Optional) 19-5
S44 Mode Damper Switch for the Air Conditioning System (Optional) 19-4
S47 Gear Selector – “Direct Drive” (FUNK) Transmission 25-3
S47a Gear Selector – “Torque Converter” (ZF) Transmission 21-8
S48 Switch for the Manual Parking Brake Lever – “Direct Drive” (FUNK) Transmission 25-7
S49 “Come-Home” Safety Mode Switch – “Direct Drive” (FUNK) Transmission 25-10
S50 Magnetic Engine Speed Pickup Sensor – “Direct Drive” (FUNK) Transmission 25-11
Magnetic Engine Speed Pickup Sensor – “Torque Converter” (ZF) Transmission
S50a 21-4
(B1)
S51 Magnetic Output Speed Pickup Sensor – “Direct Drive” (FUNK) Transmission 25-11
Magnetic Turbine Speed Pickup Sensor – “Torque Converter” (ZF) Transmission
S51a 21-4
(B2)
S52 Magnetic Cylinder Speed Pickup Sensor – “Direct Drive” (FUNK) Transmission 25-12
Internal Magnetic Speed Pickup Sensor – “Torque Converter” (ZF) Transmission F
S52a 21-4
(B3)
S53 Temperature Sensor – “Direct Drive” (FUNK) Transmission 25-12
S53a Temperature Sensor – “Torque Converter” (ZF) Transmission 21-12
S55 Fan Drive Inverter Switch 11-3
S58 Water in Fuel Sensor 23-1
S59 Valve Camshaft Sensor 24-6
S60 “Common Rail” Pressure Sensor 24-6
S61 Engine Coolant Temperature Sensor 24-6
S62 Fuel Temperature Sensor 24-6
S63 Crankshaft Sensor 24-6
S64 Engine Oil Pressure/Temperature Sensor 24-6
S65 Air Intake Pressure/Temperature Sensor 24-6
S66 Tire Inflator Switch 22-6
S67 Fan Drive On/Off Switch (Optional) 14-4
S68 Coolant Temperature (87°C) Switch for the Fan Drive On/Off (Optional) 14-5
S78 Parking Brake Panel Switch – “Torque Converter” (ZF) Transmission 21-6
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S79 Declutch Switch 21-3
S79a Declutch Pressure Switch 21-3
S80 Automatic/Manual Transmission Switch 21-4
S82 Restriction Switch for the Transmission Fluid Filter 21-7
S84 Torque Converter Temperature Sensor (B15) 21-7
SP1 Left-hand Speaker 22-4
SP2 Right-hand Speaker 22-4
TLM Telematics 10-5 to 6
v2 Varistor for the Differential Lock Solenoid Valve (Optional) 11-1
V4 Varistor for the Solenoid Valve of the Saddle Lock Pin 11-5
V5 Varistor for the Left Solenoid Valve of the Ripper or Scarifier (Optional) 15-1
V7 Varistor for the Right Solenoid Valve of the Ripper or Scarifier (Optional) 15-4
V9 Varistor for the Left Float Solenoid Valve of the Blade (Optional) 12-1
V11 Varistor for the Right Float Solenoid Valve of the Blade (Optional) 12-4
V13 Varistor for the Anti-Impact Solenoid Valve of the Left Lift Cylinder (Optional) 13-1
V17 Varistor for the Anti-Impact Solenoid Valve of the Right-hand Lift Cylinder (Optional) 13-5
V18 Varistor for the Anti-Impact Solenoid Valve of the Right-hand Lift Cylinder (Optional) 13-6
V19 Varistor for the Float Solenoid Valve of the Front Blade (Optional) 14-1
V21 Varistor for the Magnetic Clutch/Compressor (Optional) 19-1
V27 Varistor for the Drive Inverter Solenoid of the Fan (Optional) 11-4
V28 Varistor for the Fan Drive On/Off Solenoid (Optional) 14-5
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Electrical system - Electrical schematic sheet 03 (Models with Tier

3 Engine)
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Electrical system - Electrical schematic sheet 09 (Models equipped

with Tier 3 engine and “Torque Converter” transmission)
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Electrical system - Electrical schematic sheet 09 - (Models equipped

with Tier 3 engine and “Direct Drive” transmission)
845B Direct drive transmission, Tier 3, made in Brazil [HBZN0845VBAF00184 - ]
885B Direct drive transmission, Tier 3, made in Brazil [HBZN0885LBAF00098 - ]
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Electrical system - Electrical schematic sheet 11 (Models with Tier 3

Engine)
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Electrical system - Component identification (Models with Tier 3

Engine)
[HBZN0845VBAF00184 - ]
[HBZN0845VCAF01093 - ]
-]
[HBZN0885PCAF00871 - ]
Component list
X1 Main Rear Wiring Harness – Side Console 70-Pin Connector –
X1DB Main Rear Wiring Harness – Side Console Eyelet Connector – Power –
X2 Main Rear Wiring Harness – 40-Pin Side Console Connector –
X4 Main Rear Wiring Harness – 2-Pin Fuel Tank Connector –
X6 Main Rear Wiring Harness – 70-Pin Front Console Connector –
X7 Main Rear Wiring Harness – 20-Pin Main Front Connector –
Main Rear Wiring Harness – 6-Pin Connector of the Wiper of the Lower Front
X7A –
Windshield, Ripper/Scarifier
X7a 4-Pin Male Gear Selector Connector – “Torque Converter” (ZF) Transmission –
X7b 4-Pin Female Gear Selector Connector – “Torque Converter” (ZF) Transmission –
X8 Main Rear Wiring Harness – 2-Pin Fan Drive On/Off Connector –
Main Rear Wiring Harness – 3-Pin Connector of the Magnetic Clutch of the Air
X9 –
Conditioning, Fan Drive On/Off, and Auxiliary Start System
X10 Mechanical Engine Wiring Harness – 3-Pin Electrical Engine Cut–Off Connector –
X11 Main Rear Wiring Harness – 6-Pin Connector of the Reverse Alarm –
X12 Main Rear Wiring Harness – 2-Pin Connector of the Position Lights –
Main Rear Wiring Harness – 6-Pin Connector of the Differential Lock and Air
X15 –
Conditioning Pressure Switch
Side Console Wiring Harness – 6-Pin Power Connector of the Radio and “Can
X19 –
Bus” of the Cab
X20 Side Console Wiring Harness – 20-Pin Connector of the Cab – Black –
X23S – X23T Normal Operation – “Direct Drive” (FUNK) Transmission and X23S –
X23S/T –
X23TA 20-Pin Connector of the “Come-Home” – Gray
X23SA – X23TA Normal Operation – “Direct Drive” (FUNK) Transmission and
X23SA/TA –
X23SA – X23T 20-Pin Connector of the “Come-Home” – Gray
Lateral Wiring Harness – 6-Pin Connector of the Air Conditioning System (Fan
X24 –
Speed)
X24S – X24T Normal Operation – “Direct Drive” (FUNK) Transmission and X24S
X24S/T –
Disconnected from the X24T = Maintenance (Weld) 20-Pin Connector – Black
X25 – –
X26 Lateral Wiring Harness – 6-Pin Connector of the Air Conditioning System –
X27 Lateral Wiring Harness – 6-Pin Connector for the Air Conditioning Control –
X27A Lateral Wiring Harness – 3-Pin Connector for the Air Conditioning Control –
Electronic and Mechanical Engine Wiring Harness – 6-Pin Connector of the
X29 –
Transmission and Hydraulic Switch
X30 Main Front Wiring Harness – 2-Pin Damper Connector of the Lift Cylinder (Optional) –
Main Front Wiring Harness – 3-Pin Float Connector of the Right-Hand and
X31 –
Left-Hand Blade (Optional)
X32 Main Front Wiring Harness – 2-Pin Float Connector of the Front Blade (Optional) –
X36 2-Pin Connector of the Lateral Wiring Harness for Calibration –
X37 2-Pin “Jump” Connector of the Lateral Wiring Harness for Calibration –
3-Pin Connector of the Lateral Wiring Harness for Computer Diagnostics – “Direct
X38 –
Drive” (FUNK) Transmission
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Hydraulic Sensor Wiring Harness – 1-Way Restriction Connector of the
X39 –
Transmission Fluid Filter
X40 Cab Wiring Harness – 2-Pin Connector of the Rear Left Beacon Light –
X42 Lateral Wiring Harness – 2-Pin Connector of the Air Suspension Seat (Optional) –
X47 Main Rear Wiring Harness – 20-Pin Connector of the Electronic Engine – Gray –
X52 1-Pin Power Connector of the Direct Converter for the Battery “BAT” –
X53 1-Pin Power Connector of the Converter After the Ignition Key “IGN” –
X53a 1-Pin Power Connector of the Converter –
X64 Lateral Wiring Harness – Diagnostics Tool –
X65 Main Rear Wiring Harness – 5-Pin Male Connector of the Brake Lights –
X66 Main Rear Wiring Harness – 5-Pin Female Connector of the Brake Lights –
X86 Main Rear Wiring Harness – 2-Pin Connector of the Fan Reverse Solenoid –
Main Rear Wiring Harness – 2-Pin Connector of the Solenoid PWM – Pulse
X87 –
Width Modulation
XA Power Derivation Point on the Rear Chassis Near the Cab Floor –
XAE Main Rear Wiring Harness – 6-Pin Connector of the Electronic Throttle –
6-Pin Connector of the Transmission Diagnostics Tool – “Torque Converter” (ZF)
XAEB –
Transmission
XBLD Lateral Wiring Harness – 6-Pin Connector for the Blade Control –
XCAN Main Rear Wiring Harness – 6-Pin Connector of the Engine –
XCV Lateral Wiring Harness – 6-Pin Connector of the 12 – 24 V Voltage Converter –
XD12 Diode Module – 2-pin Connector for the Ignition Switch “ACC” 3-5
XD13 Diode Module – 2-pin Connector for the Ignition Switch “IGN” 3-5
1-Pin “Jump” Connector of the Differential Lock – “Torque Converter” (ZF)
XDIF –
Transmission
XDV1 2-Pin Power Shunt Connector –
XEDC7(A) Engine Power Wiring Harness – 16-Pin Connector of the Engine EDC –
Electrical Wiring Harness of the Electronic Engine – 89-Pin Connector of the
XEDC7(B) –
Engine EDC
XEDC7(C) Engine Power Wiring Harness – 36-Pin Connector of the Engine EDC –
Electrical Wiring Harness of the Electronic Engine – 1-Way Connector of the
XG1 –
Engine Block (Ground)
XG2 –
Main Rear Wiring Harness – 31-Pin Connector of the Electrical Wiring Harness of
XJ6 –
the Transmission
XMS Main Rear Wiring Harness – 3-Pin Connector of the Main Switch –
Hydraulic Sensor Wiring Harness – 2-Pin Connector of the Transmission Fluid
XPS –
Pressure Switch
XRS-232 Lateral Wiring Harness – 4-Pin Diagnosis Connector of RS-232 10-5 to 6
XTLM Lateral Wiring Harness – 12-Pin Connector of the Telematics 10-5 to 6
Lateral Wiring Harness – 6-Pin Connector of the Transmission Voltage Protection
XT7 –
(TVP)
XT9 Lateral Electrical Wiring Harness – 3-Pin Connector of the Parking Brake Switch –
XT11 Main Rear Wiring Harness – 6-Pin Connector of the “Inching” Pedal –
XY7 Main Rear Wiring Harness – 2-Pin Connector of the “Lock-Up” of the Transmission –
XY7a Brake Electrical Wiring Harness – 2-Pin Connector of the Parking Brake Solenoid –
Lateral Wiring Harness – 68-Pin Connector of the Transmission ECU – “Torque
XZF –
Converter” (ZF) Transmission
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Electrical system - Component identification (Models equipped

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Component list
ECA fuse box
Fuse Description Page
1F Fuse 7,5 A – Work light behind the blade and front light control 5–3
2F 7,5 A fuse – Front cab lights 8–1
3F 7,5 A fuse – Front blade work lights 8–2
4F 3 A fuse – Cooling fan reverser 11-4
15 A fuse – Hydraulic systems for the saddle, on-off of the lock pin, float system,
5F 11-5
and anti-shock of the ripper/scarifier
6F 10 A fuse – Top front window wiper and washer pump 17–2
7F 10 A fuse – Rear window wiper and washer pump 17-5
8F 10 A fuse – Bottom front window wiper and washer pump 18-2
9F 7,5 A fuse – Front, rear, side door windshield defroster 18-5
10F 10 A fuse – Air suspension seat 18-4
11F 7,5 A fuse – Alternator regulator 3–3
12F 5 A fuse – Electric engine shutdown 23-6
13F 7,5 A fuse – Parking brake solenoid 9–1
7,5 A fuse – “IGN” (Ignition) transmission power, TCU, selector lever, switches,
14F 21-2
relay for the reverse alarm and AEB
15F 7,5 A fuse – Back up –
16F 3 A fuse – Telematics, “IGN” (Ignition) Circuit and Blade control (Opt.) 10-4
17F 5 A fuse – Back up –
ECB fuse and relay box

1F 7,5 A fuse – Front blade work light 5–1
2F 7,5 A fuse – Rear work light 7-5
3F 20 A fuse – Rear window and outside rear view mirrors defroster 20-2
5F 7,5 A fuse – Air-conditioning compressor and commands 19-1
6F 3 A cab – Cab air recirculation 19–6
20 A fuse – 24 V to 12 V converter after ignition key “ACC” (Accessory) (radio,
7F 22-4
cigarette lighter)
8F 7,5 A fuse – Work light for snow 8–2
K1 Front blade work light relay 5–2
K2 Rear work light relay 7-5
K3 – –
K4 Parking brake relay 9–4
K5 Air Conditioning compressor relay 19-1
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ECC fuse and relay box

3F 20 A fuse – Cigarette lighter and 12 V socket 22-2
4F 7,5 A fuse – 12 V radio 22-3
7F 15 A fuse – 24 V socket 20-5
8F 10 A fuse – Beacon lights and cab interior light 16-5
9F 3 A fuse – Brake light 8–4
10F 3 A fuse – Reverse alarm fuse 8–5
K1 Top front window wiper relay – High speed 17-3
K2 Top front window wiper relay – Low speed 17-1
K3 Front wiper speed control relay 17-1
K4 Cooling fan reverser relay 11-4
K5 Backup alarm relay 8–5
ECD fuse and relay box

4F 7,5 A fuse – TCU transmission main supply 21-2
5F 5 A fuse – Telematics – “BAT” (Battery) circuit 10-4
6F 20 A fuse – 24 V to 12 V converter “BAT” (battery) 22-4
7F 5 A fuse – Master switch timer and EST diagnostic connector 9 or 9a–11
8F 25 A fuse – Blade control (Opt.) 12-1
9F 5 A fuse – “ACC” (Accessories) circuit 4–3
10F 5 A fuse – “IGN” (Ignition) circuit 4–2
Start-up relay (Neutral from the transmission and “START” signal from the ignition
K1 21–8
key)
K2 Start-up relay (Command from the EDC7 starter) 21–7
K3 Start-up relay (Ignition switch, EDC7 starter) 23-6
K4 Timer relay for the master switch 9 or 9a–11
K5 On-off relay for the cooling fan 14-4
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Electrical system - Component identification - (Models equipped

[HBZN0845VBAF00184 - ]
-]
Component list
ECA fuse box
5F 11-5
15F 7,5 A fuse – Transmission power 25–2
16F 3 A fuse – Telematics, “IGN” (Ignition) Circuit and Blade control (Opt.) 10-4
19F 5 A fuse – Used only in models with “AWD” –

5F 7,5 A fuse – Air-conditioning compressor and commands 19-1
20 A fuse – 24 V to 12 V converter after ignition key “ACC” (Accessory) (radio,
7F 22-4
cigarette lighter)
K3 Used only in models with “AWD” –
K4 – –
K5 Air Conditioning compressor relay 19-1
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4F 7,5 A fuse – 12 V radio 22-3
K4 Cooling fan reverser relay 11-4

1F 10 A fuse – Transmission main supply 25–2
3F 3 A fuse – Transmission lever reverse signal 25-3
5F 5 A fuse – Telematics – “BAT” (Battery) circuit 10-4
9F 5 A fuse – Ignition switch, “ACC” (Accessory) circuit 4–3
10F 5 A fuse – Ignition switch, “IGN” (Ignition) circuit 4–2
K1 25–6
key)
K5 On-off relay for the cooling fan 14-4
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[HBZN0845VBAF00184 - ]
-]
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Electrical system - Component identification (Models with Tier 3

Engine)
[HBZN0845VBAF00184 - ]
[HBZN0845VCAF01093 - ]
-]
[HBZN0885PCAF00871 - ]
Component list
ECE fuse and relay box
1F 15 A fuse – Horn 6-1
2F 5 A fuse – Front left-hand and rear right-hand position light 6-2
7,5 A fuse – Front right-hand and rear left-hand position light, license plate light,
3F 6-2
and illumination of the instrument clusters and switches
4F 5 A fuse – Differential lock 11-1
5F 7,5 A fuse – Turn signals and hazard lights 6–6
6F 7,5 A fuse – Low beams 7-2
7F 7,5 A fuse – High beams 7-1
8F 7,5 A fuse – Voltmeter (AIC) 9 or 9a–2
9F 7,5 A fuse – Main supply of the panel (AIC) “IGN” (Ignition) 9 or 9a–10
10F 10 A fuse – Main supply of the panel (AIC) “BAT” (Battery) 9 or 9a–10
K1 Horn relay 6-1
Differential lock relay – For models equipped with “Direct Drive” transmission
K2 11-2
(FUNK)
K3 Low beam headlights relay 7-2
K4 High beam headlights relay 7-1
K5 Voltmeter relay 9 or 9a–2
PRM A – ACC (Accessories)

FA1 40 A fuse – Supply of “ACC” (Accessories) circuits 4–5
FA2 20 A fuse – Air conditioning fan power 4–5
PRM B – IGN (Ignition)

FB1 20 A fuse – Supply of “IGN” (Ignition) circuits 4–4
FB2 30 A fuse – Used for Tier III, Tier 3, MAR 1 engines 4–4
PRM C – ACC (Accessories)

FC1 40 A fuse – Supply of “ACC” (Accessories) circuits 4–3
FC2 20 A fuse – Back up 4–3
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3 Engine)
[HBZN0845VBAF00184 - ]
[HBZN0845VCAF01093 - ]
-]
[HBZN0885PCAF00871 - ]
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Electrical system - Electrical schema index (Models equipped with

Tier 3 engine, “Direct Drive” transmission, and “AWD”)
Component list
DB Electronic Throttle 23-6
AIC Adv. Instrument Cluster 9a-6
AT Aerial, Antenna for Radio 22-3
BLD-C Blade Control (Optional) 12-1
CB1 105 A Circuit Breaker 3-4
D12 Diode for Electric Master Switch “ACC” (Accessories) 3-5
D13 Diode for Electric Master Switch “IGN” (Ignition) 3-5
DB1 Diode Box for the Turn Signal 6-3
DB2 Diode Box for the Wipers and Demister Fans 17-4
DMC.H Diode Box for “Come-Home” 25-8
DR Diode and Resistor Box for Parking Brake Signal and “AWD” 21-1/25-7
ECA Fuse Box on the Lateral Console 32 and 33
ECB Fuse and Relay Box on the Lateral Console 32 and 33
ECC Fuse and Relay Box on the Lateral Console 32 and 33
ECD Fuse and Relay Box on the Lateral Console 32 and 33
ECE Fuse and Relay Box on the Front Console 34
EDC7 Engine Data Controller on the Lateral Console 23 and 24
EM Electromagnetic Clutch for the Air Conditioning 19-1
EV2 Differential Lock Solenoid Valve (Optional) 11-1
EV4 Solenoid Valve for the Saddle Lock Pin 11-5
EV27 Drive Inverter Solenoid Valve of the Fan (Optional) 11-5
EV28a Fan Control Solenoid Valve (Optional) 11-3
EVTA Proportional Solenoid Valve A – Speed 25-9
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EVTB Proportional Solenoid Valve B – Speed 25-10
EVTC Proportional Solenoid Valve C – Speed 25-10
EVTD Proportional Solenoid Valve D – Speed 25-11
EV- MLE Proportional Solenoid Valve of the Left-Hand Side Hydraulic Motor 21-10
EV–MRI Proportional Solenoid Valve of the Right-Hand Side Hydraulic Motor 21-11
EV–MS Pilot Solenoid Valve of the Hydraulic Pump 21-12
EV–MY Proportional Solenoid Valve of the Reverse Gear Pump 21-11
EV–MZ Proportional Solenoid Valve of the Forward Gear Pump 21-12
FGH 125 A Mega Fuse – “Grid Heater” Intake Air Heater 23-4
FH Fuel Filter Heater 3-6
G3 28 V 90 A Alternator 3-2
GH Intake Air Heater “Grid Heater” 23-3
H1 Right-Hand Work Light in the Front of the Blade 5-2
H2 Left-Hand Work Light in the Front of the Blade 5-3
H3 Right-Hand Work Light Behind the Blade 5-3
H4 Left-Hand Work Light Behind the Blade 5-4
H5 Front Left Position Light 6-2
H6 Rear Right Position Light 6-2
H7 Right Fog Work Light 5-5
H8 Left Fog Work Light 5-6
H9 Front Right Turn Signal of the Cab – Reserve 6-5
H10 Rear Right Turn Signal Light 6-5
H11 Front Right Turn Signal Light 6-5
H12 Front Left Turn Signal Light 6-4
H13 Rear Left Turn Signal Light 6-4
H14 Front Left Turn Signal on the Cab – Reserve 6-4
H16 Left Headlight (High Beam) 7-1
H17 Right Headlight (High Beam) 7-2
H18 Left Headlight (Low Beam) 7-2
H19 Right Headlight (Low Beam) 7-3
H20 Front Right Position Light 7-3
H21 Rear Left Position Light 7-3
H22 License Plate Light (Optional) 7-4
H27 Rear Right Reflector (Cab) 7-6
H28 Rear Left Reflector (Cab) 7-6
H29 Left Cab Headlight (Optional) 8-1
H30 Right Cab Headlight (Optional) 8-2
H31 Left-Hand Light of the Front Blade (Optional) 8-2
H32 Right-Hand Light of the Front Blade (Optional) 8-3
H33 Left-Hand Brake Light 8-4
H34 Right-Hand Brake Light 8-4
H40 Front Right Beacon Light (Optional) 16-6
HA1 Horn 6-1
HA2 Audible Signal (AIC) 9a-3
HA3 Reverse Alarm (Optional) 8-5
J1–J2–J3 ECU connectors 25
J4 Gear Selector Connector 25-3
J6 Connector 25-8
K15 Hazard Light Relay 6-3
KBLD Blade Control Unit 12-2
K C1 12 – 24 V Cigarette Lighter and Radio Voltage Converter 22-1
K ECU Electronic Control Unit for the Transmission 25
K EHC “AWD” System Electronic Module 21
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K FH Heater Relay for the Fuel Filter and Water Separator 3-5
K IP “Inching” pedal 25-1
K PT Auxiliary Magnetic Switch for the Tire Inflator 22-6
KR Radio 22-4
KRD Demister Relay for the Rear Window and Side Mirrors 20-2
KRV1 Air Conditioning Fan – 1st Speed Relay 19-2
KRV2 Air Conditioning Fan – 2nd Speed Relay 19-3
KRV3 Air Conditioning Fan – 3rd Speed Relay 19-4
KSR Starter Relay 3-4
KTVP Transient Voltage Protection 25-1
M1 Starter Motor 3-3
M2 Front Windshield Wiper 17-3
M3 Front Windshield Washer Pump 17-4
M4 Rear Windshield Wiper 17-6
M5 Rear Windshield Washer Pump 18-1
M6 Washer Pump for the Lower Front Windshield (Optional) 18-4
M7 Lower Front Windshield Wiper (Optional) 18-2
M8 Air Suspension Seat (Optional) 18-4
M9 Rear Demister Fan (Optional) 18-5
M10 Demister Fan for the Left-Hand Windshield (Optional) 18-5
M10a Demister Fan for the Right-Hand Door (Optional) 18-6
M11 Air Conditioning Regulator 19-5
MLS Demister for the Left-Hand Side Mirror 20-4
M PT Tire Inflator Compressor 22-5
MRS Demister for the Right-Hand Side Mirror 20-4
M.T. Air-Conditioning Evaporator Unit (Optional) 19-4
PO1 Energy Socket 20-5
PRM A Power Relay Module A – Accessories 5-4
PRM B Power Relay Module B – Ignition 4-4
PRM C Power Relay Module C – Accessories 3-4
R3 12 V Cigarette Lighter 22-2
RWDR Rear Window Demister 20-2
S1 Electronic Master Switch 3-1
S2 Ignition Switch 4-1
S3 Work Light Switch for the Front and Rear of the Blade 5-2
S4 Switch for the Headlights/Reflector Lights, Horn and Turn Signal 6-4
S5 Blinking Warning Light Switch 6-3
S6 Rear Reflector Switch 7-5
S7 Switch for the Cab Headlights and Fog Lights (Optional) 8-1
S8 Front Blade Switch (Optional) 8-2
S9 Brake Light Switch 8-4
S9a “AWD” Brake Switch 8-4
S12 Function Keys Switch 10-4
S14 Fuel Level Sensor 9a-1
S15 Engine Coolant Temperature Switch 10-2
S16 Air Filter Restriction Switch 10-4
S17 Restriction Switch for the Transmission Fluid Filter 9a-11
S18 Transmission Fluid Pressure Switch 9a-9
S20 Hydraulic Fluid Temperature Switch 9a-2
S21 Brake Low Pressure Switch 9a-12
S23 Restriction Switch for the Hydraulic Fluid Filter 10-4
S24 Differential Lock Switch (Optional) 11-2
S26 Switch for the Saddle Lock Pin 11-6
S27 Switch for the Ripper or Scarifier (Optional) 15-3
S28 Left Float Switch of the Blade (Optional) 12-3
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S29 Right Float Switch of the Blade (Optional) 12-5
S30 Lift Cylinder Damper Switch (Optional) 13-3
S31 Front Blade Float Switch (Optional) 14-1
S32 Switch for the Left-Hand Cab Dome Light (Next to the Left-Hand Door) 16-3
S33 Switch for the Right-Hand Cab Dome Light (Above the Console) 16-4
S34 Beacon Light Switch (Optional) 16-5
S35 Switch for the Front Windshield Wiper, Windshield Washer Pump and the Timer 17-1
S37 Rear Windshield Wiper Switch 17-5
S38 Switch for the Rear Windshield Washer Pump 18-1
S39 Switch for the Washer and Wiper of the Lower Front Windshield (Optional) 18-3
S40 Demister Fan Switch (Optional) 18-6
S40a Switch for the Rear Window and Mirror Demister (Optional) 18-6
S41 High Pressure Switch for the Air-Conditioning System (Optional) 19-2
S42 Switch for the Three-Speed Fans of the Air-Conditioning System (Optional) 19-3
S43 Air Conditioning On/Off Switch (Optional) 19-5
S44 Mode Damper Switch for the Air Conditioning System (Optional) 19-4
S47 Gear Selector 25-3
S49 “Come-Home” Back-up Mode Switch 25-10
S50 Magnetic Engine Speed Pickup Sensor 25-11
S51 Magnetic Output Speed Pickup Sensor 25-11
S52 Cylinder Speed Magnetic Pickup Sensor 25-12
S53 Transmission Temperature Sensor 25-12
S55 Fan Drive Inverter Switch 11-3
S58 Water in Fuel Sensor 23-1
S59 Valve Camshaft Sensor 24-6
S60 “Common Rail” Pressure Sensor 24-6
S61 Engine Coolant Temperature Sensor 24-6
S62 Fuel Temperature Sensor 24-6
S63 Crankshaft Sensor 24-6
S64 Temperature/Engine Oil Pressure Sensor 24-6
S65 Air Intake Pressure/Temperature Sensor 24-6
S66 Tire Inflator Switch 22-6
S85 Speed Sensor of the “AWD” Left-Hand Side Hydraulic Motor 21-3
S86 Speed Sensor of the “AWD” Right-Hand Side Hydraulic Motor 21-4
S87 Additional Speed Sensor of the “AWD” Machine 21-4
S88 “AWD” Line A Pressure Sensor 21-5
S89 “AWD” Line B Pressure Sensor 21-5
SDB “AWD” Electronic Switch 21-6
SP1 Left-hand Speaker 22-4
SP2 Right-hand Speaker 22-4
v2 Varistor for the Differential Lock Solenoid Valve (Optional) 11-1
V4 Varistor for the Solenoid Valve of the Saddle Lock Pin (Optional) 11-5
V17 Varistor for the Anti-Impact Solenoid Valve of the Right Lift Cylinder (Optional) 13-5
V18 Varistor for the Anti-Impact Solenoid Valve of the Right Lift Cylinder (Optional) 13-6
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V21 Varistor for the Magnetic Coupler/Compressor (Optional) 19-1
V27 Varistor for the Drive Inverter Solenoid of the Fan (Optional) 11-4
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Electrical system - Electrical schematic sheet 07 (Models Equipped

with Tier 3 engine, “Direct Drive” transmission and “AWD” traction)
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Electrical system - Electrical schematic sheet 08 (Models Equipped

with Tier 3 engine, “Direct Drive” transmission and “AWD” traction)
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865B AWD
885B AWD
Component list
X1 Main Rear Wiring Harness – Side Console 70-Pin Connector –
X1DB Main Rear Wiring Harness – Eyelet Connector of the Side Console – Power –
X2 Main Rear Wiring Harness – 40-Pin Side Console Connector –
X4 Main Rear Wiring Harness – 2-Pin Fuel Tank Connector –
X6 Main Rear Wiring Harness – 70-Pin Front Console Connector –
X7 Main Rear Wiring Harness – 20-Pin Main Front Connector –
Main Rear Wiring Harness – 6-Pin Connector of the Wiper of the Lower Front
X7A –
Windshield, Ripper/Scarifier
X8 Main Rear Wiring Harness – 2-Pin Fan Drive On/Off Connector –
Main Rear Wiring Harness – 3-Pin Connector of the Magnetic Coupler of the Air
X9 –
Conditioning, Fan Drive On/Off, and Auxiliary Start System
X11 Main Rear Wiring Harness – 6-Pin Connector of the Reverse Alarm –
X12 Main Rear Wiring Harness – 2-Pin Connector of the Position Lights –
Main Rear Wiring Harness – 6-Pin Connector of the Differential Lock and Air
X15 –
Conditioning Pressure Switch
Side Console Wiring Harness – 6-Pin Power Connector of the Radio and “Can
X19 –
Bus” of the Cab
X20 Side Console Wiring Harness – 20-Pin Connector of the Cab – Black –
X23S – X23T Normal Operation and X23S – X23TA 20-Pin Connector of the
X23S/T –
“Come-Home” – Gray
X23SA – X23TA Normal Operation and X23SA – X23T 20-Pin Connector of the
X23SA/TA –
“Come-Home” – Gray
Lateral Wiring Harness – 6-Pin Connector of the Air Conditioning System (Fan
X24 –
Speed)
X24S – X24T Normal Operation and X24S Disconnected from the X24T =
X24S/T –
Maintenance (Weld) 20-Pin Connector – Black
X26 Lateral Wiring Harness – 6-Pin Connector of the Air Conditioning System –
X27 Lateral Wiring Harness – 6-Pin Connector for the Air Conditioning Control –
X27A Lateral Wiring Harness – 3-Pin Connector for the Air Conditioning Control –
Electronic and Mechanical Engine Wiring Harness – 6-Pin Connector of the
X29 –
Transmission and Hydraulic Switch
X30 Main Front Wiring Harness – 2-Pin Damper Connector of the Lift Cylinder (Optional) –
Main Front Wiring Harness – 3-Pin Float Connector of the Right-Hand and
X31 –
Left-Hand Blade (Optional)
X32 Main Front Wiring Harness – 2-Pin Float Connector of the Front Blade (Optional) –
X36 2-Pin Connector of the Lateral Wiring Harness for Calibration –
X37 2-Pin “Jump” Connector of the Lateral Wiring Harness for Calibration –
3- Pin Connector of the Lateral Harness for Computer Diagnostics of the
X38 –
Transmission
Hydraulic Sensor Wiring Harness – 1-Way Restriction Connector of the
X39 –
Transmission Fluid Filter
X40 Cab Wiring Harness – 2-Pin Connector of the Rear Left Beacon Light –
X42 Lateral Wiring Harness – 2-Pin Connector of the Air Suspension Seat (Optional) –
X47 Main Rear Wiring Harness – 20-Pin Connector of the Electronic Engine – Gray –
X52 1-Pin Power Connector of the Direct Converter for the Battery “BAT” –
X53 1-Pin Power Connector of the Converter After the Ignition Key “ACC” (Accessories) –
X53a 1-Pin Power Connector of the Converter –
X62 “AWD” Electronic Switch – 4-Pin Machine Code Connector –
X63 “AWD” 170 Hp Class Machine Code –
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X63A “AWD” 200 Hp Class Machine Code –
X64 Lateral Wire Harness – Diagnostics Tool –
X86 Main Rear Wiring Harness – 2-Pin Connector of the Fan Reverse Solenoid –
X87 Main Rear Wiring Harness – 2-Pin Connector of the PWM Solenoid (Reverse) –
XA Power Derivation Point on the Rear Chassis Near the Cab Floor –
XAE Main Rear Wiring Harness – 6-Pin Connector of the Electronic Throttle –
XBLD Lateral Wiring Harness – 6-Pin Connector for the Blade Control –
XCAN Main Rear Wiring Harness – 6-Pin Connector of the Engine –
XCV Lateral Wiring Harness – 6-Pin Connector of the 12 – 24 V Voltage Converter –
XD12 Diode Module – 2-pin Connector for the Ignition Switch “ACC” (Accessories) 3-5
XD13 Diode Module – 2-pin Connector for the Ignition Switch “IGN” (Ignition) 3-5
XDV1 2-Pin Power Shunt Connector –
XEDC7(A) Engine Power Wiring Harness – 16-Pin Connector of the Engine EDC –
Electrical Wiring Harness of the Electronic Engine – 89-Pin Connector of the
XEDC7(B) –
Engine EDC
XEDC7(C) Engine Power Wiring Harness – 36-Pin Connector of the Engine EDC –
XEHC Lateral Wiring Harness – “AWD” Electronic Control Unit –
XG1 –
XG2 –
Main Rear Wiring Harness – 31-Pin Connector of the Electrical Wiring Harness of
XJ6 –
the Transmission
XMS Main Rear Wiring Harness – 3-Pin Connector of the Main Switch –
XPB Brake Electrical Wire Harness – 3-Pin Connector of the Parking Brake Switch –
Hydraulic Sensor Wiring Harness – 2-Pin Connector of the Transmission Fluid
XPS –
Pressure Switch
XRS-232 Lateral Wiring Harness – 4-Pin Diagnosis Connector of RS-232 10-5 to 6
XTLM Lateral Wiring Harness – 12-Pin Connector of the Telematics 10-5 to 6
Lateral Wiring Harness – 6-Pin Connector of the Transmission Voltage Protection
XT7 –
TVP
XT9 Lateral Electrical Wiring Harness – 3-Pin Connector of the Parking Brake Switch –
XT11 Main Rear Wiring Harness – 6-Pin Connector of the “Inching” Pedal –
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865B AWD
885B AWD
Component list
ECA fuse box
5F 11-5
13F 7,5 A fuse – Back up
15F 7,5 A fuse – Transmission power 25–2
16F 3 A fuse – “Telematics”, “IGN” (Ignition) circuit 10-4
17F 5 A fuse – Back up
19F 10 A fuse – Electronic power relay switch 21–7
20F 5 A fuse – Speed sensors 21-5

5F 7,5 A fuse – Air-conditioning controls and compressor clutch 19-1
20 A fuse – 24 V to 12 V converter after ignition key “ACC” (Accessories) (radio,
7F 22-4
cigarette lighter)
K3 Power relay, “IGN” (Ignition) circuit 21–7
K4 Not used
K5 Air-conditioning compressor clutch relay 19-1
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1F 10 A fuse – Main power (EHC 22, 23, 45) 21–9
2F 3 A fuse – Resistors of the hydraulic engine speed sensors 21-4
4F 7,5 A fuse – 12 V radio 22-3
5F 3 A fuse – Supply (EHC-54 + Relay) 21–8
6F 3 A fuse – Supply (EHC-18) 21-10
K4 Cooling fan control relay 11-4

3F 3 A fuse – Transmission lever reverse signal 25-3
5F 5 A fuse – Telematics – BAT circuit 10-4
9F 5 A fuse – Ignition switch, “ACC” (Accessory) circuit 4–3
10F 5 A fuse – Ignition switch, “IGN” (Ignition) circuit 4–2
K1 25–6
key)
K5 – –
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865B AWD
885B AWD
Component list
ECE fuse and relay box
1F 15 A fuse – Horn 6-1
2F 5 A fuse – Front left-hand and rear right-hand position light 6-2
7,5 A fuse – Front right-hand and rear left-hand position light, license plate light,
3F 6-2
and illumination of the instrument clusters and switches
4F 5 A fuse – Differential lock 11-1
5F 7,5 A fuse – Turn signals and hazard lights 6–6
6F 7,5 A fuse – Low beams 7-2
7F 7,5 A fuse – High beams 7-1
8F 7,5 A fuse – Voltmeter (AIC) 9 or 9a–2
9F 7,5 A fuse – Main supply of the panel (AIC) “IGN” (Ignition) 9 or 9a–10
10F 10 A fuse – Main supply of the panel (AIC) “BAT” (Battery) 9 or 9a–10
K1 Horn relay 6-1
K2 Differential lock relay 11-2
K3 Low beam headlights relay 7-2
K4 High beam headlights relay 7-1
K5 Voltmeter relay 9 or 9a–2
PRM A – ACC (Accessories)

FA1 40 A fuse – Supply of “ACC” (Accessories) circuits 4–5
FA2 20 A fuse – Air conditioning fan power 4–5
PRM B – IGN (Ignition)

FB1 20 A fuse – Supply of “IGN” (Ignition) circuits 4–4
FB2 30 A fuse – Used for Tier III, Tier 3, MAR 1 engines 4–4
PRM C – ACC (Accessories)

FC1 40 A fuse – Supply of “ACC” (Accessories) circuits 4–3
FC2 20 A fuse – Back up 4–3
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47653814_34B 1
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Index

Electrical system - Electrical schematic sheet 09 - (Models equipped with Tier 3 engine and “Direct
Drive” transmission) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electrical system - Component identification (Models equipped with Tier 3 engine and “Torque Con-
verter” transmission) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Electrical system - Component identification (Models equipped with Tier 3 engine, “Direct Drive”
transmission, and “AWD”) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Electrical system - Component identification (Models with Tier 3 Engine) (*) . . . . . . . . . . . . . . . . . . . 63
Electrical system - Component identification (Models with Tier 3 Engine) (*) . . . . . . . . . . . . . . . . . . . 77
Electrical system - Component identification - (Models equipped with Tier 3 engine and “Direct Drive”
transmission) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Electrical system - Electrical schema index (Models equipped with Tier 3 engine, “Direct Drive” trans-
mission, and “AWD”) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Electrical system - Electrical schema index (Models with Tier 3 Engine) (*) . . . . . . . . . . . . . . . . . . . . 5
Electrical system - Electrical schematic sheet 03 (Models equipped with Tier 3 engine, “Direct Drive”
Electrical system - Electrical schematic sheet 03 (Models with Tier 3 Engine) (*) . . . . . . . . . . . . . . . . 10
Electrical system - Electrical schematic sheet 07 (Models Equipped with Tier 3 engine, “Direct Drive”
transmission and “AWD” traction) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Electrical system - Electrical schematic sheet 08 (Models Equipped with Tier 3 engine, “Direct Drive”
transmission and “AWD” traction) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
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Electrical system - Electrical schematic sheet 09 (Models equipped with Tier 3 engine and “Torque
Converter” transmission) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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Harnesses and connectors - 100

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Contents
FUNCTIONAL DATA
Harnesses and connectors

Electrical schematic sheet 01 (ECU - EDC17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrical schematic sheet 04 (ECU - EDC17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Electrical systems - Harnesses and connectors
Harnesses and connectors - Electrical schematic sheet 01 (ECU -

EDC17)
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5802081998_01JA 1
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Harnesses and connectors - Electrical schematic sheet 02 (ECU - EDC17)
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47907412A0002JA 1
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47907412A0003JA 1
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47907412A0004JA 1
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Index

Harnesses and connectors - Electrical schematic sheet 02 (ECU - EDC17) . . . . . . . . . . . . . . . . . . . . 6
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Engine starting system - 201

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Contents
FUNCTIONAL DATA
Engine starter
Drawing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Engine starter
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Electrical systems - Engine starting system
Engine starter - Drawing

LAIL11MG0204F0A 1
1. Starter Motor
2. Screw
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Engine starter - Remove

NOTE: The starter is located on the left-hand side of the engine, mounted to the engine flywheel housing.
1. Turn the master disconnect switch to the “OFF” posi-
tion.
2. Remove the air cleaner and the air cleaner bracket.
3. Open the cover to access the bolts.
Use a 10 mm wrench
4. Remove the starter.
LAIL11MG0610A0A 1
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Engine starter - Install

1. Install the starter. Tighten the bolts using a 10 mm

wrench with a torque of 43 N·m (32 lb ft).
LAIL11MG1719A0A 1
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Engine starter - Remove

NOTE: The starter is located on the left-hand side of the engine, mounted to the engine flywheel housing.
1. Turn the master disconnect switch to the “OFF” posi-
tion.
2. Remove the air cleaner and the air cleaner bracket.
3. Open the cover to access the bolts.
Use a 12 mm wrench
4. Remove the starter.
LAIL11MG0926A0A 1
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Engine starter - Install

1. Apply a coat of Three Bond ® sealant to the mounting

surface of the starter motor and to both sides of the
spacer and of the joint, if applicable.
LAIL11MG0925A0A 1
2. Apply LOCTITE® 567™ PST PIPE SEALANT thread

sealant to the starter motor screws. Install the starter.
Tighten the screws using a 12 mm wrench to a torque
of 77 N·m (57 lb ft)
3. Starter motor screws pre-coated with Vibra Seal ® re-
quire a lower torque, 68 N·m (50 lb ft)
LAIL11MG0926A0A 2
4. Install the positive cables.
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Index

Engine starter - Drawing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine starter - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine starter - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine starter - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine starter - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Alternator - 301

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Contents
Alternator - 301
FUNCTIONAL DATA
Alternator
- Drawing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Alternator
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Electrical systems - Alternator
Alternator - Drawing
LAIL11MG2079G0A 1
Alternator 80 A
1. Support 9. Nut
2. Screw 10. Alternator
3. Screw 11. Washer
4. Arm 12. Washer
5. Screw 13. Locking nut
6. Washer 14. Cable
7. Screw 15. Cable
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8. Bushing
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Alternator - Remove
1. Remove the alternator fixing bolts. Then remove the

alternator.
LAIL11MG0612A0A 1
LAIL11MG0613A0A 2
2. Remove the alternator bracket bolts. Then remove the

bracket.
LAIL11MG0614A0A 3
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Alternator - Install
1. Install the alternator bracket on the thermostat housing,

using a 10 mm wrench, to a torque of 24 N·m (18 lb ft)
.
LAIL11MG0076A0A 1
2. Position the alternator on the bracket and secure it with

the fixing screw and spacer.
LAIL11MG0078A0A 2
NOTICE: Do not tighten at this point. To avoid misaligning

and overloading the upper bracket mounting lug on the al-
ternator, leave the fixing screws loose until all of the parts
of the alternator have been installed.
3. Install the alternator coupling.
LAIL11MG0077A0A 3
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4. Check the alternator pulley visually or with a ruler to

make sure that it is aligned with the other pulleys and
parallel with the front of the block.
LAIL11MG0079A0A 4
5. After all of the parts have been assembled, tighten the

fixing screws in the following sequence:
(1) Alternator-alternator bracket fixing screw.
(2) Alternator-bottom bracket fixing screw.
(3) Water inlet-alternator fixing screw.
(4) Block-water inlet fixing screw.
LAIL11MG0080A0A 5
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Alternator - Remove
Alternator Arm
Remove the fixing screw from the alternator arm (A),
and the fixing screw from the rear bracket (B), using
10 mm and 19 mm wrenches.
LAIL11MG0244A0A 1
Alternator
1. Remove the fixing screws from the alternator and its
nuts using 15 mm, 18 mm and 19 mm wrenches.
2. Remove the alternator.
LAIL11MG0094A0A 2
Alternator Support
3. Remove the alternator support using a 13 mm wrench.
LAIL11MG0095A0A 3
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Alternator - Install
Alternator Support
1. Install the alternator support on the thermostat case
using a 13 mm wrench with a torque of 24 N·m (18 lb
ft).
LAIL11MG1079A0A 1
Alternator
2. Position the alternator on the support and insert the
assembling bolts.
NOTE: The bolts must be installed with the nuts facing the
inside of the support.
Do not tighten at this moment.
LAIL11MG1080A0A 2
Alternator Arm
3. Install the bolt on the alternator bracket and the water
pump. Tighten the bolts by hand.
LAIL11MG1081A0A 3
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NOTICE: Check that the alternator bracket is correctly po-

sitioned for the belt to be aligned correctly.
4. Connect the alternator bracket to the alternator.
Tighten the bolts by hand.
LAIL11MG1082A0A 4
5. Tighten the water pump assembly bolts using a 13 mm

wrench with a torque of 24 N·m (18 lb ft).
LAIL11MG1083A0A 5
6. Tighten the alternator assembly bolts, using 15 mm,

18 mm and 19 mm wrenches, with a torque of:
(A) 43 N·m (32 lb ft)
(B) 24 N·m (18 lb ft)
(C) 80 N·m (59 lb ft)
LAIL11MG1084A0A 6
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Index
Alternator - 301
Alternator - Drawing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Alternator - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Alternator - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Alternator - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Alternator - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Battery - 302

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Contents
Battery - 302
TECHNICAL DATA
Battery
Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Battery
Check Electrolyte Level (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cleaning /Inspection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical test Charge Capacity (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Prepare (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Electrical systems - Battery
Battery - Special tools

845B
865B
885B
CAS-10147
Device used to perform the Load Capacity Test.
LAIL11CW1154A0A 1
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Battery - Check Electrolyte Level

845B
865B
885B
If the battery is a maintenance-free battery, check the

electrolyte level every 1000 h of operation or every six
months, whichever occurs first. As for other types of
batteries, check the electrolyte level every 250 h of op-
eration.
NOTE: Maintenance-free batteries will have the words
(Maintenance Free) on the decal located at the top of
the batteries. If the central part of the decal has been
removed to gain access to the battery covers, the words
(Maintenance Free) may have been erased.
Check the electrolyte level more often during periods of
hot weather. The use of a large amount of water in the
battery can be caused by a high battery temperature or
a voltage regulator setting that is too high. Always keep
the electrolyte level above the battery plates in order to
prevent damage to the plates.
NOTE: In maintenance-free batteries, it is necessary to re-
move the central part of the decal in order to gain access
to the battery caps. Do not discard the center part of the
decal. Put it back after re-installing the caps.
If the electrolyte level is low, top up with distilled water or
other clean water until the electrolyte level is just below
the cell opening. Do not add more water than is needed.
Excess water can damage performance, shorten the
useful life of the battery, and cause corrosion around
the battery.
NOTE: Only add clean water, DO NOT add electrolyte.
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Battery - Cleaning /Inspection

845B
865B
885B
If any damage causes an electrolyte leakage, replace

the battery.
If the battery in the machine has anti-spill caps, consult
Battery - Service instruction (55.302) and check the
condition of the caps.
Inspect the battery at regular intervals for dirt, corrosion,
and damage. The accumulation of electrolyte and dirt
on top of the battery can cause it to discharge by form-
ing a passage along which the current can flow.
If it is necessary to clean the battery, remove the bat-

tery from its support bracket and clean the battery, the
terminals of the battery cables, and the battery support
bracket. If available, use New Holland Battery Saver
and Cleaner according to the instructions on the pack-
aging. New Holland Battery Saver and Cleaner also
helps prevent corrosion. If New Holland Battery Saver
and Cleaner is not available, use bicarbonate of soda
and water as a cleaner. DO NOT allow cleaner of any
type to enter the battery cells.
Install the battery in the machine, making sure that

the fixing screws are tight. Apply Battery Saver and
Cleaner or a coat of Urethane Sealer to the cable
terminals to prevent corrosion. DO NOT apply grease.
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Battery - Service instruction

845B
865B
885B
Anti-spill type caps

If the machine has one or more batteries with anti-spill
caps, do not operate the machine if the caps are not
working properly or if they are not in place. The anti-spill
caps prevent the leakage of electrolyte which can cause
personal injury and damage to the machine in the event
of a rollover accident.
The anti-spill caps have a valve with a stem made from
lead and rubber. When the anti-spill cap is turned, the
weight of the lead secures the rubber stem against the
breather hole, thus preventing a loss of electrolyte.
If the breather hole and the valve are clogged by foreign
material, the pressure inside the battery may increase
enough to crack the battery case. Always check the
breather hole for clogging when checking the electrolyte LAIL11MG1370A0A 1
level. If the breather hole is clogged, turn the anti-spill
cap and clean it. Rapidly move the anti-spill cap up and
down. You should feel the displacement of the valve.
Otherwise, wash the anti-spill cap and loosen the valve.
Rapidly move the anti-spill cap up and down in order to
remove the water.
When removing an anti-spill cap, check the condition
of the rubber gasket. If the rubber gasket is missing or
damaged, fit a new anti-spill cap.
Anti-spill caps that are missing or broken MUST be re-
placed with new ones. DO NOT use any other type of
cap to replace the anti-spill caps.
When fitting a new battery, the battery MUST have anti-
spill caps. If the anti-spill caps of the old battery are in
good condition, the caps may be re-used.
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Battery - Test
845B
865B
885B
NOTE: To properly test a battery, perform every step of the

test until you discover the condition of the battery.
Visual checks
1. Make sure that the cable connections are clean and
tight. Clean any foreign material from the top of the
battery.
2. Inspect the battery case, the battery posts, and the ca-
bles for damage.
3. Check the electrolyte level, see Battery - Check Elec-
trolyte Level (55.302).
4. If water was added to the battery, this must be charged
for 15 min at 15 – 25 A in order to mix the water with
the electrolyte.
Specific gravity check

NOTE: A densimeter is used to check the specific gravity
of the electrolyte. The specific gravity is an indication of
the level of charge for each cell.
NOTE: Densimeters are made to show the correct specific
gravity when the temperature of the electrolyte is 26.7 °C
(80 °F).
NOTE: When checking the specific gravity, you must know
the temperature of the electrolyte. If your densimeter is not
equipped with a thermometer, get a thermometer to mea-
sure the electrolyte temperature. The thermometer should
read 52 °C (126 °F).
1. Remove enough electrolyte from the cell so that the
float becomes free in the tube.
NOTE: If the specific gravity cannot be verified without first
adding water to the cell, the battery must be charged for
15 min at 15 – 25 A in order to mix the water with the elec-
trolyte. Then check the specific gravity.
2. Read the float.
3. Read the thermometer. If the reading is above 26.7 °C
(80 °F), add specific gravity points to the specific grav-
ity reading. If the reading is below 26.5 °C (80 °F),
subtract specific gravity points from the specific grav-
ity reading. See the following illustration and add or
subtract specific gravity points as required.
BRCE12ALLCCM902 1
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Specific gravity table

1. Note the correct specific gravity reading of each cell.
2. If the difference between the high reading and the low
reading is 0.050 or more, charge the battery and check
the specific gravity again. If the difference is still 0.050
or more after charging, replace the battery for a new
one.
3. The corrected specific gravity reading shows the level
of charge of each cell. The level of charge must be
at least 75% in each cell. In maintenance-free batter-
ies, the level of charge is at least 75% if the corrected
specific gravity reading is 1.240 or higher. In all other
batteries the level of charge is at least 75% if the cor-
rected specific gravity reading is 1.230 or higher.
reading is less than 0.050, and the level of charge is
at least 75% in all of the cells, perform the Capacity
(Load) Test.
reading is less than 0.050, but the level of charge is at
least 75% in any one of the cells, charge the battery
and check the specific gravity again. If after charging:
A. The level of charge is less than 75% in any of the
cells, discard the battery.
B. The level of charge is at least 75% in all the cells,
perform the Capacity (Load) Test.
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Battery - Electrical test Charge Capacity

845B
865B
885B
NOTE: This test can be done using variable load test equip-
ment, such as the “Sun Electric VAT-33”. Other test equip-
ment may be used. Connect the test equipment according
to the instructions of the equipment manufacturer.
1. The battery charge level must be at least 75%. Perform
the "Specific Gravity Check" in Battery - Test (55.302).
2. Prepare the “Sun Electric VAT 33” test equipment.
A. Select the voltmeter scale that will measure from 1
– 28 V.
B. Make sure that the load control knob is in the “OFF”
position.
C. Select the ammeter scale that will measure from 0
– 1000 A.
D. Move the volt lead switch to the “INT” position.
3. Connect the test equipment to the battery as shown.
(1) Load control knob.
(2) Ammeter clip (Tip of the arrow away from the bat-
tery).
NOTE: Never apply a load for longer than 15 s. After every
15 s, turn the load control knob to the “OFF” position for at
least one minute.
4. Apply a load of 15 A to the battery for 15 s. Wait at
least three minutes before applying the load again.
5. Check and make a record of the temperature of the
electrolyte.
LAIL11MG1371A0A 1
6. See the Specifications for the correct load for this test.
NOTE: The correct load is half of the cold cranking am-
peres at -17 °C (1 °F).
7. Turn the load control knob until the ammeter indicates
the specified load. Maintain the load for 15 s and read
the voltmeter. Turn the load control knob to “OFF”.
8. Compare the test reading and the electrolyte tempera-
ture with "Table 1".
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Table 1
Electrolyte temperature Minimum voltage
21 °C (70 °F)and above 9.6
16 °C (61 °F) 9.5
10 °C (50 °F) 9.4
4 °C (39 °F) 9.3
-1 °C (30 °F) 9.1
-7 °C (19 °F) 8.9
-12 °C (10 °F) 8.7
-18 °C (0 °F) 8.5
A. If the test result is equal to or more than the voltage

indicated, the battery is in good condition.
B. If the test result is less than the voltage indicated,
replace the battery.
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Battery - Service instruction

845B
865B
885B
Charging a battery
Before you charge a battery, check the electrolyte level
of the battery.
It is difficult to establish a precise charge rate due to the
following variable conditions.
1. Electrolyte temperature.
2. Charge level.
3. Condition of the battery.
4. Use the charge guide for the correct charge rate
and time.
See the Specifications for the reserve capacity of the
battery of this machine.
The charge rate should be reduced if:
1. Excess gases cause an electrolyte flow through the
cells.
2. The electrolyte temperature rises above 52 °C
(125 °F).
NOTE: For a better charge, use a slow charge rate.
The battery is fully charged when no cell produces ex-
cess gas and the specific gravity does not change after
three hours of charging at a slow charge rate.
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Charging guide for maintenance-free batteries

NOTE: Recommended speed (*) and time for a completely flat battery.
Battery capacity – See the reserve

Slow Charge Fast Charge
capacity under the specifications
10 h@ 5 A 2.5 h@ 20 A
80 min or less
5 h@ 10 A 1.5 h@ 30 A
15 h@ 5 A 3.75 h@ 20 A
Above 80 – 125 min
7.5 h@ 10 A 1.5 h@ 50 A
20 h@ 5 A 5 h@ 20 A
10 h@ 10 A 2 h@ 50 A
30 h@ 5 A 7.5 h@ 20 A
15 h@ 10 A 3 h@ 50 A
* Initial speed for standard chargers
NOTE: Maintenance-free batteries will have the words Maintenance Free on the decal located at the top of the bat-
teries. If the central part of the decal has been removed to gain access to the battery covers, the words Maintenance
Free may have been deleted.
Charging guide for other batteries that are not maintenance-free

NOTE: Recommended speed (*) and time for a completely flat battery.
Battery capacity – See the reserve

Slow Charge Fast Charge
capacity under the specifications
10 h@ 5 A 2.5 h@ 20 A
80 min or less
5 h@ 10 A 1.5 h@ 30 A
15 h@ 5 A 3.75 h@ 20 A
7.5 h@ 10 A 1.5 h@ 50 A
20 h@ 5 A 5 h@ 20 A
10 h@ 10 A 2 h@ 50 A
30 h@ 5 A 7.5 h@ 20 A
15 h@ 10 A 3 h@ 50 A
24 h@ 10 A
Above 250 min 6 h@ 40 A
4 h@ 60 A
* Initial speed for standard chargers
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Battery - Prepare
845B
865B
885B
Preparing a dry-charged battery for use

1. Remove the caps from the battery.
2. Fill each cell with electrolyte until it covers the plates.
This will make the electrolyte volume increase as the
temperature rises when charging the battery.
3. Fit the battery caps. If the battery in the machine should
have anti-spill caps, fit anti-spill caps. See the Speci-
fications to know if the battery in the machine should
have anti-spill caps.
4. Connect a battery charger to the battery.
5. Charge the battery at 30 A until the specific gravity
reaches 1250 or more and the electrolyte temperature
is at least 15.5 °C (60 °F).
6. If necessary, fill each cell with electrolyte until the elec-
trolyte is just below the split ring at the bottom of the
cell opening.
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Index
Battery - 302
Battery - Check Electrolyte Level (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Battery - Cleaning /Inspection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Battery - Electrical test Charge Capacity (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Battery - Prepare (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Battery - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Battery - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Battery - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Battery - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Fuel injection system - 010

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Contents
SERVICE
Injection control solenoids

Injection control solenoids - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Electrical systems - Fuel injection system
Injection control solenoids - Remove

1. Disconnect the fuel shut-off solenoid wiring.

2. Remove the pin clip, the fixing screws, and the fuel
shut-off solenoid using a 10 mm wrench.
LAIL11MG0538A0A 1
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Electrical systems - Fuel injection system
Injection control solenoids - Install

Install the solenoid and connect the wires using an

8 mm wrench, with a torque of 8 N·m (71 lb in).
LAIL11MG1140A0A 1
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Index

Injection control solenoids - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Injection control solenoids - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Transmission control system - 024

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55.7 [55.024] / 1
Contents
SERVICE
Transmission wiring harness

Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Electrical systems - Transmission control system
Transmission wiring harness - Remove

1. Loosen nut (A).

NOTE: Tag all of the wiring connectors before removing the
wiring harness.
LAIL11MG1936A0A 1
2. Disconnect all of the connectors (B).

3. Remove the wiring harness (C).
LAIL11MG1937A0A 2
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Transmission wiring harness - Install

1. Tighten all of the connectors with protection (B).

2. Place the main wiring harness connector (C) in the
bracket.
LAIL11MG1937A0A 1
3. Tighten the bolt (A) to a torque between 18 – 27 N·m

(13 – 20 lb ft).
LAIL11MG1936A0A 2
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1. Loosen nut (A).

NOTE: Tag all of the wiring connectors before removing the
wiring harness.
LAIL11MG1936A0A 1
2. Disconnect all of the connectors (B).

LAIL11MG1857A0A 2
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1. Tighten all of the connectors with protection (B).

2. Place the main wiring harness connector (A) in the
bracket.
LAIL11MG1857A0A 1
3. Tighten the bolt (A) to a torque between 18 – 27 N·m

(13 – 20 lb ft).
LAIL11MG1936A0A 2
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Transmission wiring harness - Replace

Connectors “Deutsch®”
1. Select the correct size Extractor Tool for the size of wire
to be removed.
A. Extractor tool for 12 to 14 gauge wire.
B. Extractor tool for 16 to 18 gauge wire.
C. Extractor tool for 20 gauge wire.
2. Fit the correct size extractor tool over the wire at the
handle (A).
3. Slide extractor tool rearward along wire until tool tip
snaps onto wire.
NOTICE: Do not twist the tool when inserting it into the
connector. LAIL11MG1223A0A 1
4. Slide extractor tool along wire into connector body until

it is positioned over terminal contact.
5. Pull wire out of connector body, using extractor tool.
NOTICE: Install the contact in the proper location using the
correct size grommet.
LAIL11MG1224A0A 2
6. Push contact straight into connector body until positive

stop is felt.
7. Pull on the wire slightly to check that the contact is
locked in place.
8. Fix the remaining wires to the correct terminals in the
new connector.
LAIL11MG1225A0A 3
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Connectors “Weather Pack®”

NOTICE: Identify the colored wire locations with the con-
nector terminal letters.
1. Open connector body.
2. Insert Extraction Tool over terminal contact in connec-
tor body.
3. Hold extractor tool fully seated and pull wire from con-
nector body.
NOTE: If the terminal cannot be removed, insert the wire or
a nail through the tool handle and pull the terminal contact
from the connector.
LAIL11MG1226A0A 4
NOTICE: Carefully spread the contact lances to ensure

good seating on the connector body.
NOTE: The connector bodies are “keyed” to ensure proper
contact mating. Check that the contacts are aligned prop-
erly.
4. Push contact into new connector body until fully seated.
5. Pull on the wire slightly to be certain that the contact is
locked in place.
6. Transfer remaining wires to correct terminal in new con-
nector.
7. Close connector body. LAIL11MG1227A0A 5
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Replace Connector “Sureseal” with Connector “Weather Pack®”

1. Pull the wire to remove contact from the “Sureseal” con-
nector.
LAIL11MG1228A0A 6
2. Remove wire as close as possible to contact, using

Universal Electrical Plier.
LAIL11MG1464A0A 7
NOTICE: The bodies of the “Sureseal” and “Weather

Pack®” connectors are identified to ensure proper con-
tact mating. Be sure contacts are in proper alignment.
The “Sureseal” connectors are identified by 1, 2, 3. The
“Weather Pack®” connectors are identified by A, B, C.
“A” matches 1, “B” matches 2 and “C” matches 3. See
component replacement stories for any exceptions on
connector codes.
LAIL11MG1575A0A 8
3. Install the contact “Weather Pack®” on the wire, see in-

stalling Connectors “Weather Pack®” described above.
4. Push the contact into the body of the “Weather Pack®”
connector until fully seated.
5. Pull on wire slightly to be certain contact is locked in
place.
6. Close connector body.
LAIL11MG1229A0A 9
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Connector Body from the Blade Terminals

1. Press the locking tab (A) on the terminal using a small
screwdriver.
2. Slide connector body off.
NOTE: Do not forget to bend the locking tab back to its
original position (B) before installing the connector body.
LAIL11MG0776A0A 1
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Contacts “Deutsch®”
1. Strip 6 mm (0.24 in) of insulation from the wire.
2. Adjust the selector (A) on the crimper for the correct
wire size.
3. Loosen the lock nut (B) and screw in the adjusting
screw (C) until it stops.
LAIL11MG1230A0A 1
NOTICE: Select the correct size contact “sleeve” or “pin”

to fit the connector body.
4. Insert the contact (A) and turn, adjusting the screw (D)
until contact is flush with the cover (B).
5. Tighten the lock nut (C).
LAIL11MG1231A0A 2
NOTICE: The contact must remain centered between the

notches while crimping.
6. Insert wire in contact and crimp until handle touches
stop.
7. Release handle and remove contact.
LAIL11MG1232A0A 3
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NOTICE: If all of the wire strands are not crimped into con-
tact, cut off the wire at contact and repeat the contact in-
stallation procedure.
NOTE: Readjust the tool for each connector assembly pro-
cedure.
8. Inspect contact to be certain all wires are in crimped
barrel.
LAIL11MG1233A0A 4
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Contacts “Weather Pack®”

NOTE: Cable seals are color coded for three sizes of wire:
a. Green: 18 to 20 gauge wire
b. Gray: 14 to 16 gauge wire
Tractors with turbocharged engines Blue: 10 to 12 gauge
wire
1. Slip correct size cable seal on wire.
2. Pull back the wiring insulation to expose 6 mm (0.24 in)
and align the cover with the edge of the insulation.
LAIL11MG1234A0A 5
NOTE: The contacts have numbered identification for two

sizes of wire:
a. # 15 for 14 to 16 gauge wire.
b. # 19 for 18 to 20 gauge wire.
3. Put proper size contact on wire and crimp in place with
a “W” type crimp, using Terminal Applicator.
LAIL11MG1235A0A 6
4. Secure cable seal to contact as shown, using Terminal

Applicator.
LAIL11MG1236A0A 7
NOTICE: The correct installation of the contact for the

“sleeve” (A) and “pin” (B) is illustrated
LAIL11MG1237A0A 8
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Index

Transmission wiring harness - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Transmission wiring harness - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Transmission wiring harness - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls -

051

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55.8 [55.051] / 1
Contents
Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls - 051
SERVICE
Air-conditioning system control

Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Air-conditioning switch panel
Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Electrical systems - Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls
Air-conditioning system control - Replace

845B
865B
885B
Recirculation Relays
1. Position the operator's seat (1) to its maximum forward
adjustment.
LAIL11MG1965A0A 1
2. Locate and loosen the two fixing handles (2) and (3)
of the internal air filter located in the rear part of the
evaporator box without needing to use a wrench.
LAIL11MG1966A0A 2
LAIL11MG1693A0A 3
48050419D 06/10/2017
55.8 [55.051] / 3
3. Locate and replace relays (2) and (3) inside the evap-
orator housing (1).
LAIL11MG1695A0A 4
LAIL11MG1696A0A 5
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Air-conditioning system control - Replace

845B
865B
885B
Air Conditioning Relays and Fuses

1. Open the access cover (1) to the relays and fuses (2)
inside the machine on the lower part of the right con-
sole.
LAIL11MG1699A0A 1
LAIL11MG1700A0A 2
2. In the table below, locate the fuses and relays to be

replaced.
Component Box Localisation Function

Fuse ( 7.5 A) ECB 5F Control panel electrical circuit protection
Fuse ( 3 A) ECB 6F Recirculation electrical circuit protection
Fuse ( 20 A) PRM-A PRM-A Fan electrical circuit protection
Relay ECB K5 Compressor electric circuit activation
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Air-conditioning switch panel - Replace

845B
865B
885B

(1) and the right protection cover from the chassis.
LAIL11MG1697A0A 1
2. Using a 1/4 in wrench, loosen the valve screw (2), that

holds the steel cable to the valve body and remove the
steel cable.
LAIL11MG2016A0A 2
3. Inside the cab, place the appropriate tool in the holes

in the panel sides and pull the control panel from the
console (3).
4. Disconnect the electrical connectors and remove the
panel.
closed. If the cable is not adjusted, the air conditioning
will not function correctly. The panel comes with four side LAIL11MG1698A0A 3
holes, partially covered, and after the tool is introduced they
will stay open. If water is lost from the engine cooling sys-
tem, follow the machine manufacturer's recommendations
to top up the level.
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Index
Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls - 051

Air-conditioning switch panel - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air-conditioning system control - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Air-conditioning system control - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Heating, Ventilation, and Air-Conditioning (HVAC) control system -

050

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55.9 [55.050] / 1
Contents
Heating, Ventilation, and Air-Conditioning (HVAC) control system - 050
SERVICE
Recirculation or pressurizer blower

Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Air-conditioning system pressure switch
Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system
Recirculation or pressurizer blower - Replace

845B
865B
885B
Recirculation actuator
driver's seat to the cover of the evaporator box, remov-
ing the seat.
cover of the evaporator box, removing the cover.
upper left cover of the evaporator box, removing the
cover.
4. Using a 1/4 in wrench, loosen the three bolts (1) that
hold the actuator into the evaporator box (see illustra-
tion 1). LAIL11MG2069A0A 1
5. Disconnect the wiring harness (2) from the actuator in-

side the evaporator box, removing the actuator.
LAIL11MG2070A0A 2
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Air-conditioning system pressure switch - Replace

Using a 14 mm wrench, loosen and remove the pres-

sure switch (1) from the liquid reservoir.
NOTE: The coolant does not need to be removed from the
system to replace the pressure switch.
LAIL11MG1920A0A 1
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Air-conditioning system pressure switch - Replace

Using a 14 mm wrench, loosen and remove the pres-

sure switch (1) from the liquid reservoir.
NOTE: The coolant does not need to be removed from the
system to replace the pressure switch.
LAIL11MG2025A0A 1
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Index
Heating, Ventilation, and Air-Conditioning (HVAC) control system - 050

Air-conditioning system pressure switch - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air-conditioning system pressure switch - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Recirculation or pressurizer blower - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Transmission speed sensors - 020

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Contents
SERVICE
Transmission speed sensors

Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Output speed sensor
Powershift - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Powershift - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Powershift - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Powershift - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission gear speed sensor
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Transmission input speed sensor
Powershift - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Powershift - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Electrical systems - Transmission speed sensors
Transmission speed sensors - Remove

845B (6 x 3 torque converter) OR (Tier 1) OR (Tier 3-VHP)
865B (6 x 3 torque converter) OR (Tier 2) OR (Tier 3-VHP) OR (Tier 0)
1. Attach transmission to assembly truck.

(S) Assembly trestle 5870 350 000
(S) Holding fixtures 5870 350 063
(S) Clamping profiles 5870 350 090
2. Remove positioned parts.
(1) Screw plug (Oil drain hole)
(2) Oil filler tube with dipstick
(3) Vent
(4) Inductive sensor – Central gear chain rotation
(5) Inductive sensor – Turbine rotation
(6) Inductive sensor – Engine speed
LAIL11MG1009B0A 1
3. Loosen the Allen bolt (1) and remove the speed sensor
( “Hall” effect sensor).
NOTE: Remove the O-ring.
Socket head screw (1)
(2) Speed sensor - Output rotation
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Transmission speed sensors - Install

845B (6 x 3 torque converter) OR (Tier 1) OR (Tier 3-VHP)
865B (6 x 3 torque converter) OR (Tier 2) OR (Tier 3-VHP) OR (Tier 0)
1. Mount the inductive sensors (1), (2), and (3) with new
O-rings (15 x 2).
(1) Inductive sensor – Engine speed
(2) Inductive sensor – Speed/current in the central gear
(3) Inductive sensor – Turbine speed
2. Fit the breather ( (4), ).
Tightening torque (3) MA = 12 N·m
NOTE: On some versions, it is also necessary to fit the
inductive sensor (3) with three adjusting washers and to LAIL11MG0440A0A 1
secure it with LOCTITE® 262™.

NOTE: For the related parts lists, see the spare parts/sub-
assembly list: inductive sensor.
3. Mount the speed sensor (1) with a new 15.54 x 2.62
O-ring and secure this using an Allen screw (2).
(1) Speed sensor (Hall sensor) – Output speed
LAIL11MG0441A0A 2
4. Mount the oil drain plug (1) with a new 35 x 2 O-ring.

5. Bring the oil level tube (2) with a seal into the contact
position with the front part of the housing and secure it
using hexagonal screws (3).
6. Fasten the dipstick (4) in the oil level tube.
7. Fix the identification plate (5) to the front part of the
housing.
NOTE: Use Loctite 5069. LAIL11MG0442A0A 3
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8. Bring the cover (1) with a seal into the contact position
with the front part of the housing and secure it using
LAIL11MG0443A0A 4
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Output speed sensor Powershift - Remove

1. Remove the two bolts (A), the two pressure washers

(B), the two smooth washers (C), the cover (D), the
sensor (E), and the O-ring (F).
2. Clean and inspect for wear and damage.
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Output speed sensor Powershift - Install

1. Lubricate and install the new O-ring (F), then install the
sensor (E), the cover (D), the two smooth washers (C),
the two lock washers (B), and the two bolts (A).
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Output speed sensor Powershift - Remove


2. Install a new O-ring.
3. Install the magnetic pickup sensor (B).
4. Install the cover (A).
5. Install the screws (2) with the pressure washers and
washers.
6. Tighten torque 10 N·m (7 lb ft).
LAIL11MG1856A0A 1
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Output speed sensor Powershift - Install

1. Remove the bolts (2), washer, and pressure washer.

2. Remove the cover (A).
LAIL11MG1854A0A 1
3. Remove the magnetic pickup sensor (B).

4. Remove and discard o-ring.
LAIL11MG1855A0A 2
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Transmission gear speed sensor - Remove


snap rings.
1. Remove the snap ring (A), the washer (B), and the
magnetic sensor (C).
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Transmission gear speed sensor - Install


snap rings.
1. Lubricate and install the new O-ring (D), then install the
magnetic sensor (C), the washer (B), and the snap ring
(A).
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Transmission gear speed sensor - Remove

The cylinder speed magnetic pickup (C) reads the cylin-

der RPM by measuring the number of pulses per minute
generated from the teeth of the cylinder gear.
1. Remove the snap ring (A).
2. Remove the flat washer (B).
3. Remove the magnetic pickup sensor (C).
4. Remove the O-ring (D).
6. Discard the O-ring (D).
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Transmission gear speed sensor - Install

1. Lubricate a new O-ring with the transmission fluid.

2. Install a new O-ring (D) onto the magnetic pickup sen-
sor (C).
3. Install the magnetic pickup sensor (C).
4. Install the smooth washer (B).
5. Install the snap ring (A).
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Transmission input speed sensor Powershift - Remove

1. Remove the two bolts (A), the two pressure washers

(B), the two smooth washers (C), the cover (D), the
sensor (E), and the O-ring (F).
2. Clean and inspect for wear and damage.
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Transmission input speed sensor Powershift - Install

1. Lubricate and install the new O-ring (F), then install the
sensor (E), the cover (D), the two smooth washers (C),
the two lock washers (B), and the two bolts (A).
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1. Remove the bolts (2), washer, and pressure washer.

2. Remove the cover (A).
LAIL11MG1850A0A 1
3. Remove the magnetic pickup sensor (B).

4. Remove and discard o-ring.
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2. Install a new O-ring.
3. Install the magnetic pickup sensor (B).
4. Install the cover (A).
5. Install the screws (2) with the pressure washers and
washers.
6. Tighten torque 10 N·m (7 lb ft).
LAIL11MG1852A0A 1
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1. Remove the two cap screws, two lock washers, and

two flat washers (A).
2. Remove the magnetic pickup cover (B).
3. Remove the magnetic pickup sensor with the O-ring
(C).
NOTE: Install the magnetic pickup after installing the driven
gears.
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1. Lubricate O-ring.
2. Install a new O-ring in the groove on the magnetic
pickup sensor (A).
3. Push magnetic pickup sensor into input housing.
4. Install the magnetic pickup cover (B).
5. Install the cap screws and lock washers (C)).
LAIL11MG1466A0A 1
6. Torque the bolts to 10 N·m (7 lb ft)
LAIL11MG1867A0A 2
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Index

Output speed sensor Powershift - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Output speed sensor Powershift - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Output speed sensor Powershift - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Output speed sensor Powershift - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Transmission gear speed sensor - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Transmission gear speed sensor - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Transmission gear speed sensor - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transmission gear speed sensor - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Transmission input speed sensor Powershift - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Transmission input speed sensor Powershift - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Transmission speed sensors - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Transmission speed sensors - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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FAULT CODES - DTC

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Contents
FAULT CODES - DTC
DIAGNOSTIC
1310 - Hydraulic Filter Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1311 - Engine Air Filter Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1312 - Hydraulic Oil Temperature Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1313 - Hydraulic Oil Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1314 - Transmission Oil Temperature Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1315 - Transmission Oil Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1316 - Brake Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1317 - Steering Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1318 - Engine Coolant Temperature Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1319 - Engine Coolant Temperature High - Critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1320 - Engine Oil Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1321 - Engine Oil Pressure Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1322 - Engine Oil Pressure Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1323 - Battery Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1324 - Battery Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1325 - Engine Oil Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1326 - Coolant Level Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1331 - Electrical Charging System Voltage Too Low - Critical Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1332 - Water Detected In Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1333 - Engine Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1334 - Intake Manifold Temperature High - Critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1335 - Brake Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1346 - Engine Coolant Temperature Sensor Failure Out of Range High . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1347 - Engine Coolant Temperature Sensor Failure Short Circuit to Ground . . . . . . . . . . . . . . . . . . . . . . . 40
1348 - Engine Coolant Temperature Sensor Failure Out of Range Low . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1351 - Voltmeter Input and Key Switch Input not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1353 - Engine Oil Pressure Sensor Failure Out of Range High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1354 - Engine Oil Pressure Sensor Failure Out of Range Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1355 - Transmission Oil Pressure Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1356 - Transmission Oil Pressure Sensor OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1358 - Fan Control Valve short to ground OR open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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1359 - Fan Control Valve short to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1360 - OC/ SC to Bat. at Hydraulic Oil Temperature. Sensor Severity: yellow . . . . . . . . . . . . . . . . . . . . . 49
1361 - SC to GND. at Hydraulic Oil Temperature. Sensor Severity: yellow . . . . . . . . . . . . . . . . . . . . . . . . 50
1364 - Intake Manifold Temperature Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3000 - ZF power curves adjustable via CAN, TSC1 CAN interface disabled VCM2EDC . . . . . . . . . . . . . 52
3001 - Foot Throttle Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3002 - Foot Throttle Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3003 - Foot Throttle Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3004 - Foot Throttle Sensor - No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3005 (DTC 4B84) - Air filter clog or circuit failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3006 - Coolant Temperature Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3007 - Coolant Temperature Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3008 - Coolant Temperature Sensor - Signal Below Range Minimun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3009 - Coolant Temperature Sensor - (via CAN) Null . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3010 - Air Intake Temperature Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3011 - Air Intake Temperature Sensor - Signal Above Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3012 - Air Intake Temperature Sensor - Signal Above Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3014 (DTC 4C84) - Air filter clog or circuit failure present for a long time . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3014 (DTC 4C84) - Air filter clog or circuit failure present for a long time [ECU] . . . . . . . . . . . . . . . . . . . . 68
3015 - Fuel Temperature Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3016 - Fuel Temperature Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3019 - Boost Pressure Sensor - Signal Above Range Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3021 - Boost Pressure Sensor - (via CAN) Null . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3022 - Boost Pressure Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3023 - Atmospheric Pressure Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3024 - Atmospheric Pressure Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3025 - Atmospheric Pressure Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3028 - OIL PRESSURE SENSOR LOW VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3029 - Oil Pressure Sensor - Short Circuit To Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3030 - Oil Pressure Sensor - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3031 - Oil Pressure Sensor - ADC Conversion Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3032 - Oil Pressure Sensor - Pressure Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3033 - Oil temperature sensor - signal not plausible [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3034 - Oil Temperature Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3035 - Oil Temperature Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3036 - Oil Temperature Sensor - CAN Transmission Disturbed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3037 - Boost Pressure Sensor - Signal Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3047 - High Pressure Pump Relay - Short Circuit to Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3048 - High Pressure Pump Relay - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3051 - Battery Voltage to ECM too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3052 - Battery Voltage to ECM too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3059 - ECM Afterrun was Interrupted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
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3060 - Cylinder 1 - Unclassifiable Error In Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3061 - Cylinder 1 - Injector Cable Short Circuit (Low Side To Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3062 - Cylinder1 - Signal Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3063 - Cylinder1 - Injector Cable Shortcircuit (High Side to Low Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
3064 - Cylinder 5 - Unclassifiable Error In Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3065 - Cylinder 5 - Injector Cable Short Circuit (Low Side To Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3066 - Cylinder5 - Signal Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3067 - Cylinder5 - Injector Cable Shortcircuit (High Side to Low Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3068 - Cylinder 3 - Unclassifiable Error In Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3069 - Cylinder 3 - Injector Cable Short Circuit (Low Side To Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3070 - Cylinder3 - Signal Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3071 - Cylinder3 - Injector Cable Shortcircuit (High Side to Low Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3074 - Cylinder 6 - Signal Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3075 - Cylinder 6 - Injector Cable Shortcircuit (High Side to Low Side) . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3088 - Crankshaft sensor lost synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3089 - Crankshaft Sensor - Defective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3090 - Camshaft Sensor - Lost Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3091 - Camshaft Sensor Phase Synchronization Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3092 - Offset Between Camshaft and Crankshaft - Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3093 - Offset Between Camshaft And Crankshaft - Outside Boundaries . . . . . . . . . . . . . . . . . . . . . . . . . 122
3095 - Operating with Camshaft Sensor Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3096 (DTC 951B) - CAN A Bus off failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3102 - Rail Pressure Sensor CP3 - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3104 - Rail Pressure Relief Valve - Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3105 - Rail Pressure Relief Valve - Pressure Shock Requested . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3106 - Rail Pressure Relief Valve - Did Not Open After Pressure Shock . . . . . . . . . . . . . . . . . . . . . . . . . 129
3107 - Metering unit output short circuit to battery on low side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3108 - Metering Unit - Shortcircuit to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
3110 - Rail Pressure Sensor Offset Monitoring - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . 132
3111 - Rail Pressure Sensor Offset Monitoring - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . 133
3112 - Rail Pressure Sensor CP3 - Signal Above Maximum Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3113 - Main relay 1 (high pressure pump) - short to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
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3114 - Grid heater battery switch relay short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3118 - ECM 12V sensor supply voltage high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
3119 - ECM 12V sensor supply voltage low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3131 - Grid Heater Always Switched On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3137 - Metering Unit - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3138 - Metering Unit - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
3141 - Set point of fuel volume flow through metering unit is lower than calculated limit . . . . . . . . . . . . 142
3146 (DTC 4415) - Water in fuel detected or water in fuel circuit failure [ECU]. . . . . . . . . . . . . . . . . . . . . 143
3147 - Oil Temperature Sensor - Signal Above Normal Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3154 - Grid Heater Relay - Short Circuit To Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
3155 - Grid Heater Relay - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
3156 - Grid Heater Relay - No Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3176 - Fuel delivery exceeded threshold for pressure in overrun mode . . . . . . . . . . . . . . . . . . . . . . . . . . 149
3178 - Timeout of CAN Message BC2EDC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3179 - Timeout of CAN Message BC2EDC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
3180 - Time-out Of CAN Message VCM2EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
3188 - Cylinder 1 - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
3210 - Bank 1 - General Short Circuit On Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
3211 - Bank 1 - Injector Cable Short Circuit Low Side To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
3212 - Bank 1 - No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
3213 - Bank 1 - Unclassifiable Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3218 - Bank 2 - General Short Circuit On Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
3219 - Bank 2 - Injector Cable Short Circuit Low Side To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
3220 - Bank 2 No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3221 - Bank 2 - Unclassifiable Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3227 - Injection Processor Error - Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3228 - Injection Processor Error - Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3229 - Injection processor error - stop engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3235 (DTC F936) - Exceeded the number of injections for a given engine speed [ECU] . . . . . . . . . . . . 175
3236 (DTC F836) - Number of injections is limited by system [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3237 (DTC 1636) - Number of desired injections exceeds threshold [ECU] . . . . . . . . . . . . . . . . . . . . . . . 177
3238 - Communication error of CJ940 processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
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3242 - Recovery which is locked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
3243 - Recovery which is suppressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3244 - Recovery which is visible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
3245 - Communication supervision Watchdog/controller-Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3246 - Redundant shutoff paths during initial. / ECU HW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
3247 - Redundant shutoff paths during initial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
3248 - Redundant shutoff paths during initial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
3249 - TPU monitoring - Time deviation between TPU and system not plausible . . . . . . . . . . . . . . . . . . 187
3250 - ECU Software Varian Dataset failure - Dataset not valid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
3251 - Dataset - Requested Variant Could Not Be Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
3252 - Controller Watchdog - SPI Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
3253 - Error status ADC monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3258 - High side power - short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3259 - High side power - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3260 - Low side power - open load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
3261 - Shortcircuit to Battery or Excessive Temperature at Low Side Power Stage . . . . . . . . . . . . . . . . 198
3262 - Shortcircuit to Ground at Low Side Power Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
3265 - Energising time exceeds limit of overrun monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
3266 - Plausibility Error in Engine Speed Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3278 - Supply voltage CJ940 upper limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3279 - Supply voltage CJ940 lower limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3280 - Sensor Supply Voltage 1 - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3281 - Sensor Supply Voltage 1 - Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3290 - Turbo Compound Monitoring - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
3293 (DTC 2265) - Fuel rail pressure has exceeded maximum positive deviation limits [ECU]. . . . . . . 211
3301 (DTC 1565) - Fuel rail pressure has exceeded maximum negative deviation limits [ECU] . . . . . . 212
3305 (DTC 2765) - Fuel rail pressure has exceeded minimum limit [ECU] . . . . . . . . . . . . . . . . . . . . . . . . 213
3309 (DTC 1865) - Fuel rail pressure has exceeded maximum limit [ECU]. . . . . . . . . . . . . . . . . . . . . . . . 214
3315 - Minimum Number of Injections Not Reached - Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3361 (DTC E16D) - There was an error during Write/Read EEPROM operation [ECU] . . . . . . . . . . . . . 219
3362 (DTC E1FD) - ECU internal failure - Fuel calibration [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
3363 - Atmospheric Pressure Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
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3368 (DTC F6EF) - Torque limitation caused by performance limiter [ECU] . . . . . . . . . . . . . . . . . . . . . . . 222
3370 (DTC F2EF) - Strong torque limitation from engine protection active [ECU] . . . . . . . . . . . . . . . . . . 223
3371 (DTC F3EF) - Strong torque limitation from injection system active [ECU] . . . . . . . . . . . . . . . . . . . 224
3403 (DTC 8A22) - Starter relay low side ECU driver circuit over temperature failure [ECU]. . . . . . . . . 225
3443 (DTC F3A2) - Torque limitation due to excessive coolant temperature [ECU]. . . . . . . . . . . . . . . . . 227
3444 (DTC F4A2) - Torque limitation due to excessive exhaust gas temperature [ECU] . . . . . . . . . . . . 228
3445 (DTC F5A2) - Torque limitation due to excessive fuel temperature [ECU] . . . . . . . . . . . . . . . . . . . . 229
3446 (DTC F6A2) - Torque limitation due to excessive intake air temperature [ECU] . . . . . . . . . . . . . . . 230
3447 (DTC F7A2) - Torque limitation due to excessive oil temperature [ECU] . . . . . . . . . . . . . . . . . . . . . 231
3448 (DTC F8A2) - Torque limitation due to turbocharger protection after start [ECU] . . . . . . . . . . . . . . 232
3449 (DTC E812) - ECU internal failure - Calculated engine speed [ECU] . . . . . . . . . . . . . . . . . . . . . . . . 233
3457 (DTC 1374) - Intake manifold temperature sensor voltage is higher than expected [ECU]. . . . . . 234
3459 (DTC 1BD3) - Oil temperature too high [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
3460 (DTC 2CD3) - Oil temperature too low [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
3461 (DTC E69D) - ECU internal failure - Timeout in the shut off path test error [ECU] . . . . . . . . . . . . . 240
3462 (DTC E79D) - ECU internal failure - Overvoltage monitoring error [ECU] . . . . . . . . . . . . . . . . . . . . 241
3491 (DTC F176) - Missing adjustment value programming for injector in cylinder 1 . . . . . . . . . . . . . . . 242
3501 (DTC ED1D) - ECU internal failure - Software resets in DSM 0 [ECU] . . . . . . . . . . . . . . . . . . . . . . . 248
3502 (DTC EE1D) - ECU internal failure - Software resets in DSM 1 [ECU] . . . . . . . . . . . . . . . . . . . . . . . 249
3507 (DTC 4761) - Engine cranked for too long or key switch failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . 250
3508 (DTC FAEF) - Torque limitation active [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
3581 (DTC FD8F) - Torque limitation is active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
3594 (DTC F7EF) - Torque limitation caused by SCR catalyst protection [ECU] . . . . . . . . . . . . . . . . . . . 254
3616 (DTC F1EF) - Torque limitation caused by turbo charger protection [ECU] . . . . . . . . . . . . . . . . . . . 255
3638 (DTC F4EF) - Torque limitation caused by engine brake [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
3652 (DTC 911B) - CAN A Bus off passive failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
3680 (DTC E536) - Engine speed limitation via fuel injection cut off is active [ECU] . . . . . . . . . . . . . . . . 259
3699 (DTC E56D) - ECU EEPROM memory failure - EEPData1 block [ECU] . . . . . . . . . . . . . . . . . . . . . 260
3703 (DTC 2B36) - The minimum rail pressure value necessary to allow fuel injection has not been reached
[ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
3735 (DTC 8355) - Fuel metering unit has an over-temperature error [ECU] . . . . . . . . . . . . . . . . . . . . . . 262
3738 (DTC E71D) - ECU internal failure - ROM error [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
3739 (DTC E13D) - ECU internal failure - Loss of synchronization to MM from CPU [ECU] . . . . . . . . . 265
3740 (DTC E23D) - ECU internal failure - ECU shutdown test failure [ECU]. . . . . . . . . . . . . . . . . . . . . . . 266
3741 (DTC E33D) - ECU internal failure - Wrong set response time [ECU]. . . . . . . . . . . . . . . . . . . . . . . . 267
3742 (DTC E43D) - ECU internal failure - SPI errors during MoCSOP execution [ECU] . . . . . . . . . . . . 268
3743 (DTC E53D) - ECU internal failure - Undervoltage monitoring error [ECU] . . . . . . . . . . . . . . . . . . . 269
3745 (DTC E63D) - ECU internal failure - WDA is not working correctly [ECU] . . . . . . . . . . . . . . . . . . . . 270
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3746 (DTC E73D) - ECU internal failure - Alarm task period error [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . 271
3747 (DTC E83D) - ECU internal failure - Positive test failed [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
3749 (DTC E5B1) - ECU internal failure - Accelerator pedal position sensor [ECU] . . . . . . . . . . . . . . . . 273
3750 (DTC EC36) - ECU internal failure - Fuel injection energizing time is not plausible [ECU] . . . . . . 274
3751 (DTC ED36) - ECU internal failure - Fuel injection energizing phase is not plausible [ECU] . . . . 275
3752 (DTC EE36) - Fuel injection correction has exceeded a minimum limit [ECU] . . . . . . . . . . . . . . . . 276
3753 (DTC E5DD) - ECU internal failure - Injection quantity correction [ECU] . . . . . . . . . . . . . . . . . . . . . 277
3754 (DTC E6DD) - ECU internal failure - Rail pressure plausibility [ECU] . . . . . . . . . . . . . . . . . . . . . . . . 278
3755 (DTC E7DD) - ECU internal failure - Torque request comparison [ECU] . . . . . . . . . . . . . . . . . . . . . 279
3756 (DTC E1DD) - ECU internal failure - Post injection quantity [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . 280
3757 (DTC E2DD) - ECU internal failure - Post injection shut-off failure [ECU] . . . . . . . . . . . . . . . . . . . . 281
3758 (DTC E3DD) - Post injection efficiency failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
3759 (DTC E8DD) - ECU internal failure - Torque request due to fuel pressure exceeds maximum torque
limit [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
3760 (DTC E9DD) - ECU internal failure - Torque request due to air control exceeds maximum torque limit
[ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
3761 (DTC EADD) - ECU internal failure - Torque request exceeds maximum torque limit [ECU] . . . . 285
3762 (DTC EBDD) - ECU 5 volt supply voltage is higher than expected [ECU] . . . . . . . . . . . . . . . . . . . . 286
3763 (DTC ECDD) - ECU 5 volt supply voltage is lower than expected [ECU] . . . . . . . . . . . . . . . . . . . . . 287
3764 (DTC F561) - ECU after run power interruption [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
3767 (DTC E81D) - ECU internal failure - 'WDA active' reported due to errors in query/response commu-
nication [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
3768 (DTC E91D) - ECU internal failure - 'ABE active' reported due to undervoltage detection [ECU] 292
3769 (DTC EA1D) - ECU internal failure - 'ABE active' reported due to overvoltage detection [ECU] . 293
3770 (DTC EB1D) - ECU internal failure - 'WDA/ABE active' reported [ECU] . . . . . . . . . . . . . . . . . . . . . . 294
3799 (DTC F345) - Fuel pressure relief valve is forced to open, perform pressure shock [ECU] . . . . . 295
3805 (DTC 1D85) - Maximum rail pressure exceeded [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
3808 (DTC 3C65) - High pressure pump fuel delivery quantity at low idle is too high [ECU] . . . . . . . . . 297
3810 (DTC 4125) - Rail pressure sensor value is intermittent [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
3811 (DTC E22D) - ECU internal failure - Sensor 5 volt supply 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
3812 (DTC 115D) - ECU temperature sensor 1 is too high [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
3813 (DTC 235D) - ECU temperature sensor 1 is too low [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
3814 (DTC E55D) - ECU temperature sensor error detected [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
3856 - Coolant Temperature does not rise as expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
3870 (DTC 936B) - CAN communication failure between vehicle controller and ECU - BC2ECU1 message
[ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
3877 (DTC 647D) - Supply UB1 short to battery failure [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
3880 (DTC 6A7D) - Actuator relay 3 circuit short to battery failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
3881 (DTC 757D) - Supply UB1 circuit short to ground failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
3882 (DTC 777D) - Supply UB2 short to ground failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
3883 (DTC 797D) - Supply UB3 short to ground failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
3903 (DTC 1A15) - Fuel temperature is too high [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
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3905 (DTC 8814) - Intake air heater ECU driver has an over-temperature error [ECU] . . . . . . . . . . . . . 328
3911 (DTC 6455) - Fuel metering unit is shorted to battery voltage at the high side [ECU] . . . . . . . . . . 330
3912 (DTC 7555) - Fuel metering unit is shorted to ground at the high side . . . . . . . . . . . . . . . . . . . . . . 332
3916 (DTC 1745) - Fuel pressure relief valve has reached maximum allowed open time [ECU]. . . . . . 333
3936 (DTC E52D) - ECU internal: error sensor supplies voltage tracker [ECU] . . . . . . . . . . . . . . . . . . . . 334
3964 (DTC 125D) - ECU temperature sensor 2 is too high [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
3965 (DTC 245D) - ECU temperature sensor 2 is too low [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
3966 (DTC 165D) - ECU temperature sensor voltage is higher than expected [ECU]. . . . . . . . . . . . . . . 337
3967 (DTC 275D) - ECU temperature sensor voltage is lower than expected [ECU] . . . . . . . . . . . . . . . 338
4113 - Logical error at gear range signal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
4114 - Logical error at direction select signal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
4116 - Logical error at park brake status (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
4117 - Logic error at direction select signal 2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
4119 - Short circuit to ground at ride control (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
4120 - Short circuit to battery voltage at ride control (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
4121 - Open circuit at ride control (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
4133 - Short circuit to battery voltage or open circuit at transmission sump temperature sensor input (*)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
4134 - Short circuit to ground at transmission sump temperature sensor input (*) . . . . . . . . . . . . . . . . . 347
4135 - Short circuit to battery voltage or open circuit at retarder/ torque converter temperature sensor input
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
4136 - Short circuit to ground at retarder/ torque converter temperature sensor input (*) . . . . . . . . . . . 349
4137 - Short circuit to battery voltage or open circuit at parking brake sensor input (*) . . . . . . . . . . . . . 350
4145 - Short circuit to battery voltage or open circuit at engine speed input (*) . . . . . . . . . . . . . . . . . . . . 351
4146 - Short circuit to ground at engine speed input (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
4147 - Logical error at engine speed input (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
4148 - Short circuit to battery voltage or open circuit at turbine speed input (*) . . . . . . . . . . . . . . . . . . . . 354
4149 - Short circuit to ground at turbine speed input (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
4150 - Logical error at turbine speed input (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
4151 - Short circuit to battery voltage or open circuit at internal speed input (*) . . . . . . . . . . . . . . . . . . . 357
4152 - Short circuit to ground at internal speed input (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
4153 - Logical error at internal speed input (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
4154 - Short circuit to battery voltage or open circuit at output speed input (*) . . . . . . . . . . . . . . . . . . . . 360
4155 - Short circuit to ground at output speed input (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
4156 - Logical error at output speed input (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
4158 - Output speed zero, doesn't fit to other speed signals (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
4160 - Gear range restriction signal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
4161 - Short circuit to battery voltage at load sensor input (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
4162 - Short circuit to ground open circuit at load sensor input (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
4163 - DCT1 timeout (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
4164 - Engine configuration timeout (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
4165 - EEC1 timeout (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
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4166 - EEC3 timeout (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
4167 - Short circuit to battery at converter chutch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
4168 - Short circuit to ground at converter chutch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
4169 - Open circuit at converter clutch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
4170 - Slippage at converter lockup clutch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
4171 - Short circuit to battery voltage at display output (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
4172 - Short circuit to ground at display output (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
4173 - Engine torque can signal is defective (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
4174 - Reference engine torque can signal is defective (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
4175 - Actual engine torque can signal is defective (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
4176 - No friction torque can signal is defective (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
4177 - EEC2 timeout (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
4185 - Test mode signal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
4186 - Invalid park brake status (CAN) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
4209 - Short circuit to battery voltage at clutch K1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
4210 - Short circuit to ground at clutch K1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
4211 - Open circuit at clutch K1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
4214 - Open circuit at clutch K2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
4228 - Short circuit to battery voltage at clutch KV (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
4229 - Short circuit to ground at clutch KV (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
4230 - Open circuit at clutch KV (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
4231 - Short circuit to battery voltage at clutch KR (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
4232 - Short circuit to ground at clutch KR (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
4233 - Open circuit at clutch KR (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
4241 - Short circuit to ground at relay reverse warning alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
4242 - Short circuit to battery voltage at relay reverse warning alarm (*) . . . . . . . . . . . . . . . . . . . . . . . . . 403
4243 - Open circuit at relay reverse warning alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
4273 - Slippage at clutch K1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
4277 - Slippage at clutch KV (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
4278 - Slippage at clutch KR (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
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4279 - Overtemp sump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
4282 - Differential pressure oil filter (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
4291 - Overtemp converter output (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
4292 - Short circuit to ground at joystick status indicator (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
4293 - Short circuit to battery voltage at joystick status indicator (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
4294 - Open circuit at joystick status indicator (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
4305 - Short circuit to battery voltage at power supply for sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
4306 - Short circuit to ground at power supply for sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
4307 - Low voltage at battery (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
4308 - High voltage at battery (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
4309 - Error at valve power supply VPS1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
4310 - Error valve power supply VPS2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
4325 - VehicleID#1 timeout (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
4337 - General EEPROM fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
4338 - Configuration lost (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
4339 - Application error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
4341 - Clutch failure during AEB (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
4342 - Clutch adjustment data lost (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
4346 - Time Out of CAN Message "Gear Range Select" from AWD (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
4347 - Time Out of CAN Message "AWD Status" from AWD (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
4348 - CAN Message "AWD Status" contains invalid data (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
4349 - Short circuit to ground at DLM transversal output (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
4350 - Short circuit to battery voltage at DLM transversal output (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
4351 - Short circuit to battery voltage at DLM indicator lamp output (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 434
4352 - Open circuit DLM indicator lamp output (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
4900 - Solenoid 1 open circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
4904 - Solenoid A open circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
4905 - Solenoid B open circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
4906 - Solenoid C open circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
4907 - Solenoid D open circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
4908 - Driver open circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
4909 - Torque Converter lockup open circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
4910 - Solenoid 1 Short circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
4911 - Solenoid 2 Short circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
4914 - Solenoid A Short circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
4915 - Solenoid B Short circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
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4916 - Solenoid C Short circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
4917 - Solenoid D Short circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
4918 - Driver Short circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
4919 - Torque Converter Lockup Short circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
4920 - Request for undefined shift being made (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
4921 - Power up in gear (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
4922 - Bottom of clutch input is passive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
4923 - Park and NOT Park values match (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
4924 - Park Status and Gear Input are not compatible (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
4925 - Upshit and Downshift both active (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
4926 - variable need gear has taken on invalid value (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
4927 - Start went active (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
4928 - Valve driver supply voltage too low (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
4929 - illegal or undefined vehicle mode code (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
4930 - Inching voltage low but bottom of clutch is open (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
4931 - seat switch and neutral are both passive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
4932 - Engine speed is at or near manufacturers warranty void level (*) . . . . . . . . . . . . . . . . . . . . . . . . . 468
4934 - illegal wheel mode change out of neutral (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
4935 - sump temperature too low for calibration (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
4936 - Engine speed too high for calibration (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
4937 - Engine speed too low for calibration (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
4938 - Output speed sensed during calibration (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
4939 - no cylinder speed during calibration (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
4940 - incorrect FWD/REV cylinder ratio (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
4941 - Cylinder speed will not drop below start count speed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476
4942 - hold clutch exceeds 90 psi (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477
4943 - Fast fill 1 exceeds 300 ms (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
4947 - Fast fill A exceeds 300 ms (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
4948 - Fast fill B exceeds 300 ms (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
4949 - Fast fill C exceeds 300 ms (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
4950 - Fast fill D exceeds 300 ms (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
4951 - Calibrating without park brake set (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
4952 - Analog inching voltage too low (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
4953 - Temperature sensor circuit shorted or open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488
4954 - Analog inching voltage too high (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489
4955 - Engine MPU SC or OC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
4956 - Output MPU SC or OC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491
4957 - Cannot get shift constants from EEPROM (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
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4958 - Group 1 enable low; should be high (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
4963 - Engine controller not communicating (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
4964 - AWD controller not communicating (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
4965 - Transmission controll not equipped for AWD control (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
4967 - Sump temperature too high (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
4968 - Slippage in clutch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
4970 - Driver SC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
4971 - Variable need gear has taken on invalid value (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
4976 - Driver short circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
4977 - Driver short circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
4980 - illegal wheel mode change out of neutral (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
4989 - Slippage in clutch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
4990 - group 1 enable low; should be high (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
4993 - hold clutch exceeds 90 psi (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
4994 - incorrect FWD/REV cylinder ratio (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
5160 - AWD Controller detects Yellow Warning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
5161 - AWD Controller detects Red Warning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528
5301 - No connection at CAN Bus number 1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529
5308 - Ignition is switched on but no EEC1 message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
5311 - Ignition is switched on but no EEC2 message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531
5314 - Engine is running but no ETC1 message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
5317 - Engine is running but no ETC2 message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
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5320 - Ignition is switched on but no AIC1 message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534
5323 - Wrong engine speed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535
5324 - Wrong pedal position (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
5328 - Output shaft speed above maximum (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537
5331 - Open circuit at pilot dump valve of AWD pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
5332 - Short circuit to ground at pilot dump valve of AWD pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
5333 - Short circuit to power at pilot dump valve of AWD pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540
5341 - Open circuit at pilot valve on forward direction of AWD pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 541
5342 - Short circuit to ground at pilot valve on forward direction of AWD pump (*) . . . . . . . . . . . . . . . . . 542
5343 - Short circuit to power at pilot valve on forward direction of AWD pump (*) . . . . . . . . . . . . . . . . . . 543
5344 - Wrong current level at pilot valve on forward direction of AWD pump (*) . . . . . . . . . . . . . . . . . . . 544
5347 - Control software failure at pilot valve on forward direction of AWD pump (*) . . . . . . . . . . . . . . . . 545
5351 - Open circuit at pilot valve on reverse direction of AWD pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 546
5352 - Short circuit to ground at pilot valve on reverse direction of AWD pump (*) . . . . . . . . . . . . . . . . . 547
5353 - Short circuit to power at pilot valve on reverse direction of AWD pump (*) . . . . . . . . . . . . . . . . . . 548
5354 - Wrong current level at pilot valve on reverse direction of AWD pump (*) . . . . . . . . . . . . . . . . . . . 549
5357 - Control software failure at pilot valve on reverse direction of AWD pump (*) . . . . . . . . . . . . . . . . 550
5361 - Open circuit at pilot valve on left front wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551
5362 - Short circuit to ground at pilot valve on left front wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 552
5363 - Short circuit to power at pilot valve on left front wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 553
5364 - Wrong current level at pilot valve on left front wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
5367 - Control software failure at pilot valve on left front wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . 555
5371 - Open circuit at pilot valve on right front wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
5372 - Short circuit to ground at pilot valve on right front wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . 557
5373 - Short circuit to power at pilot valve on right front wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . 558
5374 - Wrong current level at pilot valve on right front wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 559
5377 - Control software failure at pilot valve on right front wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . 560
5379 - Comparison error of rear axle rpm and CAN value TCU ETC1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . 561
5381 - Open circuit at PIN 2 on left front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562
5382 - Short circuit to ground at PIN 2 on left front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . . 563
5383 - Short circuit to power at PIN 2 on left front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . 564
5384 - Open circuit at PIN 4 on left front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565
5385 - Short circuit to ground at PIN 4 on left front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . . 566
5386 - Short circuit to power at PIN 4 on left front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . 567
5387 - Open circuit at power connection PIN 1 on left front wheel speed sensor (*) . . . . . . . . . . . . . . . 568
5388 - Open circuit at ground connection PIN 3 on left front wheel speed sensor (*) . . . . . . . . . . . . . . . 569
5389 - Open circuit at resistor ground connection on left front wheel speed sensor (*) . . . . . . . . . . . . . 570
5390 - Different frequencies at PIN 2/4 on left front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . 571
5391 - Direction failure on left front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
5392 - Wrong input signals on left front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573
5393 - Revolutions on left front wheel speed sensor above maximum (*) . . . . . . . . . . . . . . . . . . . . . . . . 574
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5401 - Open circuit at PIN 2 on right front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575
5402 - Short circuit to ground at PIN 2 on right front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . 576
5403 - Short circuit to power at PIN 2 on right front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . 577
5404 - Open circuit at PIN 4 on right front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
5405 - Short circuit to ground at PIN 4 on right front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . 579
5406 - Short circuit to power at PIN 4 on right front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . 580
5407 - Open circuit at power connection PIN 1 on right front wheel speed sensor (*) . . . . . . . . . . . . . . 581
5408 - Open circuit at ground connection PIN 3 on right front wheel speed sensor (*) . . . . . . . . . . . . . 582
5409 - Open circuit at resistor ground connection on right front wheel speed sensor (*) . . . . . . . . . . . . 583
5410 - Different frequencies at PIN 2/4 on right front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . 584
5411 - Direction failure on right front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585
5412 - Wrong input signals on right front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586
5413 - Revolutions on right front wheel speed sensor above maximum (*) . . . . . . . . . . . . . . . . . . . . . . . 587
5421 - Open circuit at forward pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588
5422 - Short circuit to power at forward pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589
5426 - Return line pressure at pump port A above allowed value (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590
5427 - Forward pressure sensor test failed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591
5431 - Open circuit at reverse pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592
5432 - Short circuit to power at reverse pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593
5436 - Return line pressure at pump port B above allowed value (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594
5437 - Return line pressure exceeds maximum when driving machine forward (*) . . . . . . . . . . . . . . . . . 595
5440 - Sensor test at reverse pressure sensor failed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596
5442 - AWD mode key not available on drive behavior module C6 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 597
5443 - Incorrect status of AWD mode key on drive behavior module C6 (*) . . . . . . . . . . . . . . . . . . . . . . . 598
5445 - Creep mode key not available on drive behavior module C6 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 599
5446 - Incorrect status of creep mode key on drive behavior module C6 (*) . . . . . . . . . . . . . . . . . . . . . . 600
5448 - Encoder button not available on drive behavior module C6 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
5451 - Drive behavior encoder not available on module C6 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
5452 - Incorrect status of drive behavior encoder on module C6 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
5459 - Logical error at brake pressure switches ZR1 and VG1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
5461 - Open circuit at neutral contact of accelerator pedal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
5463 - Short circuit to ground at neutral contact of accelerator pedal (*) . . . . . . . . . . . . . . . . . . . . . . . . . 606
5467 - Short circuit to power at FNR switch of gear shift unit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
5469 - Logical error at FNR switch of gear shift unit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
5474 - Logical error at machine code plug (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
5475 - Wrong signal on digital input of machine code plug (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
5487 - Configuration incomplete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
5491 - Calibration of pump forward direction not complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
5492 - Calibration of pump reverse direction not complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613
5493 - Calibration of left front wheel motor not complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614
5494 - Calibration of right front wheel motor not complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615
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5495 - Low Voltage at 2nd ignition input of controller (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
5497 - No charge pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
5498 - Too high pressure at both hydraulic lines (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
9121 - Logical error when retreiving flash data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
9128 - CAN timed out during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623
9133 - Never started receiving message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627
9160 - Hour Meter Failure - Both copies are wrong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630
9161 - Hour Meter Failure - one of two copies are wrong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631
9162 - Hour Meter Failure - Pre-crank And After-crank Checks Are Wrong . . . . . . . . . . . . . . . . . . . . . . . 632
9173 - Configuration Error - Engine Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633
9174 - Configuration Error - Transmission Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634
9175 - Configuration Error - AWD selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635
9176 - Configuration Error - not set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636
19001 (DTC 1361) - Battery voltage is higher than expected [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 637
19002 (DTC 2461) - Battery voltage is lower than expected [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 638
19071 (DTC 2DDA) - SCR catalyst efficiency lower than first NOx production threshold level [ECU]. . 640
19323 (DTC 94FB) - External engine shutdown request received [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . 643
19434 (DTC E26D) - ECU internal failure - EEPROM erase error [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . 644
19435 (DTC E36D) - ECU internal failure - EEPROM read error [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . 645
19436 (DTC E46D) - ECU internal failure - EEPROM write error [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . 646
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Electrical systems - FAULT CODES
1310 - Hydraulic Filter Blocked

Cause:
Hydraulic filter blocked.
Solution:
1. Change Filter.
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1311 - Engine Air Filter Blocked

Cause:
Engine air filter blocked
Solution:
1. Change Filter.
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1312 - Hydraulic Oil Temperature Above Normal

Cause:
Hydraulic oil temperature above normal.
Solution:
1. Stop machine operations.

2. Run engine at 1500 RPM .
3. Check fan operation.
4. Check cooling core for clogs.
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1313 - Hydraulic Oil Temperature Too High

Cause:
Hydraulic oil temperature too normal.
Solution:

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1314 - Transmission Oil Temperature Above Normal

Cause:
Transmission oil temperature above normal.
Solution:

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1315 - Transmission Oil Temperature Too High

Cause:
Transmission oil temperature too high
Solution:

2. Run engine at 1500 RPM.
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1316 - Brake Pressure Too Low

Cause:
Brake Pressure Too Low
Solution:

3. Check brake system pressure.
4. Check brake system for leaks.
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1317 - Steering Pressure Too Low

Cause:
Steering pressure too low
Solution:

3. Check steering system for operation.
4. Check steering system for leaks.
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1318 - Engine Coolant Temperature Above Normal

Cause:
Engine Coolant Temperature Above Normal
Solution:

4. Check radiator core for clogs.
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1319 - Engine Coolant Temperature High - Critical

Cause:
Engine Coolant Temperature High - Critical
Solution:

4. Check radiator core for clogs.
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1320 - Engine Oil Pressure Too Low

Cause:
Engine Oil Pressure Too Low
Solution:

2. Check engine oil level .
3. Check pressure sender unit.
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1321 - Engine Oil Pressure Below Normal

Cause:
Engine Oil Pressure Below Normal
Solution:

2. Check engine oil level.
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1322 - Engine Oil Pressure Above Normal

Cause:
Engine Oil Pressure Above Normal
Solution:
1. Check engine oil for proper type.

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1323 - Battery Voltage Too Low

Cause:
Battery Voltage Too Low
Solution:
1. Check charging system.
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1324 - Battery Voltage High

Cause:
Battery Voltage High
Solution:
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1325 - Engine Oil Temperature Too High

Cause:
Engine Oil Temperature Too High
Solution:

3. Check sending unit.
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1326 - Coolant Level Low

Cause:
Coolant Level Low
Solution:
1. Fill radiator level.
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1331 - Electrical Charging System Voltage Too Low - Critical Level

Cause:
Electrical Charging System Voltage Too Low - Critical Level
Solution:

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1332 - Water Detected In Fuel

Cause:
Water Detected In Fuel
Solution:
1. Drain fuel filter.
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1333 - Engine Overspeed

Cause:
Engine Overspeed
Solution:
1. Check engine speeds.
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1334 - Intake Manifold Temperature High - Critical

Cause:
Intake Manifold Temperature High - Critical
Solution:
1. Check for defective or clogged after cooler.
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1335 - Brake Pressure Too Low

Cause:
Brake Pressure Too Low
Solution:

3. Check brake system pressure.
4. Check brake system for leaks.
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1346 - Engine Coolant Temperature Sensor Failure Out of Range

High
Solution:
1. Check actual engine coolant temp. for any discrepancies.

2. If the temperature is ok, check wiring connection between engine coolant temperature sensor and AIC connector
CN1 pin 8 for any open circuits or short circuit ground, passing through connector X13 (pin 3) at the engine harness
and connector X6 (pin 9) at the front column harness.
3. In case the circuit is ok, replace sensor and check if the error code is resumed.
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1347 - Engine Coolant Temperature Sensor Failure Short Circuit

to Ground
Solution:
1. Check wiring connection between engine coolant temperature sensor and AIC connector CN1 pin 8 for any short
circuit to ground, passing through connector X13 (pin 3) at the engine harness and connector X6 (pin 9) at the
ground, passing through connector X13 (pin 3) at the engine harness and connector X6 (pin 9) at the front column
harness.
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1348 - Engine Coolant Temperature Sensor Failure Out of Range

Low
Solution:
1. Check actual engine coolant temp. for any discrepancies.

2. If the temperature is ok, check wiring connection between engine coolant temperature sensor and AIC connector
CN1 pin 8 for any open circuits or short circuit passing through connector X13 (pin 3) at the engine harness and
connector X6 (pin 9) at the front column harness.
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1351 - Voltmeter Input and Key Switch Input not plausible

Solution:
1. Check fuse F8 on ECE. Replace it in case of damage.

2. If the duse is ok, check relay K5 on ECE. Replace it in case of damage.
3. In case the relay is ok, check wiring connection between relay pin 87 and AIC CN1 (pin 1).Check relay pin 85
connection to ground. Check voltage availability on pins 86 and 30 of relay when the key is in IGN position. In
case any of these conditions are not satisfied, repair wiring connection accordingly.
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1353 - Engine Oil Pressure Sensor Failure Out of Range High

Solution:
1. Check actual engine oil pressure for any discrepancies.

2. If the pressure is ok, check wiring connection between engine oil pressure sensor(S10) and AIC connector CN1
pin 11 for any open circuits or short circuits, passing through connector X13 (pin 2) at the engine harness and
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1354 - Engine Oil Pressure Sensor Failure Out of Range Low

Solution:
1. Check actual engine oil pressure for any discrepancies.

2. If the pressure is ok, check wiring connection between engine oil pressure sensor (S10) and AIC connector CN1
pin 11 for any open circuits or short circuits, passing through connector X13 (pin 2) at the engine harness and
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1355 - Transmission Oil Pressure Below Normal

Cause:
Transmission Oil Pressure Below Normal
Solution:
1. Check actual transmission oil pressure for any discrepancies.

2. If the pressure is ok, check wiring connection between transmission oil pressure switch (S18) and AIC connector
CN1 pin 24 for any short circuits to ground, For details of the circuit routing, check service manual.
3. In case the circuit is ok, replace switch and check if the error code is resumed.
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1356 - Transmission Oil Pressure Sensor OC

Cause:
Transmission Oil Pressure Sensor OC
Solution:
1. Check wiring connection between transmission oil pressure switch (S18) and AIC connector CN1 pin 24 for any
open circuits, For details of the circuit routing, check service manual.
2. In case the circuit is ok, replace switch and check if the error code is resumed.
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1358 - Fan Control Valve short to ground OR open circuit

Cause:
Fan Control Valve short to ground OR open circuit
Solution:
1. If the machine does not have a proporcional valve for the engine fan (valve available only for 200/885 with ZF
transmission or AWD units), re-set the machine model in the AIC correctly.
2. If the valve is present, check through the AIC menu if the AIC software version is 1.7.0.0 or above. Update the
software to one of these versions (preferebly 1.9.0.0 or above) and set the machine model correctly.
3. Check wiring connection between fan drive control valve and AIC connector CN1 pin 24 for any open circuits or
short circuits to ground, passing through connector X6 (pin 58) at the interface between the rea main and front
column harness.
4. In case the circuit is ok, replace solenoid valve and check if the error is resumed.
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1359 - Fan Control Valve short to battery

Cause:
Fan Control Valve short to battery
Solution:
1. If the machine does not have a proporcional valve for the engine fan (valve available only for 200/885 with ZF
transmission or AWD units), re-set the machine model in the AIC correctly.
2. If the valve is present, check through the AIC menu if the AIC software version is 1.7.0.0 or above. Update the
software to one of these versions (preferebly 1.9.0.0 or above) and set the machine model correctly.
3. Check wiring connection between fan drive control valve and AIC connector CN1 pin 24 for any short circuits,
passing through connector X6 (pin 58) at the interface between the rea main and front column harness.
4. In case the circuit is ok, replace solenoid valve and check if the error is resumed.
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1360 - OC/ SC to Bat. at Hydraulic Oil Temperature. Sensor

Severity: yellow
Cause:
OC/ SC to Bat. at Hydraulic Oil Temperature. Sensor Severity: yellow
Solution:
1. Check actual hydraulic oil temp. for any discrepancies.

2. If the temperature is ok, check wiring connection between hydraulic oil temperature sensor (S20 located at the
bottom of the hydraulic tank) and AIC connector CN1 pin 9 for any open circuits or short circuits. For details of the
circuit routing, check service manual.
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1361 - SC to GND. at Hydraulic Oil Temperature. Sensor Severity:

yellow
Cause:
SC to GND. at Hydraulic Oil Temperature. Sensor Severity: yellow
Solution:
1. Check actual hydraulic oil temp. for any discrepancies.

2. If the temperature is ok, check wiring connection between hydraulic oil temperature sensor (S20 located at the
bottom of the hydraulic tank) and AIC connector CN1 pin 9 for any open circuits or short circuits. For details of the
circuit routing, check service manual.
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1364 - Intake Manifold Temperature Above Normal

Cause:
Intake Manifold Temperature Above Normal
Solution:

2. Check engine oil level.
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3000 - ZF power curves adjustable via CAN, TSC1 CAN interface

disabled VCM2EDC
Cause:
ZF power curves adjustable via CAN, TSC1 CAN interface disabled VCM2EDC
Solution:
1. Engine dataset Version 5801526773 or 5801561814 (170 / 865 class and 140 / 845 class)
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3001 - Foot Throttle Sensor - Signal Not Plausible

Cause:
Foot Throttle Sensor - Signal Not Plausible
Solution:
1. Idle switch defect or wiring of idle switch broken or accelerator pedal defect. Check wiring, replace
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3002 - Foot Throttle Sensor - Signal Above Range Maximum

Cause:
Foot Throttle Sensor - Signal Above Range Maximum
Solution:
1. Short circuit in wiring or in accelerator pedal.

2. Check wiring or replace accelerator pedal.
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3003 - Foot Throttle Sensor - Signal Below Range Minimum

Cause:
Foot Throttle Sensor - Signal Below Range Minimum
Solution:
1. Short circuit in wiring or in accelerator pedal.

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3004 - Foot Throttle Sensor - No Signal

Cause:
Foot Throttle Sensor - No Signal
Solution:
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3005 (DTC 4B84) - Air filter clog or circuit failure

Control Module: ECU
Context:
The Electronic Control Unit (ECU) A-095 monitors the air filter clogging switch. If engine speed is greater than
1400 RPM after 10.00 min of engine running time and an air filter clog or circuit failure is detected, this fault will
occur.
Cause:
An air filter clog or circuit failure has been detected.
Possible failure modes:
1. Faulty air filter, clogged

2. Faulty air filter clogging switch S-022 wiring or switch
3. Faulty A-095, software
Solution:
1. Verify fault is present and active.
Use the Electronic Service Tool (EST) to check the status of this fault.
A. If the fault is present and active, continue with Step 2.
B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active.
Continue with Step 6.
2. Inspect the engine air filter and air intake system for a clogged or obstructed condition.
A. If the filter or air intake system is clogged or obstructed, repair or replace the air filter as necessary.
B. If the air filter or air intake system is not clogged or obstructed, continue to Step 3.
3. Check the S-022 circuit for a short circuit condition.
Disconnect connector X-911.
Disconnect connectors X-223 and X-224.
Turn the ignition switch OFF.
Use a multimeter to perform the following continuity check:
From To Value
X-911 pin 37, wire 9234 (YE) X-911 pin 27, wire 6570A (BL) There should be no continuity.
A. If there is continuity, there is a short circuit condition in the S-022 circuit. Locate and repair the shorted con-
ductor.
B. If there is no continuity, leave the connectors disconnected and continue to Step 4.

4. Check the S-022 circuit for a short to ignition battery power condition.
Turn the ignition switch ON.
Use a multimeter to perform the following voltage check:
From To Value
X-911 pin 37, wire 9234 (YE) Chassis ground There should be no voltage.
X-911 pin 27, wire 6570A (BL) Chassis ground There should be no voltage.
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A. If there is voltage, there is a short circuit to ignition battery power in the S-022 circuit. Locate and repair the
shorted conductor.
B. If there is no voltage, continue to Step 5.

5. Replace the S-022.
Use the EST to verify the status of this fault, 3005 (DTC 4B84) – Air filter clog or circuit failure.
A. If the fault has been resolved, return the machine to service.
B. If the fault has not been resolved, check the ECU A-095 for the appropriate software and re-flash, if necessary.
6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals,
or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent
breaks or shorts in the wiring concerned. Operate the machine while you monitor the display.
A. If you find damage or the display indicates other than normal display readings, then repair the damage discov-
ered during the inspection or locate and repair the other than normal display condition and verify that the error
has been resolved.
B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue
operation.
Wiring harnesses - Electrical schematic sheet 12 (55.100)
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3006 - Coolant Temperature Sensor - Signal Not Plausible

Cause:
Coolant Temperature Sensor - Signal Not Plausible
Solution:
1. See OTS (Oil Temperature Sensor) plausibility check (Fault 3033)
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3007 - Coolant Temperature Sensor - Signal Above Range Maximum

Cause:
Coolant Temperature Sensor - Signal Above Range Maximum
Solution:
1. Sensor defective or short circuit to external source. Check wiring or replace sensor.
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3008 - Coolant Temperature Sensor - Signal Below Range Minimun

Cause:
Coolant Temperature Sensor - Signal Below Range Minimun
Solution:
1. Sensor defective or short circuit to ground. Check wiring or replace sensor.
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3009 - Coolant Temperature Sensor - (via CAN) Null

Cause:
Coolant Temperature Sensor - (via CAN) Null
Solution:
1. No CAN plausibility check performed, restart system, if problem reoccurs. Check wiring or replace sensor.
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3010 - Air Intake Temperature Sensor - Signal Above Range

Maximum
Cause:
Air Intake Temperature Sensor - Signal Above Range Maximum
Solution:
1. The Engine Control Unit (ECU) generated an error from a fault associated with the Boost Pressure sensor. The
Boost Pressure sensor is an integrated sensing device used to sense both temperature and pressure. This fault
is related to the temperature sensing function of the device.
2. This error could result from a signal out of range or a signal that is either erratic or intermittent.
3. Check pressure sender unit.When the ECU determines that the Boost Pressure sensor value is not valid, it will
substitute a default value of 29.96 °C (86 °F). Cause: The Boost Pressure sensor signal to the ECU is out of range
of the upper threshold limit.
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Minimum
Cause:
Air Intake Temperature Sensor - Signal Above Range Minimum
Solution:
1. The Engine Control Unit (ECU) generated an error from a fault associated with the Boost Pressure sensor. The
Boost Pressure sensor is an integrated sensing device used to sense both temperature and pressure. This fault
is related to the temperature sensing function of the device.
2. This error could result from a signal out of range or a signal that is either erratic or intermittent.
3. When the ECU determines that the Boost Pressure sensor value is not valid, it will substitute a default value of
29.96 °C (86 °F). Cause: The Boost Pressure sensor signal to the ECU is out of range of the lower threshold limit.
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Minimum
Cause:
Air Intake Temperature Sensor - Signal Above Range Minimum
Solution:
1. See engine manual for details.
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3014 (DTC 4C84) - Air filter clog or circuit failure present for a long
time
Context:
The Electronic Control Unit (ECU) A-9000 monitors the air filter clogging switch. Monitoring is performed in two levels.
The first level warning is detected if the A-9000 detects an air filter clogging or circuit failure condition. A second level
warning is detected if no action is taken after the first level warning. If engine speed is greater than 1400 RPM after
10.00 min of engine running time and a second warning is detected, this fault will occur.
Cause:
An air filter clog or circuit failure has been detected for longer than 30.00 min.
1. Faulty air filter, clogged.

2. Faulty air filter clogging switch S-9101 wiring or switch.
3. Faulty A-9000, software.
Solution:
2. Check for the following related faults: 3005
A. If the fault is active, resolve the other fault first and then return to this fault.
B. If the fault is not active, continue to Step 3.

They keyswitch must be in the off position.
From To Value
X-9001 pin 37 X-9001 pin 27 There should be no continuity.
ductor.

5. Check the S-9101 circuit for a short to key battery power condition.
The keyswitch must be in the on position.
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From To Value
X-9001 pin 37 Chassis ground There should be no voltage.
A. If there is voltage, there is a short circuit to key battery power in the S-9101 circuit. Locate and repair the
shorted conductor.

Test sensor operation. Check if the fault remains active.
has been resolved.
operation.
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3014 (DTC 4C84) - Air filter clog or circuit failure present for a long
time
Control Module: ECU
Context:
The Electronic Control Unit (ECU) A-095 monitors the air filter clogging switch. Monitoring is performed in two levels.
The first level warning is detected if the A-095 detects an air filter clogging or circuit failure condition. A second level
warning is detected if no action is taken after the first level warning. If engine speed is greater than 1400 RPM after
10.00 min of engine running time and a second warning is detected, this fault will occur.
Cause:
An air filter clog or circuit failure has been detected for longer than 30.00 min.
1. Faulty air filter, clogged

2. Faulty air filter clogging switch S-022 wiring or switch
Solution:
2. Check for the following related faults:
3005 (DTC 4B84) – Air filter clog or circuit failure
A. If the fault is active, diagnose it first and then return to this fault, 3014 (DTC 4C84) – Air filter clog or circuit
failure present for a long time.

Disconnect connectors X-223 and X-224.
From To Value
X-911 pin 37, wire 9234 (YE) X-911 pin 27, wire 6570A (BL) There should be no continuity.
ductor.
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5. Check the S-022 circuit for a short to ignition battery power condition.
Turn the ignition switch ON.
From To Value
X-911 pin 37, wire 9234 (YE) Chassis ground There should be no voltage.
A. If there is voltage, there is a short circuit to ignition battery power in the S-022 circuit. Locate and repair the
shorted conductor.

Use the EST to verify the status of this fault, 3005 (DTC 4B84) – Air filter clog or circuit failure.
has been resolved.
operation.
Wiring harnesses - Electrical schematic sheet 12 (55.100)
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3015 - Fuel Temperature Sensor - Signal Above Range Maximum

Cause:
Fuel Temperature Sensor - Signal Above Range Maximum
Solution:
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3016 - Fuel Temperature Sensor - Signal Below Range Minimum

Cause:
Fuel Temperature Sensor - Signal Below Range Minimum
Solution:
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3019 - Boost Pressure Sensor - Signal Above Range Max

Cause:
Boost Pressure Sensor - Signal Above Range Max
Solution:
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3021 - Boost Pressure Sensor - (via CAN) Null

Cause:
Boost Pressure Sensor - (via CAN) Null
Solution:
1. No CAN plausibility check performed, restart system, if problem reoccurs. Check wiring or replace sensor.
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3022 - Boost Pressure Sensor - Signal Not Plausible

Cause:
Boost Pressure Sensor - Signal Not Plausible
Solution:
1. Difference of ambient and boost pressure is out of range. Check wiring or replace sensor.
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3023 - Atmospheric Pressure Sensor - Signal Not Plausible

Cause:
Atmospheric Pressure Sensor - Signal Not Plausible
Solution:
1. Ambient pressure sensor inside ECU is defect. Replace ECU (not necessary if never running in high altitude and
if turbocharger is without VGT).
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3024 - Atmospheric Pressure Sensor - Signal Above Range

Maximum
Cause:
Atmospheric Pressure Sensor - Signal Above Range Maximum
Solution:
if turbocharger is without VGT)
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3025 - Atmospheric Pressure Sensor - Signal Below Range

Minimum
Cause:
Atmospheric Pressure Sensor - Signal Below Range Minimum
Solution:
if turbocharger is without VGT)
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3028 - OIL PRESSURE SENSOR LOW VALUE

Cause:
OIL PRESSURE SENSOR LOW VALUE
Solution:
1. Inaccurate oil pressure sensor or defect (e.g. too low oil level, leakage...) in the oil system. Check oil pressure
sensor for accuracy and check oil system.
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3029 - Oil Pressure Sensor - Short Circuit To Battery

Cause:
Oil Pressure Sensor - Short Circuit To Battery
Solution:
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3030 - Oil Pressure Sensor - Short Circuit To Ground

Cause:
Oil Pressure Sensor - Short Circuit To Ground
Solution:
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3031 - Oil Pressure Sensor - ADC Conversion Error

Context:
The Engine Control Unit (ECU) generated a fault associated with the Oil temp / press sensor. The Oil temp / press
sensor is an integrated sensing device used to sense both temperature and pressure. This fault is related to the
pressure sensing function of the device. This error could result from a signal out of range or a plausibility check (oil
pressure too high). The plausibility check is only started if there are no sensor power supply ( 5 volts dc) or Analog
to Digital Converter (ADC) signal errors detected.
Cause:
The Oil temp / press sensor signal to the ECU is either erratic or intermittent.
Solution:
1. Faulty Oil temp / press sensor.

2. Caulty electrical wiring or intermitente connection between Oil temp / press sensor and ECU.
3. Faulty ECU, supply voltages or grounds.
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3032 - Oil Pressure Sensor - Pressure Too High

Cause:
Oil Pressure Sensor - Pressure Too High
Solution:
1. Oil pressure sensor pressure too high.
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3033 - Oil temperature sensor - signal not plausible

Control Module: ECU
Cause:
Oil temperature sensor - signal not plausible
Solution:
1. Inaccurate oil or coolant temperature sensors or insufficient oil or coolant recirculation (low coolant level etc.).
2. Check oil and coolant temperature sensor for accuracy and check oil and coolant system for proper functioning.
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3034 - Oil Temperature Sensor - Signal Above Range Maximum

Cause:
Sensor defective or short circuit to external source
Solution:
1. Check wiring or replace sensor.
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3035 - Oil Temperature Sensor - Signal Below Range Minimum

Cause:
Sensor defective or short circuit to ground.
Solution:
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3036 - Oil Temperature Sensor - CAN Transmission Disturbed

Cause:
No CAN plausibility check performed, restart system, if problem reoccurs.
Solution:
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3037 - Boost Pressure Sensor - Signal Low

Cause:
Sensor defective or short circuit to ground.
Solution:
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3047 - High Pressure Pump Relay - Short Circuit to Battery

Cause:
High Pressure Pump Relay - Short Circuit to Battery
Solution:
1. Faulty reading from component.

2. Connectors not mated fully, pins not pushed into connector fully, bent pin or broken wire at rear of connector.
3. Wiring or circuits open.
4. Wiring or circuits shorted.
5. Connector pins corroded or dirty. When removing connectors inspect and clean pins. Clean female pins by in-
stalling and removing.
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3048 - High Pressure Pump Relay - Short Circuit To Ground

Cause:

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3051 - Battery Voltage to ECM too High

Cause:
Alternator voltage governor defect.
Solution:
1. Replace alternator governor device or.
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3052 - Battery Voltage to ECM too Low

Cause:
Battery defect, alternator defect, wiring problems (too high resistance) or ECU defect. Occurrence possible during
cold start.
Solution:
1. Replace battery or alternator. Check ECU and wiring.
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3059 - ECM Afterrun was Interrupted

Solution:

5. Connector pins corroded or dirty. When removing connectors inspect and clean pins. Clean female pins by in-
stalling and removing.
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3060 - Cylinder 1 - Unclassifiable Error In Injector

Context:
• Depending on the pattern, various reasons can cause the defect, internal ECU problems also possible.
Solution:
1. Check the wiring and the injection signals, replace ECU.
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3061 - Cylinder 1 - Injector Cable Short Circuit (Low Side To Battery)

Cause:
Short circuit in wiring with external source.
Solution:
1. Check the wiring or replace injector.
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3062 - Cylinder1 - Signal Low

Solution:
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3063 - Cylinder1 - Injector Cable Shortcircuit (High Side to Low Side)

Cause:
Defective coil of injector..
Solution:
1. Check the wiring and replace injector.
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Context:
Depending on the pattern, various reasons can cause the defect, internal ECU problems also possible.
Solution:
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Cause:
Solution:
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Solution:
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Cause:
Solution:
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Cause:
Solution:
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Cause:
Solution:
1. Short circuit in wiring with external source.
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Solution:
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Cause:
Defective coil of injector.
Solution:
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Cause:
Solution:
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Cause:
Solution:
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3074 - Cylinder 6 - Signal Low

Solution:
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3075 - Cylinder 6 - Injector Cable Shortcircuit (High Side to Low

Side)
Cause:
Solution:
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Cause:
Solution:
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Cause:
Short circuit in wiring with external source..
Solution:
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Solution:
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Side)
Cause:
Solution:
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Cause:
Solution:
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Cause:
Solution:
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Solution:
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Side)
Cause:
Solution:
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3088 - Crankshaft sensor lost synchronization

Cause:
Signal interrupted due to wiring problem, defective or incorrectly installed crankshaft speed sensor.
Solution:
1. Check wiring, sensor installation and proper functioning of crankshaft sensor (evaluate raw signals).
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3089 - Crankshaft Sensor - Defective

Solution:
1. Check wiring, sensor installation and proper functioning of crankshaft sensor (evaluate raw signals).
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3090 - Camshaft Sensor - Lost Phase

Cause:
Signal interrupted due to wiring problem, defective or incorrectly installed camshaft phase sensor.
Solution:
1. Check wiring, sensor installation and proper functioning of camshaft phase sensor (evaluate raw signals).
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3091 - Camshaft Sensor Phase Synchronization Failure

Solution:
1. Check wiring, sensor installation and proper functioning of camshaft phase sensor (evaluate raw signals).
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3092 - Offset Between Camshaft and Crankshaft - Not Plausible

NOTE: See engine manual for details.
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3093 - Offset Between Camshaft And Crankshaft - Outside

Boundaries
Cause:
Signal interrupted due to wiring problem, defective or incorrectly installed camshaft or crankshaft sensor.
Solution:
1. Check wiring, sensor installations and proper functioning of camshaft and crankshaft sensors (evaluate raw sig-
nals).
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3095 - Operating with Camshaft Sensor Only

Solution:
1. Check wiring, sensor installation and proper functioning of crankshaft sensor (evaluated raw signals).
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3096 (DTC 951B) - CAN A Bus off failure

Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 is capable of connecting to and communicating on two separate Controller Area
Networks (CAN). Proper configuration and monitoring of the two twisted pair configured networks is also a function
of the ECU A-057. CAN Node A Bus is the main vehicle interface bus. The ECU A-057 provides a CAN termination
resistor for the CAN Node A Bus, internal to the ECU A-057. If the ECU A-057 senses that CAN Node A Bus is not
functioning properly, this fault will occur.
Cause:
ECU A-057 has sensed a Bus Off state to be present at the CAN Node A.
1. Faulty supply voltage or ground, missing.

2. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit.
3. Faulty ECU A-057, termination resistor or software.
Solution:
1. Verify fault is present and in active state.
B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active.
2. Check for other vehicle CAN faults.
Use the EST to determine if vehicle CAN faults exist.
A. If other vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that 3096 (DTC 951B) –
CAN A Bus off failure is also resolved.
B. If other vehicle CAN faults do not exist, continue with Step 3.

3. Check the ECU A-057 supply voltage.
Disconnect the vehicle harness from the ECU A-057 at connector X-937.
To energize the Main relay K-013, place a jumper wire between the vehicle harness side of connector X-937 pin
28 and chassis ground.
Use a multimeter to check for voltage on the vehicle harness side:
From To Value
X-937 pin 1 chassis ground There should be 12.0 V.
A. If the voltage is present on all of the checks, leave connector X-937 disconnected and continue with Step 4.
B. If the voltage is not present for one or more of the checks, see the appropriate vehicle service manual and
electrical schematics, if necessary, to locate and restore supply power to the ECU A-057.
4. Check the ECU A-057 ground circuits.
Use a multimeter to check for continuity on the vehicle harness side:
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From To Value
X-937 pin 2 chassis ground There should be continuity.
A. If there is continuity on all of the checks, leave connector X-937 disconnected and continue with Step 5.
B. If there is no continuity for one or more of the checks, see the appropriate vehicle service manual and electrical
schematics, if necessary, to locate and restore the ground circuits to the ECU A-057.
5. Determine the condition of the ECU A-057 CAN circuit.
With the key switch in the OFF position, use a multimeter to measure the resistance of the CAN connection on the
vehicle harness side:
From To Value
X-937 pin 24 X-937 pin 25 There should be 120 Ω.
X-937 pin 24 chassis ground There should not be continuity.
Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU A-057:
From To Value
A. If the measured resistances are correct and neither conductor is grounded, check the ECU A-057 for the ap-
propriate software and re-flash, if necessary.
B. If the measured resistances are not correct or one or both of the conductors is grounded, see the appropriate
vehicle service manual and electrical schematics, if necessary, to locate and restore the termination resistance
to the CAN circuit.
has been resolved.
operation.
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3102 - Rail Pressure Sensor CP3 - Signal Below Range Minimum

Cause:
Short circuit of wiring to ground or defective pressure sensor.
Solution:
1. Check wiring and proper functioning of rail pressure sensor.
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3104 - Rail Pressure Relief Valve - Open

Cause:
Defective rail pressure sensor, defect in other injection relevant component.
Solution:
1. Check rail pressure sensor for plausible values, ensure proper functioning of the injection components.
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3105 - Rail Pressure Relief Valve - Pressure Shock Requested

Cause:
PRV does not open once the pressure limit is reached: Mechanical defect or wrong application parameter.
Solution:
1. Check application value of maximum rail pressure, check functioning of the PRV.
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3106 - Rail Pressure Relief Valve - Did Not Open After Pressure
Shock
Cause:
PRV does not open even after pressure shock.
Solution:
1. Stuck PRV or wrong application parameter. Check application value of maximum rail pressure, check functioning
of the PRV.
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3107 - Metering unit output short circuit to battery on low side

Cause:
Short circuit of wiring to external source or inside relay.
Solution:
1. Check wiring or replace relay.
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3108 - Metering Unit - Shortcircuit to Ground

Context:
The engine control unit (ECU) has determined that a short to low source circuit condition exists in the fuel high pres-
sure pump low side circuit. The metering unit of the fuel high pressure pump regulates the pressure in the common
rail. The metering unit is closed-loop controlled by both main relay 1 (high side) and a low side power stage (Main
Relay 1 is an electronic control circuit within the ECU, providing source voltage to devices external to the ECU. The
low side power stage works in conjunction with the Main Relay 1 source, providing sensing and current limiting for the
circuit). The monitoring at low side is stopped if a short circuit to ground at the high side (main relay 1) is detected or it
is switched off for some reason. Failure detection of is only possible if the low side power stage is switched off. With
the current settings, the monitoring is shut off during after-run. This error is the result of the power stage hardware
report of ’short circuit to ground’ (on the low side of the metering unit) longer than 0.28 seconds and the power stage
has most likely switched off.
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3110 - Rail Pressure Sensor Offset Monitoring - Signal Above

Range Maximum
Cause:
Rail pressure sensor inaccurate.
Solution:
1. Ensure correct wiring and proper functioning of rail pressure sensor, replace sensor.
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3111 - Rail Pressure Sensor Offset Monitoring - Signal Below Range

Minimum
Cause:
Rail pressure sensor inaccurate.
Solution:
1. Ensure correct wiring and proper functioning of rail pressure sensor, replace sensor.
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3112 - Rail Pressure Sensor CP3 - Signal Above Maximum Range

Cause:
Short circuit of wiring to external source or defective pressure sensor, rail pressure overshoot.
Solution:
1. Check wiring and proper functioning of rail pressure sensor.
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3113 - Main relay 1 (high pressure pump) - short to battery

Cause:
Short circuit of main relay to external source or defective main relay.
Solution:
1. Check the wiring connecting the battery to the EDC or replace main relay.
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3114 - Grid heater battery switch relay short circuit to ground

Cause:
Short circuit to ground of main relay or defective main relay.
Solution:
1. Check the wiring connecting the battery to the EDC or replace main relay.
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3118 - ECM 12V sensor supply voltage high

Cause:
Ambient pressure sensor inside ECU is defective.
Solution:
1. Replace ECU (not necessary if never running in high altitude and if turbocharger without VGT).
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3119 - ECM 12V sensor supply voltage low

Cause:
Ambient pressure sensor inside ECU is defective.
Solution:
1. Replace ECU (not necessary if never running in high altitude and if turbocharger without VGT).
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3131 - Grid Heater Always Switched On

Cause:
Short circuit to ground of grid heater.
Solution:
1. Check grid heater switch and replace it.
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3137 - Metering Unit - Open Load

Cause:
Broken or disconnected wiring or defective relay.
Solution:
1. Check of wiring or replace relay.
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3138 - Metering Unit - Signal Not Plausible

Cause:
Defective wiring, ECU, power stage or metering unit.
Solution:
1. Check wiring, ECU, power stage and metering unit.
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3141 - Set point of fuel volume flow through metering unit is lower
than calculated limit
Cause:
1. High pressure system: Rail pressure sensor inaccurate, high pressure pump defective.
2. Low pressure system: Metering unit reflux too low.
Solution:
1. Check for defects according to failure list.
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3146 (DTC 4415) - Water in fuel detected or water in fuel circuit

failure
Control Module: ECU
NOTE: This fault code is for the Water in Fuel sensor with black connector housing.
Context:
The Engine Control Unit (ECU) A-057 monitors the voltage output from the water in fuel sensor B-012 to determine
if water is present in the fuel supply. If water is detected in the fuel, warnings will be displayed to alert the operator
of potential engine damage if operation continues. High voltage signal from the water in fuel sensor B-012 indicates
water present.
Cause:
This fault code is displayed to warn the operator that the ECU A-057 has detected excess water in the fuel system or
a fault in the water in fuel sensor circuit.
1. Excess water in the fuel supply.

2. Faulty water in fuel sensor B-012, wiring or internal (mechanical and/or electrical) failure.
3. Faulty ECU A-057, software.
Solution:
1. Verify this fault code is still present and in an active state.
Use the Electronic Service Tool (EST) to check the fault status.
A. If the fault is still present and active, continue with Step 2.
B. If the fault is no longer present or is in an inactive state, continue with Step 7.

2. Check fuel for water contamination.
A. If there is water contamination, continue with Step 3.
B. If there is no water contamination, Continue with Step 4.

3. Verify proper water in fuel sensor B-012 operation.
Purge fuel supply system, replace fuel filter(s) and refill with fuel that is free of water contamination.
Start and run engine for 5 minutes.
Check for code to return to active status.
A. If code returns in an active status, replace water in fuel sensor B-012.
B. If code remains inactive, return the machine to service.

4. Check for open, short and grounded circuit conditions in the water in fuel sensor B-012 circuit.
Disconnect the water in fuel sensor B-012 at connector X-950.
With the key switch in the OFF position, use a multimeter to perform the following tests, on the vehicle harness
from:
From To Value
X-950 pin 1 X-937 pin 30 There should be continuity.
X-950 pin 2 Chassis ground There should be continuity.
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From To Value
X-950 pin 3 Refer to the appropriate vehicle There should be continuity.
schematics.
Then use the multimeter to perform the following tests, on the vehicle harness from:
From To Value
Then use the multimeter to perform the following tests, on the vehicle harness from:
From To Value
X-950 pin 1 Chassis ground There should be no continuity.
A. If the results are not as expected for any of the wiring tests listed above, there is an open, short or grounded
circuit condition in the vehicle harness wiring. Use the appropriate vehicle service manual and schematics to
diagnose and repair the wiring.
B. If the results are as expected in all of the wiring tests listed above, the wiring is okay. Leave connectors X-937
and X-950 disconnected and continue with Step 5.
5. Check for key switch voltage supply to water in fuel sensor B-012.
With the key switch in an ON position, use a multimeter to perform the following test, on the vehicle harness side
from:
From To Value
X-950 pin 3 Chassis ground There should be key switch voltage.
X-950 pin 1 Chassis ground There should be no key switch
voltage.
A. If there is key switch voltage present in the first check and not present in the second check, continue with Step
6.
B. If key switch voltage is not present in the first check or present in the second check, use the appropriate vehicle
service manual and schematics to diagnose and repair the wiring.
6. Replace the water in fuel sensor B-012, then check to see if this fault has been resolved.
A. If the fault is resolved, return the machine to service.
B. If the fault is not resolved, check the ECU A-057 for the appropriate software and re-flash, if necessary.
A. If you find damage or the display indicates other than normal readings, then repair the damage discovered
during the inspection or locate and repair the other than normal display condition and verify that the error has
been resolved.
operation.
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3147 - Oil Temperature Sensor - Signal Above Normal Range

Solution:
1. Check oil temperature sensor for accuracy and check oil system.
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3154 - Grid Heater Relay - Short Circuit To Battery

Cause:
Solution:
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3155 - Grid Heater Relay - Short Circuit To Ground

Cause:
Short circuit of wiring to ground or inside relay.
Solution:
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3156 - Grid Heater Relay - No Load

Cause:
Solution:
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3176 - Fuel delivery exceeded threshold for pressure in overrun

mode
Context:
High pressure system: Leakage in the high pressure section, injection nozzle stuck in open position, worn or defective
high pressure pump, worn injector, leaking pressure relieve valve. Low pressure system: 'Zero delivery' is not active
in metering unit (excessive leakage in metering unit). Check for defects according to failure list.
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3178 - Timeout of CAN Message BC2EDC1

Context:
Defective CAN controller of Body Computer, undervoltage of BC, missing BC, CAN cable connecting the BC is dis-
connected or broken. Short circuit in wiring. Check presence and correct connection of the BC to the network, Check
correct functioning of the BC CAN controller and its voltage supply. Check wiring.
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3179 - Timeout of CAN Message BC2EDC2

Context:
Defective CAN controller of Body Computer, undervoltage of BC, missing BC, CAN cable connecting the BC is dis-
connected or broken. Short circuit in wiring. Check presence and correct connection of the BC to the network, Check
correct functioning of the BC CAN controller and its voltage supply. Check wiring.
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3180 - Time-out Of CAN Message VCM2EDC

Context:
Defective CAN controller of Vehicle Control Module, undervoltage of VCM, missing VCM, CAN cable connecting the
VCM is disconnected or broken. Short circuit in wiring. Check presence and correct connection of the VCM to the
network, Check correct functioning of the VCM CAN controller and its voltage supply. Check wiring.
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3188 - Cylinder 1 - Open Load

Cause:
Broken wire or disconnection of wiring or inside injector.
Solution:
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Cause:
Solution:
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Cause:
Solution:
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Cause:
Solution:
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Cause:
Solution:
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Cause:
Solution:
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3210 - Bank 1 - General Short Circuit On Injector Cable

Cause:
Short circuit of high-side to battery or ground.
Solution:
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3211 - Bank 1 - Injector Cable Short Circuit Low Side To Ground

Cause:
Short circuit of low-side to ground in injector cable.
Solution:
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3212 - Bank 1 - No Signal

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3213 - Bank 1 - Unclassifiable Error

Cause:
Depending on the pattern, various reasons can cause the defect, internal ECU problem.
Solution:
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3218 - Bank 2 - General Short Circuit On Injector Cable

Cause:
Short circuit of high-side to battery or ground.
Solution:
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3219 - Bank 2 - Injector Cable Short Circuit Low Side To Ground

Cause:
Short circuit of low-side to ground in injector cable.
Solution:
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3220 - Bank 2 No Signal

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3221 - Bank 2 - Unclassifiable Error

Cause:
Depending on the pattern, various reasons can cause the defect, internal ECU problem.
Solution:
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3227 - Injection Processor Error - Stop Engine

Cause:
Clock error or interruption of the power supply voltage.
Solution:
1. Check the power supply or replace ECU if problem reoccurs.
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3228 - Injection Processor Error - Stop Engine

Solution:
1. Defective ECU, reset ECU.

2. If no recovery, replace ECU.
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3229 - Injection processor error - stop engine

Cause:
Internal failure of ECU or 'TESTMODE' takes too long.
Solution:
1. Check 'TESTMODE' parameters or replace ECU if problem reoccurs.
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Cause:
Defective SPI-bus participant, timing problem due to software bug.
Solution:
1. Replace ECU if problem reoccurs (Send in ECU for investigation).
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Cause:
Defective ECU.
Solution:
1. Replace ECU if problem reoccurs.
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Cause:
Defective ECU.
Solution:
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Cause:
Defective ECU.
Solution:
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Cause:
Defective ECU.
Solution:
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3235 (DTC F936) - Exceeded the number of injections for a given

engine speed
Control Module: ECU
Context:
The Engine Control Unit A-057 monitors the compatibility between the number of injections and the current capability
of the injection system for fulfilling the number of injections requested at various engine speeds. If the number of
requested injections is greater than the maximum number of injections, established by the ECU A-057, for the current
engine speed, this fault will occur.
Solution:
1. Check the ECU A-057 for the appropriate software and re-flash, if necessary.
B. If the fault has not been resolved, escalate an ASIST concern.
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3236 (DTC F836) - Number of injections is limited by system

Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 monitors the difference between the requested number of fuel injections and
the current capability of the fuel injection system fulfilling that requested number. If the difference between the number
of requested injections and actual injection is eight injections, this fault will occur.
Solution:
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3237 (DTC 1636) - Number of desired injections exceeds threshold

Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 monitors the requested number of fuel injections. If the ECU A-057 determines
that the number of requested injections is greater than the current capability of the fuel injection system, this fault will
occur.
Cause:
The ECU A-057 has determined that the number of requested fuel injections has exceeded the current capability of
the fuel injection system.
1. Faulty battery, low voltage.

2. Faulty ECU A-057 power supply.
Solution:
1. Check battery voltage.
Load test the battery. There should be approximately 12.0 V.
A. If the battery passes the load test, continue to Step 2.
B. If the battery fails the load test, the battery has failed. Replace the battery.
2. Check the ECU A-057 power supply wiring.
Disconnect connector X-937 from the ECU A-057.
To energize the main relay and provide power to the ECU A-057, place a jumper wire between the vehicle harness
side of connector X-937 pin 28 and chassis ground.
From To Value
X-937 pin 3 Chassis ground There should be approximately
12.0 V.
12.0 V.
12.0 V.
A. If there is approximately 12.0 V, leave the connector X-937 disconnected and continue to Step 3.
B. If there is not approximately 12.0 V, there is a fault in the ECU A-057 power supply wiring. Locate and repair
the failed conductor.
3. Check the ECU A-057 ground supply wiring.
Use a multimeter to perform the following continuity check.
From To Value
A. If there is no continuity, there is a fault in the ECU A-057 ground supply wiring. Locate and repair the failed
conductor.
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B. If there is continuity, continue to Step 4.

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3238 - Communication error of CJ940 processor

Cause:
Electric disturbances, internal defect of the ECU leading to a SPI bus communication error.
Solution:
1. Replace ECU if failure remains present.
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3242 - Recovery which is locked

Context:
Electronic disturbances, various hardware defects (ECU internal) or configuration problems. Analyze what error trig-
gered the recovery (Read out label HWEMon_numRecovery and compare the value with the according table). If error
occurs repeatedly, reprogram EDC. If error remains, replace EDC.
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3243 - Recovery which is suppressed

Context:
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3244 - Recovery which is visible

Context:
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3245 - Communication supervision Watchdog/controller-Flag

Context:
Defective monitoring module or CPU (e.g. impaired functioning of the CPU clock) of the EDC. Disturbed SPI-Bus.
If error exists only temporary (i.e. injection reoccurs) error can be ignored and error deleted in the fault memory. In
case of a permanent error the injection remains blocked and the ECU has to be replaced.
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3246 - Redundant shutoff paths during initial. / ECU HW

Cause:
Watch dog switch off path defect.
Solution:
1. If failure remains after ECU initialization: replace ECU.
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3247 - Redundant shutoff paths during initial

Cause:
Electronic disturbances, internal ECU problem.
Solution:
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3248 - Redundant shutoff paths during initial

Cause:
Solution:
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3249 - TPU monitoring - Time deviation between TPU and system

not plausible
Context:
The engine control unit (ECU) has detected that the TPU (time processing unit) and CPU (central processing unit)
have operated outside the established parameters more than 4 times since last ECU recovery (initialization). As
the time base of the CPU is checked according to a query / response communication with the monitoring module
(watchdog) it should be correct if no error has been detected and therefore can be used to check the time base of the
TPU. For this purpose the time basis of the TPU and CPU are compared every 10 ms. After 100 ms the maximum and
the minimum value together with the absolute value of the sum of the time differences are evaluated. If the maximum
time difference between the TPU and CPU time base exceeds the threshold of 81 ms or the minimum time difference
is below the limit of 81 ms or the absolute value of the sum of the time differences is above 81 ms an error counter
is incremented. If this counter exceeds the value of 4, this fault is set and initiates an ECU recovery (reset). If this
failure persists, the ECU will need to be replaced.
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3250 - ECU Software Varian Dataset failure - Dataset not valid

NOTE: See engine repair manual for electrical schematic information.
Cause:
Internal ECU error.
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3251 - Dataset - Requested Variant Could Not Be Set

Cause:
Internal ECU error.
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3252 - Controller Watchdog - SPI Communication Failure

Context:
The engine control unit (ECU) has detected an internal (SPI Bus) communication failure. The central processing
unit (CPU) and monitoring module (watchdog) contained with in the ECU, communicate with each other via the SPI
bus. Both devices mutually monitor each other for correct functioning. If, however, the SPI communication between
them fails this monitoring is impaired and an error counter is incremented. If the error counter exceeds 2 over two
20 ms (two tests) checks, this fault is activated. Communication status is checked autonomously by the SPI driver
component every 20 ms and reports a detected error to the ECU. This error initiates ECU recovery (reset). If the ECU
functions correctly after recovery, the SPI error is temporary and can be ignored and deleted from fault memory. If
the SPI error is permanent and the ECU does not leave boot-block, the ECU needs to be replaced.
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3253 - Error status ADC monitoring

Context:
Buffer overrun No additional information available at time of print.
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Context:
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Context:
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Context:
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3258 - High side power - short circuit to battery

Cause:
Solution:
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3259 - High side power - short circuit to ground

Cause:
Solution:
1. Check of wiring or replace relay.
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3260 - Low side power - open load

Cause:
Solution:
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3261 - Shortcircuit to Battery or Excessive Temperature at Low

Side Power Stage
Cause:
Solution:
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3262 - Shortcircuit to Ground at Low Side Power Stage

Cause:
Solution:
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3265 - Energising time exceeds limit of overrun monitoring

Cause:
Electronic disturbances, requested torque increase via tester, wrong application of injection relevant parameters, de-
fective ECU.
Solution:
1. Check injection relevant application, if failure persists replace ECU.
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3266 - Plausibility Error in Engine Speed Check

Cause:
Solution:
1. If failure persists after reinstallation replace ECU.
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3278 - Supply voltage CJ940 upper limit

Cause:
Excessive voltage supply of a CJ940 component: High battery voltage, defective wiring, internal defect of the EDC.
Solution:
1. Check the battery for correct voltage supply, check wiring. If defect remains replace EDC (internal defect).
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3279 - Supply voltage CJ940 lower limit

Cause:
Insufficient voltage supply of a CJ940 component: Low battery voltage, defective wiring, internal defect of the EDC.
Solution:
1. Check the battery for sufficient voltage supply, check wiring. If defect remains replace EDC (internal defect).
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3280 - Sensor Supply Voltage 1 - High

Cause:
Excessive battery voltage, defect in wiring harness, electrical failure in connected sensors or in the EDC.
Solution:
1. Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC.
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3281 - Sensor Supply Voltage 1 - Low

Cause:
Insufficient battery voltage, defect in wiring harness, electrical failure connected sensors or in the EDC.
Solution:
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Cause:
Solution:
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Cause:
Insufficient battery voltage, defect in wiring harness, electrical failure connected sensors or in the EDC.
Solution:
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Cause:
Solution:
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Cause:
Insufficient battery voltage, defect in wiring harness, electrical failure connected sensors or in the EDC
Solution:
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3290 - Turbo Compound Monitoring - Signal Not Plausible

Context:
Engine will run derated.
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3293 (DTC 2265) - Fuel rail pressure has exceeded maximum

positive deviation limits
Control Module: ECU
NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure
Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service.
See Common rail - Configure - Reset ECU data (10.218), if necessary.
NOTE: If the rail pressure sensor B-015 is replaced, it is necessary to perform the Replacement of the Rail Pressure
sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See
Common rail pressure sensor - Configure - Reset ECU data (Rail pressure sensor) (55.010), if necessary.
Context:
The Engine Control Unit (ECU) A-057 monitors fuel rail pressure. If the measured rail pressure is lower than the de-
sired pressure by 100 bar (1450 psi) depending on engine speed, this fault will occur. For more information regarding
fuel system troubleshooting, see Fuel injection system - Troubleshooting (10.218).
Cause:
The ECU A-057 has determined that the measured rail pressure is 100 bar (1450 psi) lower than desired fuel pressure
based on engine speed.
1. Faulty fuel metering unit Y-011, internal failure.

2. Faulty charge gear pump, low efficiency.
3. Faulty fuel filters, clogged.
4. Faulty low pressure fuel supply lines, clogged or damaged.
5. Faulty high pressure fuel supply lines, clogged or damaged.
6. Faulty Pressure Relief Valve (PRV), leakage.
7. Faulty high pressure fuel pump, low efficiency.
8. Faulty fuel injectors, worn, clogged or internal leakage.
9. Faulty rail pressure sensor B-015, drifted or leaking.
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3301 (DTC 1565) - Fuel rail pressure has exceeded maximum

negative deviation limits
Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 monitors fuel rail pressure. If the ECU A-057 determines that fuel pressure is
higher than the desired fuel pressure, depending on engine speed, this fault will occur. For more information regarding
Cause:
The ECU A-057 has determined that the fuel rail pressure is higher than desired based on engine speed.
1. Faulty fuel metering unit Y-011 wiring.

2. Faulty fuel metering unit Y-011, stuck open or internal failure.
3. Faulty fuel back-flow lines, blocked or damaged.
4. Faulty Pressure Relief Valve (PRV), stuck closed or mechanically unable to open.
5. Faulty high pressure pump, zero delivery throttle valve clogged.
6. Faulty rail pressure sensor B-015, drifted signal.
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3305 (DTC 2765) - Fuel rail pressure has exceeded minimum limit
Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 monitors fuel rail pressure using the rail pressure sensor B-015. If the ECU
A-057 determines that the measured rail pressure is less than a dependent engine speed value, this fault will occur.
Other active faults may have caused this fault to occur. For more information regarding fuel system troubleshooting,
see Fuel injection system - Troubleshooting (10.218).
Cause:
The ECU A-057 has determined that the measured rail pressure is less than a dependent engine speed value.

2. Faulty low pressure fuel lines, clogged or damaged.
3. Faulty high pressure fuel lines, clogged or damaged.
4. Faulty electric fuel pump (if equipped).
6. Faulty high pressure pump, low efficiency or excessive leak-off.
7. Faulty fuel injectors, excessive or leaking internally.
8. Faulty Pressure Relief Valve (PRV), leaking or stuck open.
9. Faulty rail pressure sensor B-015 or sensor leaking.
10. Faulty fuel metering unit Y-011
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3309 (DTC 1865) - Fuel rail pressure has exceeded maximum limit
Control Module: ECU
Context:
A-057 determines that the measured rail pressure is greater than desired by more than a dependent engine speed
value, this fault will occur. For more information regarding fuel system troubleshooting, see Fuel injection system -
Troubleshooting (10.218).
Cause:
The ECU A-057 has determined that the measured rail pressure is greater than desired by more than a dependent
engine speed value.

3. Faulty fuel back-flow lines, blocked or damaged.
4. Faulty Pressure Relief Valve (PRV), stuck closed or mechanically unable to open.
5. Faulty high pressure pump, zero delivery throttle valve clogged.
6. Faulty rail pressure sensor B-015, drifted signal.
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3315 - Minimum Number of Injections Not Reached - Stop Engine

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Context:
The engine control unit (ECU) has determined that the minimum number of injections was not reached. The injector
shutoff function (within the ECU) can switch off a single injector valve or an entire injection bank if a defect has been
detected in a component (monitoring is performed in other fault paths). The shutoff procedure is performed either for
an individual cylinder or for an entire bank. However, if too many cylinders are shut down by the shutoff function it is
no longer possible to run the engine securely and it has to be shut down entirely. In this case the fault path at hand
is set. It is possible for the engine to continue running on two cylinders. The test frequency is once per injection.
If this error occurs, see individual injector and injection-bank errors which have triggered the shutoff or error in the
component.
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3361 (DTC E16D) - There was an error during Write/Read EEPROM

operation
Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 has the capability of reading and writing values to flash or Electrically Erasable
Programmable Read Only Memory (EEPROM). The ECU A-057 monitors the reading and writing capability of this
function. If the ECU A-057 determines that calibrated parameters for baud rate cannot be read from EEPROM during
this monitoring, this fault will occur.
Solution:
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3362 (DTC E1FD) - ECU internal failure - Fuel calibration

Control Module: ECU
Context:
The Electronic Control Unit (ECU) A-095 monitors the conversion from fuel quantity to torque for consistency during
A-095 initialization. If a calibration error is detected during this test, this fault will occur.
Solution:
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3363 - Atmospheric Pressure Sensor - Signal Not Plausible

Cause:
ECU internal error.
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3368 (DTC F6EF) - Torque limitation caused by performance limiter

Control Module: ECU
Context:
This fault has set due to a performance limitation, engine power and speed reduction greater than 25%, because of
too high NOx emissions. This fault code is for information only and does not require any further action. If the power /
speed reduction occurred due to an actual defect, the failure triggering the torque limitation should also be in failure
memory. Follow the troubleshooting procedure for the other fault.
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3370 (DTC F2EF) - Strong torque limitation from engine protection

active
Control Module: ECU
Context:
The engine is protected against too high air intake gas temperature (VGT protection), too high coolant temperature,
too high oil temperature, and too high fuel temperature by reducing the torque. If any one of the temperatures exceeds
the dedicated limit established by parameters programmed within the Engine Control Unit (ECU) A-057 the torque
is reduced. If there is a power reduction greater than 25.00% or an engine speed limitation greater than 25.00%,
depending on engine speed, for more than 120.00 s, a failure is stored as confirmation that there was an active per-
formance limitation. This is not caused by the failure of a component or system, but by an extreme working condition.
This failure is a confirmation of a temporary power limitation. This failure does not ask for any action except, to check if
other failures concerning the engine protection/engine speed are present in the failure memory. No actions necessary
due to this failure alone. If power reduction occurred due to actual defect, the failure triggering the torque limitation
should also be in the failure memory. Follow troubleshooting of the actual defect.
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3371 (DTC F3EF) - Strong torque limitation from injection system

active
Control Module: ECU
Context:
This fault has set due to a performance limitation to protect the high pressure fuel pump from high temperatures. If
there was a power reduction greater than 25.00% or an engine speed limitation greater than 25.00% is required by
the high pressure pump, depending on engine speed, for more than 120.00 s a fault code was stored. This fault
code is for information only and does not require any further action. That there was an active performance limitation
due to the high pressure fuel pump protection against too high fuel temperature, which was not caused by a failure,
but an extreme working condition. If other fault codes are present that could influence the high pressure fuel pump
temperatures, those faults could pinpoint an actual failure. Follow the troubleshooting procedure for the other fault.
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3403 (DTC 8A22) - Starter relay low side ECU driver circuit over
temperature failure
Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 controls the starter control relay K-031 using a low side and high side driver. If
the ECU A-057 detects an over temperature/current condition in the high side driver circuit, this fault will occur.
Cause:
The ECU A-057 has detected an over temperature/current condition in the starter control relay K-031 high side driver
circuit.
1. Faulty starter control relay K-031 wiring, short circuit.

2. Faulty starter control relay K-031, internal failure.
Solution:
2. Check the starter control relay K-031 coil for an internal failure.
Remove the starter control relay K-031.
Use a multimeter to measure the relay coil resistance on the starter control relay K-031 pins:
From To Value
Pin 85 Pin 86 There should be approximately 70 –
130 Ω.
A. If there is approximately 70 – 130 Ω, leave the starter control relay K-031 disconnected and continue to Step 3.
B. If there is not approximately 70 – 130 Ω, the relay has failed. Replace the starter control relay K-031.
3. Check the starter control relay K-031 high side driver vehicle harness wiring for a short to ground.
With the key in the OFF position, use a multimeter to perform the following continuity check for short to ground on
the vehicle harness side:
From To Value
A. If there is continuity, there is a short to ground in the starter control relay K-031 high side driver circuit in the
vehicle harness. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor.
B. If there is no continuity, leave the starter control relay K-031 disconnected and continue to Step 4.
4. Check the starter control relay K-031 high side driver vehicle harness wiring for a short to a voltage source.
With the key in the OFF position, use a multimeter to perform the following voltage check for a short to a voltage
source on the vehicle harness side:
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From To Value
With the key in the ON position, use a multimeter to perform the following voltage check for a short to a voltage
From To Value
A. If there is voltage, there is a short to a voltage source in the starter control relay K-031 high side driver circuit
in the vehicle harness. Use the appropriate service manual, if necessary, to locate and repair the shorted
conductor.

5. Check the starter control relay K-031 high side driver vehicle harness wiring for a short to a voltage source.
With the key in the OFF position, use a multimeter to perform the following continuity check for a short to a voltage
From To Value
X-937 pin 53 All pins in connector X-937 There should be no continuity.
A. If there is continuity, there is a short circuit in the starter control relay K-031 high side driver circuit in the vehicle
harness. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor.
B. If there is no voltage, check the ECU A-057 for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
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3443 (DTC F3A2) - Torque limitation due to excessive coolant

temperature
Control Module: ECU
Context:
This failure path is only for information. There was an active performance limitation due to high coolant temperature
with a duration longer than 50.0 ms. This failure does not require any other action except to check if other failures
concerning the cooling system are present in the failure memory. If a failure is present, follow the troubleshooting
procedure for that fault.
Cause:
One or more of the following failure modes may be the reason for the occurrence of this fault.
1. Radiator plugged
2. Coolant leak
3. Water pump or coolant flow issue
4. Fan drive issue
5. Low coolant level
6. Air in coolant
7. Thermostat stuck closed
8. Head gasket leak
9. Extreme environmental conditions
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3444 (DTC F4A2) - Torque limitation due to excessive exhaust gas

temperature
Control Module: ECU
Context:
This failure path is only for information. There was an active performance limitation due to high exhaust gas tempera-
ture which was not caused by the failure of a component or system, but an extreme working condition with a duration
longer than 3.00 s. This failure confirms there was a temporary torque limitation present. This failure does not require
any other action except to check if another failure influencing exhaust system temperature is present in the failure
memory. If another failure is present, follow the troubleshooting procedure for that fault.
Cause:
1. Excessive hydrocarbons (oil and fuel)

2. Plugging of DOC (Diesel Oxidation Catalyst)
3. Boost leak
4. High altitude operation
5. Stuck exhaust flap
6. Air filter plugged
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3445 (DTC F5A2) - Torque limitation due to excessive fuel

temperature
Control Module: ECU
Context:
This failure path is only for information. There was an active performance limitation due to high fuel temperature with
a duration longer than 50.0 ms. This failure confirms there was a temporary torque limitation present. This failure
does not require any action except to check if another failure that influences fuel temperature is present in the failure
memory. No actions are necessary due to this failure alone. If another fault is present, follow the troubleshooting
procedure for that fault.
Cause:
1. Low fuel
2. Fuel cooler, if equipped
3. Internal high pressure fuel leak
4. Fuel filter heat, if equipped, stuck on
5. Fuel system air leak
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3446 (DTC F6A2) - Torque limitation due to excessive intake air

temperature
Control Module: ECU
Context:
This failure path is only for information, that there was an active performance limitation due to high air intake temper-
ature with a duration longer than 50.0 ms. This failure does not ask for any action except, to check if other failures
influencing air intake temperature are present in the failure memory. No actions necessary due to this failure alone. If
power reduction occurred due to actual defect, the failure triggering the torque limitation should also be in the failure
memory. Follow troubleshooting of the actual defect.
Cause:
1. Radiator plugged
2. Coolant leak
3. Fan drive issue
4. Air filter issue
5. Aspirator, if equipped, issue
6. Exhaust leak before turbo, if equipped
7. Air intake leak
8. Low coolant level
9. Air in coolant
10. EGR, if equipped, stuck
11. Thermostat stuck closed
12. Plugged charged air cooler
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3447 (DTC F7A2) - Torque limitation due to excessive oil

temperature
Control Module: ECU
Context:
This failure path is only for information, that there was an active performance limitation due to high oil temperature,
which was not caused by a failure, but an extreme working condition, with a duration longer than 50.0 ms. This failure
is thought to have a confirmation in case of a temporary power lack. This failure does not ask for any action except, to
check if other failures which could influence oil temperature are present in the failure memory. No actions necessary
due to this failure alone. If power reduction occurred due to actual defect, the failure triggering the torque limitation
should also be in the failure memory. Follow troubleshooting of the actual defect.
Cause:
1. Oil cooler issue

2. High coolant temperature
3. Low oil level
4. Oil dilution (with fuel, coolant or hydraulic oil)
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3448 (DTC F8A2) - Torque limitation due to turbocharger protection

after start
Control Module: ECU
Context:
This failure path is only for information, that there was an active performance limitation due to turbocharger protection
after start, which was not caused by a failure, but an extreme working condition, with a duration longer than 50.0 ms.
This failure is thought to have a confirmation in case of a temporary power lack. This failure does not ask for any action
except, to check if other failures which could influence turbocharger protection are present in the failure memory. No
actions necessary due to this failure alone. If power reduction occurred due to actual defect, the failure triggering
the torque limitation should also be in the failure memory. Follow troubleshooting of the actual defect. Turbocharger
protection after start is a functionality which should prevent stress to the turbo until lubrication is optimal after engine
start.
Cause:
1. Hot engine soak

2. Boost too high
3. Turbine over speed
5. Excessive fueling
6. Injector issue
7. Waste gate, if equipped, stuck
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3449 (DTC E812) - ECU internal failure - Calculated engine speed

Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 monitors engine speed in multiple software levels. If the ECU A-057 determines
that there is plausibility error in the engine speed monitoring, this fault will occur.
Solution:
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3457 (DTC 1374) - Intake manifold temperature sensor voltage is

higher than expected
Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 monitors the intake manifold temperature sensor B-013. If the ECU A-057
determines that the intake manifold temperature sensor B-013 signal circuit voltage is greater than 4.94 V, this fault will
occur. If this fault is active, the intake manifold temperature value will be frozen at the last valid value for a preliminary
failure.
Cause:
The ECU A-057 has determined that the intake manifold temperature sensor B-013 signal circuit voltage is greater
than 4.94 V.
1. Faulty intake manifold temperature sensor B-013 wiring, short to a voltage source.
2. Faulty intake manifold temperature sensor B-013 wiring, open circuit.
3. Faulty intake manifold temperature sensor B-013, internal failure.
Solution:
2. Check the intake manifold temperature sensor B-013 wiring for a short to a voltage source.
Disconnect the engine harness from the intake manifold temperature sensor B-013 at connector X-961.
With the key in the OFF position, use a multimeter to perform the following voltage check on the engine harness
side:
From To Value
With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness
side:
From To Value
X-961 pin 2 Chassis ground There should be less than 5.5 V.
A. If there is voltage, there is a short to battery or switched battery in the intake manifold temperature sensor
B-013 wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor.
B. If there is no voltage, leave connector X-961 disconnected and continue to Step 3.

3. Check the intake manifold temperature sensor B-013 wiring in the engine harness for an open circuit.
Disconnect the vehicle harness from the engine interface connector X-941A.
With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness
side:
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From To Value
X-961 pin 2 X-941A pin 20 There should be continuity.
X-961 pin 1 X-941A pin 19 There should be continuity.
NOTE: Wiggle the harness during the check to promote an intermittent electrical connection.
With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness
side:
From To Value
X-941A pin 20 X-939 pin 55 There should be continuity.
A. If there is no continuity, there is an open circuit in the intake manifold temperature sensor B-013 wiring in the
engine harness. Locate and repair the broken conductor.
B. If there is continuity, leave connectors X-961, X-941A, and X-939 disconnected and continue to Step 4.
4. Check the intake manifold temperature sensor B-013 wiring in the engine harness for a short to a voltage source.
side:
From To Value
X-941B pin 20 All pins in connector X-941B There should be no continuity.
X-941B pin 19 All pins in connector X-941B There should be no continuity.
A. If there is continuity, there is a short circuit in the intake manifold temperature sensor B-013 wiring in the engine
harness.Locate and repair the shorted conductor.
B. If there is no continuity, leave connectors X-961, X-941B, and X-939 disconnected and continue to Step 5.
5. Check the intake manifold temperature sensor B-013 wiring in the vehicle harness for a short circuit.
side:
From To Value
X-941A pin 20 All pins in connector X-941A There should be no continuity.
A. If there is continuity, there is a short circuit in the intake manifold temperature sensor B-013 wiring in the vehicle
harness. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor.
B. If there is no continuity, leave connector X-961 disconnected and continue to Step 6.

6. Replace the intake manifold temperature sensor B-013.
A. If the fault is no longer active, return the machine to service.
B. If the fault is still active, check the ECU A-057 for the appropriate software and re-flash, if necessary.
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has been resolved.
operation.
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3459 (DTC 1BD3) - Oil temperature too high

Control Module: ECU
Context:
The Engine Control Unit (ECU) A-095 monitors oil temperature by the oil temperature sensor B-014. The value is
processed by the analog to digital converter, internal to the A-095, into a physical oil temperature value. If the A-095
determines that the oil temperature value is too high, this fault will occur.
Cause:
The A-095 has detected an oil temperature value greater than 124.96 °C.
1. Extreme environmental conditions.

2. Low coolant level.
3. Insufficient air flow to radiator, clogged radiator, other blockage in the cooling system.
4. Water pump failure.
5. Thermostat failure.
6. Oil dilution (with fuel, coolant or hydraulic oil)
7. Low oil level.
8. Oil cooler issue.
9. Faulty oil pressure with oil temperature sensor B-014, implausible value.
10. Faulty coolant temperature sensor B-016, implausible value.
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3460 (DTC 2CD3) - Oil temperature too low

Control Module: ECU
Context:
The Electronic Control Unit (ECU) A-095 monitors oil temperature by the oil temperature sensor B-014. The value is
processed by the analog to digital converter, internal to the A-095, into a physical oil temperature value. If the A-095
determines that the oil temperature value is too low, this fault will occur.
Cause:
The A-095 has detected an oil temperature value less than -35.04 °C.
1. Extreme ambient operating temperatures

2. Faulty B-014, implausible value
Solution:
2. Check the B-014 temperature signal circuit for a short to ground condition.
Disconnect connector X-917 from the A-095.
The ignition switch must be in the OFF position.
From To Value
X-917 pin 13 (OR) Chassis ground There should be no continuity.
X-917 pin 13 (OR) X-917 pin 6 (VT) There should be no continuity.
X-917 pin 13 (OR) All other pins There should be no continuity.
A. If there is continuity, there is a short to ground in the B-014 temperature signal circuit. Locate and repair the
shorted conductor.
B. If there is no continuity, continue to Step 3.

3. Replace the B-014.
Use the Electronic Service Tool (EST) to verify the status of 3460 (DTC 2CD3) – Oil temperature too low.
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has been resolved.
operation.
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3461 (DTC E69D) - ECU internal failure - Timeout in the shut off
path test error
Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 performs shut off paths which deactivate all power stages relevant to fuel in-
jection if certain internal ECU A-057 errors are detected. In order to test this function, every path is shortly activated
during ECU A-057 initialization. Since the shut off is active, no fuel injection should occur during this test. If a time-out
error in the power stage feedback is detected during this test, this fault will occur.
Solution:
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3462 (DTC E79D) - ECU internal failure - Overvoltage monitoring

error
Control Module: ECU
Context:
during ECU A-057 initialization. Since the shut off is active, no fuel injection should occur during this test. If a voltage
higher than expected condition is detected during this test, this fault will occur.
Solution:
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3491 (DTC F176) - Missing adjustment value programming for

injector in cylinder 1
NOTE: Injector Quantity Adaptation (IQA) Code is unique to each injector. The IQA Code must be uploaded and
programmed anytime an injector is changed, replaced or re-positioned.
Context:
The injectors are corrected individually (IQA Code) to guarantee exact fuel injection quantity of each injector from
lowest to highest fuel quantity. The data is stored in the Engine Control Unit (ECU) A-9000 in Electrically Erasable
Programmable Read Only Memory (EEPROM). The stored values in the EEPROM are protected with checksum
parameters. At each Key "ON" the correction data is read from the EEPROM and checked. If the data is missing or
not correct the injector will not be corrected and this failure will occur.
Cause:
The ECU A-9000 is reporting that the IQA code for this injector is missing or not correct.
1. Missing IQA Code, re-program

Solution:
1. Re-load IMA Code. Use the Electronic Service Tool (EST) to recover the IQA code. Check to see that the fault is
resolved.
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Context:
Cause:

Solution:
1. Re-load IMA Code. Use the Electronic Service Tool (EST) to re-cover the IQA code. Check to see that the fault
is resolved.
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Context:
Cause:

Solution:
1. Re-load IQA Code. Use the Electronic Service Tool (EST), to re-cover the IQA code. Check to see that the fault
is resolved.
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Context:
Cause:

Solution:
1. Re-load IQA Code. Use the Electronic Service Tool (EST) to re-cover the IQA code. Check to see that the fault
is resolved.
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Context:
Cause:

Solution:
is resolved.
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Context:
Cause:

Solution:
is resolved.
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3501 (DTC ED1D) - ECU internal failure - Software resets in DSM 0

Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 monitors for a possible error to the ECU A-057 internal software. If the ECU
A-057 detects a software failure, a software reset will be performed and this fault will occur. During a software reset,
all instrument panel lights could flash (power on test) and the instruments could shortly read zero.
Solution:
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3502 (DTC EE1D) - ECU internal failure - Software resets in DSM 1

Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 will perform a software reset if a software failure is detected. If this fault is
active, a software failure has been reported and a software reset has occurred.
Solution:
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3507 (DTC 4761) - Engine cranked for too long or key switch failure
Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 is notified of a request for engine cranking at connector X-937 pin 8. If the
request for cranking signal exists for longer than 80.0 s the ECU A-057 assumes a mechanical failure in the ignition
key module or start relay or a short to a voltage source condition exists in the input circuit and this fault occurs.
Cause:
The engine cranking signal has exceeded the signal ON time established be the ECU A-057.
1. Faulty vehicle cranking circuit component, key switch or crank / start relay.
2. Faulty cranking circuit wiring, shorted to a voltage source.
Solution:
1. Verify that the fault present and active.
2. Check the cranking circuit wiring for a short to voltage source condition.
Carefully disconnect the vehicle harness from the ECU A-057 at connector X-937.
With the key switch in the ON position, use a multimeter to check for voltage on the vehicle harness side:
From To Value
X-937 pin 8 chassis ground There should be no voltage.
A. If there is voltage, Use the appropriate vehicle service manual, if necessary, to locate the voltage source.
B. If there is no voltage, leave connector X-937 disconnected and continue with Step 3.
3. Check the cranking circuit wiring for an ECU A-057 sourced short to voltage condition.
With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness side:
From To Result
X-937 pin 8 To all other pins in connector X-937 There should be no continuity.
A. If there is continuity, there is a short to a voltage source condition in the vehicle harness. Use the appropriate
vehicle service manual, if necessary, to locate and repair the shorted conductors.
B. If there is no continuity, check the ECU A-057 for the appropriate software and re-flash, if necessary.
or broken wires.
Verify 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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has been resolved.
operation.
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3508 (DTC FAEF) - Torque limitation active

Control Module: ECU
Context:
This failure path is only for information, that there was an active performance limitation. One or more torque reductions
are present. No actions necessary due to this failure alone. If power reduction occurred due to actual defect, the
failure triggering the torque limitation should also be in the failure memory. Follow troubleshooting of the actual defect.
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3581 (DTC FD8F) - Torque limitation is active

NOTE: Since this fault is part of the inducement strategy, it may be necessary to perform the Engine Restart Counter
Reset / Unlock Inducement configuration with the Electronic Service Tool (EST) before you return the machine to
service, unless this was accomplished as part of the resolution of the fault causing this fault.
Context:
This fault is only for informational purposes and requires no action other than the resolution of the active fault causing
this fault to occur. Any one of many Selective Catalytic Reduction (SCR) not displayed faults that remains active for
an Engine Control Module (ECU) A-9000 predetermined length of time will trigger this fault.
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3594 (DTC F7EF) - Torque limitation caused by SCR catalyst

protection
Control Module: ECU
Context:
This failure path is only for information. There was an active performance limitation due to high Selective Catalytic
Reduction (SCR) temperature which was not caused by the failure of a component or system, but an extreme working
condition with temperature in excess of 599.96 °C (1111.93 °F) for greater than 30.00 s. This failure confirms there
was a temporary torque limitation present. This failure does not require any other action except to check if another
failure influencing exhaust system temperature is present in the failure memory. If another failure is present, follow
the troubleshooting procedure for that fault.
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3616 (DTC F1EF) - Torque limitation caused by turbo charger

protection
Control Module: ECU
Context:
This failure path is only for information. This failure does not require any further action except to check if another failure
related to turbocharger is stored in fault memory. If there is a failure present, follow the troubleshooting procedure for
that fault. This failure confirms there was a temporary torque limitation present.
Cause:
1. Air filter issue

2. Excessive fueling
3. Injector issue
4. Boost too high
5. Waste gate stuck, if equipped
6. Turbine over speed
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3638 (DTC F4EF) - Torque limitation caused by engine brake

Control Module: ECU
Context:
This failure path is only for information. There was an active performance limitation after engine brake release, which
was not caused by a failure, but an extreme working condition, with a duration longer than 60.00 s. This failure is
a confirmation of a temporary reduction in power. If a power reduction of greater than 15.00% or an engine speed
limitation of greater than 5.00% after engine brake release, this fault is set. This failure does not require any action
except to check if other failures concerning the engine brake are present in the failure memory. If another fault is
present, follow the troubleshooting procedure for that fault. No actions are necessary due to this failure alone.
Cause:
The following failure mode may be the reason for the occurrence of this fault.
1. Extended usage of engine brake
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3652 (DTC 911B) - CAN A Bus off passive failure

Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 is capable of connecting to and communicating on two separate Controller Area
Networks (CAN). Proper configuration and monitoring of the two twisted pair configured networks is also a function
of the ECU A-057. CAN Node A Bus is the main vehicle interface bus. The ECU A-057 provides a CAN termination
resistor for the CAN Node A Bus, internal to the ECU A-057. If the ECU A-057 senses that CAN Node A Bus is not
functioning properly, this fault will occur.
Cause:
ECU A-057 has sensed a “Bus Off” state to be present at the CAN Node A.
1. Faulty supply voltage or ground, missing.

2. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit.
3. Faulty ECU A-057, termination resistor or software.
Solution:
A. If the fault is present and active, continue with Step2.
2. Check for other vehicle CAN faults.
Use the EST to determine if vehicle CAN faults exist.
A. If other vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that 3652 (DTC 911B) –
CAN A Bus off passive failure is also resolved.
B. If other vehicle CAN faults do not exist, continue with Step 3.

To energize the Main relay K-013, place a jumper wire between the vehicle harness side of connector X-937 pin
28 and chassis ground.
From To Value
B. If the voltage is not present for one or more of the checks, see the appropriate vehicle service manual and
electrical schematics, if necessary, to locate and restore supply power to the ECU A-057.
4. Check the ECU A-057 ground circuits.
Use a multimeter to check for continuity on the vehicle harness side:
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From To Value
B. If there is no continuity for one or more of the checks, see the appropriate vehicle service manual and electrical
schematics, if necessary, to locate and restore the ground circuits to the ECU A-057.
With the key switch in the “OFF” position, use a multimeter to measure the resistance of the CAN connection on
From To Value
From To Value
B. If the measured resistances are not correct or one or both of the conductors is grounded, refer to the appropriate
vehicle service manual and electrical schematics, if necessary, to locate and restore the termination resistance
to the CAN circuit.
has been resolved.
operation.
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3680 (DTC E536) - Engine speed limitation via fuel injection cut
off is active
Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 will perform an injection cut-off to limit the engine speed to a controllable range,
if needed. Implausible signals from certain parameters such as accelerator pedal signal, fuel injection parameters
or engine speed can cause an injection cut-off. If torque or injection quantity are not plausible and engine speed is
greater than 1200 RPM, this fault will occur. Since other active faults may have caused this fault to occur, resolve the
related faults first.
Solution:
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3699 (DTC E56D) - ECU EEPROM memory failure - EEPData1 block

Control Module: ECU
Context:
The Electronic Control Unit (ECU) A-095 monitors the EEPROM block internal to the A-095. If the A-095 determines
that the correction values used for fuel rail pressure regulation are corrupted or are not accessible, this fault will occur.
Solution:
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3703 (DTC 2B36) - The minimum rail pressure value necessary to

allow fuel injection has not been reached
Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 monitors fuel rail pressure. If the ECU A-057 determines that fuel rail pressure
is less than 130.0 bar (1885.0 psi) or below a limit value from an ECU A-057 calculated curve, this fault will occur.
Other active faults may have caused this fault to occur. For more information regarding fuel system troubleshooting,
see Fuel injection system - Troubleshooting (10.218).
Cause:
The ECU A-057 has determined that fuel rail pressure is too low to continue engine operation.
1. Faulty fuel metering unit Y-011, stuck closed or internal failure.

2. Faulty high pressure pump, low efficiency.
5. Faulty fuel lines, leakage or blockage.
7. Faulty fuel injectors, internal leakage or stuck open.
9. Faulty rail pressure sensor B-015 drifted signal or leaking.
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3735 (DTC 8355) - Fuel metering unit has an over-temperature error

Control Module: ECU
Context:
The Engine Control Unit (ECU) monitors the fuel metering unit Y-011 signal circuit for an over temperature/current
condition. If the ECU A-057 detects an over temperature/current condition in the fuel metering unit Y-011 signal circuit,
this fault will occur.
Cause:
The ECU A-057 has detected an over temperature/current condition in the fuel metering unit Y-011 signal circuit.
1. Faulty fuel metering unit Y-011 wiring, short to a voltage source.

Solution:
2. Test the fuel metering unit Y-011 internal resistance.
Disconnect the engine harness from the fuel metering unit Y-011 at connector X-970.
Use a multimeter to measure the resistance on the fuel metering unit Y-011 pins:
From To Value
X-970 pin 1 X-970 pin 2 There should be between 2.6 – 3.2 Ω
at approximately 20.0 °C (68.0 °F).
A. If there is between 2.6 – 3.2 Ω, leave connector X-970 disconnected and continue to Step 3.
B. If there is not between 2.6 – 3.2 Ω, the fuel metering unit Y-011 has failed. Replace the fuel metering unit
Y-011.
3. Check the fuel metering unit Y-011 low side driver wiring for a short to battery condition.
side:
From To Value
side:
From To Value
A. If there is voltage, there is a short circuit to battery or switched battery in the fuel metering unit Y-011 low
side driver circuit wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted
conductor.
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B. If there is no voltage, leave connector X-970 disconnected and continue to Step 4.

4. Check the fuel metering unit Y-011 low side driver engine harness wiring for a short circuit condition.
Disconnect the vehicle harness from the engine interface at connector X-941A.
side:
From To Value
A. If there is no continuity, leave connector X-941A disconnected and continue to Step 5.
B. If there is continuity, there is a short circuit condition in the fuel metering unit Y-011 low side driver engine
harness wiring. Locate and repair the shorted conductor.
5. Check the fuel metering unit Y-011 low side driver vehicle harness wiring for a short circuit condition.
With the key in the OFF position, use a multimeter to perform the following continuity check from the vehicle
harness side:
From To Value
A. If there is continuity, there is a short circuit condition in the fuel metering unit Y-011 low side driver vehicle
harness wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor.
has been resolved.
operation.
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3738 (DTC E71D) - ECU internal failure - ROM error

Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 performs a Read-Only Memory (ROM) check during after run. If ROM memory
blocks are detected during this check, power stages will be shut off and this fault will occur.
Solution:
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3739 (DTC E13D) - ECU internal failure - Loss of synchronization to

MM from CPU
Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 performs shut off paths which deactivate all power stages relevant to injection
if certain internal ECU A-057 errors are detected. In order to test the correct functioning of the shut off procedure,
every path is shortly activated during ECU A-057 initialization to activate the fuel injection power stage. Since the
ECU A-057 has activated the shut off, no fuel injection should occur during this test. If the wrong response from the
processor to the power stage supply is detected during the shut off path test, this fault occur.
Solution:
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3740 (DTC E23D) - ECU internal failure - ECU shutdown test failure
Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 tests the correct functioning of the fuel injection path shut off procedure. During
this test, each injection path is shortly activated during ECU A-057 initialization. If at least one error is detected during
this test occurs, this fault will occur.
Solution:
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3741 (DTC E33D) - ECU internal failure - Wrong set response time
Control Module: ECU
Context:
this test, each injection path is shortly activated during ECU A-057 initialization. If a time-out error occurs during this
test, this fault will occur.
Solution:
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3742 (DTC E43D) - ECU internal failure - SPI errors during MoCSOP
execution
Control Module: ECU
Context:
this test, each injection path is shortly activated during ECU A-057 initialization. If a Serial Peripheral Interface (SPI)
communication error is detected during this test, this fault will occur.
Solution:
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3743 (DTC E53D) - ECU internal failure - Undervoltage monitoring

error
Control Module: ECU
Context:
during ECU A-057 initialization. Since the shut off is active, no fuel injection should occur during this test. If a voltage
lower than expected condition is detected during this test, this fault will occur.
Solution:
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3745 (DTC E63D) - ECU internal failure - WDA is not working

correctly
Control Module: ECU
Context:
during ECU A-057 initialization. Since the shut off is active, no fuel injection should occur during this test. If an im-
plausible response in the power stage feedback is detected during this test, this fault will occur.
Solution:
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3746 (DTC E73D) - ECU internal failure - Alarm task period error
Control Module: ECU
Context:
during ECU A-057 initialization. Since the shut off is active, no fuel injection should occur during this test. If a time-out
error during the shut off path test is detected and the alarm task cannot be set or reset, this fault will occur.
Solution:
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3747 (DTC E83D) - ECU internal failure - Positive test failed

Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 performs shut off paths which deactivate all power stages relevant to injection
if certain internal ECU A-057 errors are detected. In order to test the correct functioning of the shut off procedure,
every path is shortly activated during ECU A-057 initialization to activate the fuel injection power stage. Since the
ECU A-057 has activated the shut off, no fuel injection should occur during this test. If an error is detected during this
test, this fault will occur.
Solution:
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3749 (DTC E5B1) - ECU internal failure - Accelerator pedal position

sensor
Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 performs a diagnostic evaluation of the accelerator pedal position. If there is
an error detected using this process, this fault will occur.
Solution:
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3750 (DTC EC36) - ECU internal failure - Fuel injection energizing

time is not plausible
Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 monitors injector energizing time. If the ECU A-057 determines that the ener-
gizing time for either the pilot injection, main injection or post injection is implausible, this fault will occur.
Solution:
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3751 (DTC ED36) - ECU internal failure - Fuel injection energizing

phase is not plausible
Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 monitors for injector energizing start time. If the ECU A-057 determines that
the energizing start time for either the pilot injection, main injection or post injection is implausible, this fault will occur.
Solution:
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3752 (DTC EE36) - Fuel injection correction has exceeded a

minimum limit
Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 checks the plausibility of the Zero Fuel Quantity Calibration (ZFC) energizing
time. The ZFC is used to correct pilot injection quantity. If the ECU A-057 determines the energizing time of the ZFC
is implausible, this fault will occur.
Cause:
The ZFC is used to compensate for aging injectors. If the compensation limit is exceeded, this fault will occur.
1. Faulty fuel injectors, worn.

Solution:
1. Use the appropriate service manual to perform a leakage test in the high pressure fuel system. Also, test the fuel
injectors for internal and external leakage.
A. If any faults are found, repair as necessary.
B. If no faults are found, check the ECU A-057 for the appropriate software and re-flash, if necessary.
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3753 (DTC E5DD) - ECU internal failure - Injection quantity

correction
Control Module: ECU
Context:
Engine performance is assisted by the addition of pilot injections, main injections and three post injections. The Engine
Control Unit (ECU) A-057 monitors the efficiency of these injections and provides injection quantity corrections, if
necessary. If the ECU A-057 determines that excessive corrections to injection quantity are being made, there is a
calibration error and this fault will occur.
Solution:
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3754 (DTC E6DD) - ECU internal failure - Rail pressure plausibility

Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 monitors fuel rail pressure for proper engine performance as well as safety
concerns. Fuel rail pressure is monitored by the ECU A-057 to check if the ECU A-057 is functioning properly. If the
ECU A-057 detects an implausible rail pressure during monitoring, the ECU A-057 is not functioning correctly and this
fault will occur.
Solution:
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3755 (DTC E7DD) - ECU internal failure - Torque request comparison

Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 determines engine torque based on the requests of many vehicle functions.
The total requested engine torque is compared to the maximal engine torque allowed. If the total requested torque is
greater than the maximal allowed torque, the ECU A-057 has a calibration error and this fault will occur.
Solution:
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3756 (DTC E1DD) - ECU internal failure - Post injection quantity

Control Module: ECU
Context:
Control Unit (ECU) A-057 monitors the start angle and efficiency of post Injection 2. If the ECU A-057 determines that
the post Injection 2 is not within a plausible value, a calibration error has occurred and this fault will occur.
Solution:
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3757 (DTC E2DD) - ECU internal failure - Post injection shut-off

failure
Control Module: ECU
Context:
Control Unit (ECU) A-057 monitors the post Injection 2 shut off quantity in normal mode. If the ECU A-057 detects
that the post Injection 2 shut off quantity has exceeded the 655.34 mg limit in normal mode, this fault will occur.
Solution:
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3758 (DTC E3DD) - Post injection efficiency failure

Control Module: ECU
Context:
Engine performance is assisted by the addition of pilot injections, main injections and post injections. The Electronic
Control Unit (ECU) A-095 monitors the post injection 3 efficiency. If injection is not commanded at an engine speed
greater than 1200 RPM and an engine speed greater than 1320 RPM is then detected at least two times, this fault
will occur.
Cause:
The A-095 has detected an unwanted increase in engine speed. This failure may have been caused by unwanted
leakage of fuel or engine oil into the engine or by unwanted post injections.
1. Faulty fuel injectors, leakage

2. Engine oil leakage into cylinders, faulty piston rings
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3759 (DTC E8DD) - ECU internal failure - Torque request due to fuel
pressure exceeds maximum torque limit
Control Module: ECU
Context:
The total requested engine torque is compared to the maximal engine torque allowed. Fuel pressure is dependent on
requested torque. Therefore, torque is calculated separately, called “Lead torque.” If this fault has occurred, the ECU
A-057 has detected that the requested Lead torque value has exceeded the maximum torque allowed.
Solution:
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3760 (DTC E9DD) - ECU internal failure - Torque request due to air
control exceeds maximum torque limit
Control Module: ECU
Context:
The total requested engine torque is compared to the maximal engine torque allowed. Air control is dependent on
requested torque. Therefore, air control is calculated separately, called “Lead torque.” If this fault has occurred, the
ECU A-057 has detected that the requested Lead torque value has exceeded the maximum torque allowed.
Solution:
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3761 (DTC EADD) - ECU internal failure - Torque request exceeds

maximum torque limit
Control Module: ECU
Context:
The total requested engine torque is compared to the maximal engine torque allowed. If the total requested torque is
greater than the maximal allowed torque, the ECU A-057 has a calibration error and this fault will occur.
Solution:
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3762 (DTC EBDD) - ECU 5 volt supply voltage is higher than

expected
Control Module: ECU
Context:
The ECU A-095 monitors for a voltage error of the internal 5 V supply. If the voltage supply exceeds the internal
maximal limit, this fault will occur.
1. Faulty A-095, supply wiring

Solution:
2. Check the A-095 supply wiring.
The ignition switch must be in the ON position.
From To Value
X-911 pin 1, wire 6408B (GN) chassis ground There should be 12.0 V
X-911 pin 25, wire 6408C (GN) chassis ground There should be 12.0 V
X-911 pin 26, wire 6408D (GN) chassis ground There should be 12.0 V
X-911 pin 49, wire 6408E (GN) chassis ground There should be 12.0 V
X-911 pin 73, wire 6408F (GN) chassis ground There should be 12.0 V
A. If there is not approximately 12 V, check the charging system for proper operation and repair as necessary.
B. If there is approximately 12 V, continue to Step 3.


has been resolved.
operation.
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3763 (DTC ECDD) - ECU 5 volt supply voltage is lower than expected
Control Module: ECU
Context:
The ECU A-095 monitors for a voltage error of the internal 5 V supply. If the voltage supply is below the internal
maximal limit, this fault will occur.
Solution:
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3764 (DTC F561) - ECU after run power interruption

Control Module: ECU
Context:
The Engine Control Unit A-057 controls the main relay K-013. The main relay K-013 is powered on by the ECU A-057
to achieve after-run. The main relay K-013 is powered off once after-run is completed. If the ECU A-057 determines
that the main relay K-013 has shut off before commanded, this fault will occur.
Cause:
The ECU A-057 has determined that the main relay K-013 has shut off before commanded to shut off.
1. Faulty main relay K-013, wiring.

2. Faulty main relay K-013, internal failure.
Solution:
2. Check the main relay K-013 coil for an internal failure.
Remove the main relay K-013.
Use a multimeter to measure the resistance on the main relay K-013 pins:
From To Value
Pin 85 Pin 86 There should be approximately 70 –
130 Ω.
A. If there is approximately 70 – 130 Ω, leave the main relay K-013 disconnected and continue to Step 3.
B. If there is not approximately 70 – 130 Ω, the main relay K-013 has failed. Replace the main relay K-013.
3. Check the main relay K-013 vehicle harness wiring for a short to a voltage source.
With the key in the OFF position, use a multimeter to perform the following voltage check for a short to a voltage
From To Value
X-533 pin R2_85 Chassis ground There should be no voltage.
With the key in the ON position, use a multimeter to perform the following voltage check for a short to a voltage
From To Value
X-533 pin R2_85 Chassis ground There should be no voltage.
A. If there is voltage, there is a short to a voltage source in the main relay K-013 wiring in the vehicle harness.
Use the appropriate service manual, if necessary, to locate and repair the shorted conductor.
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B. If there is no voltage, leave the main relay K-013 disconnected and continue to Step 4.
4. Check the main relay K-013 vehicle harness wiring for a short to ground.
With the key in the OFF position, use a multimeter to perform the following continuity check for a short to ground
on the vehicle harness side:
From To Value
X-533 pin R2_85 Chassis ground There should be no continuity.
A. If there is continuity, there is a short to ground in the main relay K-013 wiring in the vehicle harness. Use the
appropriate service manual, if necessary, to locate and repair the broken or damaged conductor.
B. If there is no continuity, leave the main relay K-013 disconnected and continue to Step 5.
5. Check the main relay K-013 vehicle harness wiring for an open circuit.
With the key in the OFF position, use a multimeter to perform the following continuity check for an open circuit on
From To Value
X-533 pin R2_85 X-937 pin 28 There should be continuity.
A. If there is no continuity, there is an open circuit in the main relay K-013 wiring in the vehicle harness. Use the
appropriate service manual, if necessary, to locate and repair the broken or damaged conductor.
B. If there is continuity, leave the main relay K-013 and connector X-937 disconnected, then continue to Step 6.
6. Check the main relay K-013 wiring for a short circuit condition.
With the key in the OFF position, use a multimeter to perform the following continuity checks for a short circuit on
From To Value
X-533 pin R2_85 X-533 pin R2_86 There should be no continuity.
A. If there is continuity, there is a short circuit in the main relay K-013 vehicle harness wiring. Use the appropriate
service manual, if necessary, to locate and repair the shorted conductor.
B. If there is no continuity, leave the main relay K-013 and connector X-937 disconnected, then continue to Step
7.
7. Check the main relay K-013 load-side wiring.
With the key in the ON position, use a multimeter to perform the following voltage checks on the vehicle harness
side:
From To Value
X-533 pin R2_86 Chassis ground There should be approximately
12.0 V.
X-533 pin R2_30 Chassis ground There should be approximately
12.0 V.
A. If there is not approximately 12.0 V, there is a failure in the main relay K-013 load-side wiring. Use the appro-
priate service manual, if necessary, to locate and repair the shorted conductor.
B. If there is approximately 12.0 V, leave the main relay K-013 and connector X-937 disconnected, then continue
to Step 8.
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8. Check the main relay K-013 load-side wiring.
With the key in the OFF position, use a multimeter to perform the following continuity checks on the vehicle harness
side:
From To Value
A. If there is no continuity, there is an open circuit in the main relay K-013 load-side wiring or fuse. Use the
appropriate service manual, if necessary, to locate and repair the shorted conductor or open fuse.
B. If there is continuity, check the ECU A-057 for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
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3767 (DTC E81D) - ECU internal failure - 'WDA active' reported due
to errors in query/response communication
Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 monitors the communication, internal to the ECU A-057, between the power
stages and the power stage voltage supplier. If an unexpected communication (a wire is active when it should not be)
is detected during this monitoring, this fault will occur.
Solution:
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3768 (DTC E91D) - ECU internal failure - 'ABE active' reported due
to undervoltage detection
Control Module: ECU
Context:
stages and the power stage voltage supplier. This fault occurs if the ECU A-057 detects a low voltage condition while
the battery voltage is greater than 8.00 V and the shut off path test is not active.
Solution:
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3769 (DTC EA1D) - ECU internal failure - 'ABE active' reported due
to overvoltage detection
Control Module: ECU
Context:
stages and the power stage voltage supplier. If the ECU A-057 detects a high voltage condition while the shut off path
test is not active, this fault will occur.
Solution:
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3770 (DTC EB1D) - ECU internal failure - 'WDA/ABE active' reported

Control Module: ECU
Context:
stages and the power stage voltage supplier. Monitoring is performed continuously as long as the battery voltage is
greater than 8.00 V and the shut off path test is not active. If the WDA/ABE communication wire becomes active, this
fault will occur.
Solution:
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3799 (DTC F345) - Fuel pressure relief valve is forced to open,

perform pressure shock
Control Module: ECU
Context:
This fault is intended for information purposes only. Other active faults may have caused this fault to occur. The
Engine Control Unit (ECU) A-057, if necessary, will set the engine into limp home mode. This process is achieved in
two steps by the ECU A-057, a pressure increase and a pressure shock. The ECU A-057 will execute step two by a
fuel pressure shock. This is achieved by setting injection quantity to zero. If this fault is active, the ECU A-057 has
performed step two for achieving limp home mode, a fuel pressure shock.
Cause:
The ECU A-057 has performed a fuel pressure shock to achieve limp home mode.
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3805 (DTC 1D85) - Maximum rail pressure exceeded

Control Module: ECU
Context:
A-057 determines that rail pressure has exceeded 1790 bar (25955 psi), this fault will occur. A Pressure Relief Valve
(PRV), integral to the fuel rail, is designed to open in the event of an over-pressure in the fuel rail at approximately
1790 bar (25955 psi). If the ECU A-057 determines that rail pressure has exceeded this threshold, a PRV failure
is assumed. Other active faults may have caused this fault to occur. For more information regarding fuel system
troubleshooting, see Fuel injection system - Troubleshooting (10.218).
Cause:
The ECU A-057 has determined that rail pressure has exceeded 1900 bar (27550 psi).

3. Faulty rail pressure sensor B-015, drifted.
4. Faulty fuel back-flow, clogged.
5. Faulty PRV, unable to open to clogged return.
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3808 (DTC 3C65) - High pressure pump fuel delivery quantity at

low idle is too high
Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 monitors fuel rail pressure. If the ECU A-057 determines that the requested
fuel pressure is greater than the actual fuel pressure at idle, leakage is assumed and this fault will occur. Other active
faults may have caused this fault to occur. Use the Electronic Service Tool (EST) to check for other active faults.
Diagnose any active faults related to the fuel system first and then return to this fault. For more information regarding
Cause:
The ECU A-057 has determined that the requested fuel pressure is greater than the actual fuel pressure at idle.
1. Faulty low pressure fuel system, clogged filter or leakage/blockage.

2. Faulty charge gear pump, low efficiency or line clogged/damaged.
4. Faulty fuel metering unit, unable to fully open.
5. Faulty high pressure pump, low efficiency.
6. Faulty fuel injectors, stuck open or internal leakage.
8. Faulty rail pressure sensor B-015 drifted signal or leaking.
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3810 (DTC 4125) - Rail pressure sensor value is intermittent

Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 monitors the rail pressure sensor B-015 If the ECU A-057 detects more than 5
pressure jumps of greater than 500 bar (7250 psi) and the time between the pressure jumps is less than 3.00 s, an
intermittent connection is assumed and this fault will occur.
Cause:
The ECU A-057 has detected an intermittent connection in the rail pressure sensor B-015 signal circuit.
1. Faulty rail pressure sensor B-015 wiring, intermittent electrical connection.

2. Faulty rail pressure sensor B-015, internal failure.
Solution:
2. Check the rail pressure sensor B-015 engine harness wiring for an open circuit condition.
Disconnect the engine harness from the rail pressure sensor B-015 at connector X-967.
Disconnect the vehicle harness from the engine interface at connector X-941A.
side:
From To Value
X-967 pin 2 X-941B pin 6 There should be continuity.
A. If there is no continuity, there is an open circuit in the rail pressure sensor B-015 wiring in the engine harness.
Locate and repair the broken conductor.
B. If there is continuity, leave connectors X-967 and X-941A disconnected and continue to Step 3.
3. Check the rail pressure sensor B-015 vehicle harness wiring for an open circuit condition.
side:
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From To Value
NOTE: Shake the harness during the check to promote an intermittent electrical connection.
A. If there is no continuity, there is an open circuit in the rail pressure sensor B-015 wiring in the vehicle harness.
Use the appropriate service manual, if necessary, to locate and repair the broken conductor.
B. If there is continuity, leave connector X-967 disconnected and continue to Step 4.

4. Replace the rail pressure sensor B-015.
A. If the fault is no longer active, return the machine to service.
B. If the fault is still active, check the ECU A-057 for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
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3811 (DTC E22D) - ECU internal failure - Sensor 5 volt supply 1

Context:
The Engine Control Unit (ECU) A-9000 provides three independent five volt sensor supplies. The ECU A-9000 mon-
itors each sensor supply voltage to ensure they operate within a given range. If the ECU A-9000 determines that the
voltage for sensor supply 1 is out of range, this fault will occur.
The ECU A-9000 pin numbers associated with sensor supply 1 are A07, A08, A09, A10, A11, A12, and A13.
Cause:
The ECU A-9000 has determined that the sensor supply 1 voltage is out of range.
1. Faulty battery voltage.

2. Faulty ECU A-9000 supply voltage.
3. Faulty ECU A-9000 sensor supply 1 pins.
4. Faulty ECU A-9000 connector X-9121, corrosion or damage.
5. Faulty Throttle Valve Actuator (TVA) Z-9001, position sensor wiring or internal failure.
6. Faulty Exhaust Gas Recirculation (EGR) valve Z-9000, position sensor wiring or internal failure.
7. Faulty intake manifold pressure and temperature sensor B-9001, wiring or internal failure.
8. Faulty rail pressure sensor B-9004, wiring or internal failure.
9. Faulty exhaust manifold pressure sensor B-9005, wiring to internal failure.
10. Faulty camshaft speed sensor B-9017, wiring or internal failure.
Solution:
2. Check the battery voltage.
Charge the battery, then, perform a load test on the battery.
A. If the battery passes the load test, continue to Step 3.
B. If the battery fails the load test, the battery has failed. Replace the battery.
3. Disconnect the ECU A-9000 connector X-9121.
Check the following pins listed below on the ECU A-9000 and in connector X-9121 .
Pin Physical condition

X-9121 pin A07 The pin and connector should be free of corrosion or
damage.
damage.
damage.
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Pin Physical condition

damage.
damage.
damage.
damage.
A. If a pin or connector shows signs of corrosion or damage, repair as necessary.
B. If a pin or connector shows no signs of corrosion or damage, re-connect the ECU A-9000 at connector X-9121
and continue to Step 4.
Disconnect the ECU A-9000 connector X-9122.
Place a jumper wire between X-9122 pin K28 and chassis ground. This will energize the main relay K-9102.
With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness
(VE) side :
From To Value
X-9122 pin K03 X-9122 pin K02 There should be approximately 12 V.
A. If there is approximately 12 V, remove the jumper wire and re-connect the ECU A-9000 at connector X-9122,
then continue to Step 5.
B. If there is not approximately 12 V, there is a failure in the ECU A-9000 supply wiring. Use the appropriate
service manual, if necessary, to locate and repair the failed conductor.
5. Disconnect each of the following connectors one at a time. Monitor the status of this fault, 3811 – ECU internal
failure - Sensor 5 volt supply 1 during the check.
The TVA Z-9001 connector X-9011.
The EGR valve Z-9000 connector X-9010.
The intake manifold pressure and temperature sensor B-9001 connector X-9003.
The rail pressure sensor B-9004 connector X-9026.
The exhaust manifold pressure sensor B-9005 connector X-9018.
The camshaft speed sensor B-9017 connector X-9008.
A. If the fault is no longer active after a component disconnection, the relevant component has failed. Replace
the component.
B. If the fault is still active after the component disconnections, leave all of the connectors disconnected and
continue to Step 6.
6. Check the TVA Z-9001 voltage supply wiring.
Disconnect the vehicle harness (VE) from the ECU A-9000 at connectors X-9122 and X-9121.
(EN) side :
From To Value
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Disconnect the vehicle harness (VE) from the engine interface at connector X-9138.
With the key in the OFF position, use a multimeter to perform the following continuity checks on the engine
harness (EN) side :
From To Value
With the key in the OFF position, use a multimeter to perform the following continuity checks on the vehicle
harness (VE) side :
From To Value
X-9121 pin A08 All pins in connector X-9121 There should be no continuity.
A. If the specified values are measured, re-connect the engine interface connector X-9138 and leave the ECU
A-9000 connectors X-9121 and X-9122 disconnected. Then, continue to Step 7.
B. If the specified values are not measured, there is a failure in the TVA Z-9001 voltage supply wiring. Use the
appropriate service manual, if necessary, to locate and repair the failed conductor.
7. Check the EGR valve Z-9000 voltage supply wiring.
(EN) side :
From To Value
harness (EN) side :
From To Value
harness (VE) side :
From To Value
B. If the specified values are not measured, there is a failure in the EGR valve Z-9000 voltage supply wiring.
Use the appropriate service manual, if necessary, to locate and repair the failed conductor.
8. Check the intake manifold pressure and temperature sensor B-9001 voltage supply wiring.
(EN) side :
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From To Value
harness (EN) side :
From To Value
harness (VE) side :
From To Value
B. If the specified values are not measured, there is a failure in the intake manifold pressure and temperature
sensor B-9001 voltage supply wiring. Use the appropriate service manual, if necessary, to locate and repair
the failed conductor.
9. Check the rail pressure sensor B-9004 voltage supply wiring.
(EN) side :
From To Value
harness (EN) side :
From To Value
harness (VE) side :
From To Value
B. If the specified values are not measured, there is a failure in the rail pressure sensor B-9004 voltage supply
wiring. Use the appropriate service manual, if necessary, to locate and repair the failed conductor.
10. Check the exhaust manifold pressure sensor B-9005 voltage supply wiring.
(EN) side :
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From To Value
harness (EN) side :
From To Value
harness (VE) side :
From To Value
B. If the specified values are not measured, there is a failure in the rail pressure sensor B-9004 voltage supply
11. Check the camshaft speed sensor B-9017 voltage supply wiring.
(EN) side :
From To Value
harness (EN) side :
From To Value
harness (VE) side :
From To Value
A. If the specified values are measured, re-connect all of the connectors and continue to Step 12.
B. If the specified values are not measured, there is a failure in the camshaft speed sensor B-9017 voltage supply
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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.
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3812 (DTC 115D) - ECU temperature sensor 1 is too high

Control Module: ECU
Context:
The Electronic Control Unit (ECU) A-095 monitors A-095 internal temperature by the use of two internal temperature
sensors. If temperature sensor 1 monitors a temperature greater than 175 °C (347 °F), this fault will occur.
Cause:
The A-095 temperature sensor 1 has monitored a temperature greater than 175 °C (347 °F).
Solution:
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3813 (DTC 235D) - ECU temperature sensor 1 is too low

Control Module: ECU
Context:
The Engine Control Unit (ECU) A-095 monitors internal temperature by the use of two internal temperature sensors.
If temperature sensor 1 monitors a temperature less than -60 °C (-76 °F), this fault will occur.
Cause:
The internal ECU A-095 temperature is below the minimum acceptable level.
Solution:
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3814 (DTC E55D) - ECU temperature sensor error detected

Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 has an internal temperature sensor. If there is an error detected for the sensor,
this fault will occur. If this fault is active, the ECU A-057 will freeze the temperature value to the last valid value or
jump to a fixed replacement value of 39.96 °C (103.93 °F) if the failure is validated.
Solution:
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3856 - Coolant Temperature does not rise as expected
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3870 (DTC 936B) - CAN communication failure between vehicle

controller and ECU - BC2ECU1 message
Control Module: ECU
Context:
The Engine Control Unit (ECU) A-095 is capable of connecting to and communicating on three separate Controller
Area Networks (CAN). Proper configuration and monitoring of the three twisted pair configured networks is also a
function of the ECU A-095. CAN Node 1 Bus is the main vehicle interface bus. The ECU A-095 provides a CAN
termination resistor for the CAN Node 1 Bus, internal to the ECU A-095. The ECU A-095 receives and responds to
proprietary Body Computer (BC) information. If the ECU A-095 senses a message timeout, this fault will occur.
Cause:
ECU A-095 has sensed a BC message timeout.
1. Faulty vehicle system, related CAN fault

2. Faulty supply voltage or ground, missing
3. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit
4. Faulty ECU A-095, termination resistor or software
Solution:
2. Check for related vehicle CAN faults.
Use the EST to determine if related vehicle CAN faults exist.
A. If related vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that 3870 (DTC 936B)
– CAN communication failure between vehicle controller and ECU - BC2ECU1 message is also resolved.
B. If related vehicle CAN faults do not exist, continue with Step 3.

Disconnect the vehicle (VE) harness from the ECU A-095 at connector X-911.
With the ignition switch in the ON position, use a multimeter to check for voltage on the vehicle (VE) harness side:
From To Value
X-911 pin 1, wire 6408B (GN) chassis ground There should be 12.0 V
X-911 pin 25, wire 6408C (GN) chassis ground There should be 12.0 V
X-911 pin 26, wire 6408D (GN) chassis ground There should be 12.0 V
X-911 pin 49, wire 6408E (GN) chassis ground There should be 12.0 V
X-911 pin 73, wire 6408F (GN) chassis ground There should be 12.0 V
B. If the voltage is not present for one or more of the checks, refer to the appropriate vehicle service manual and
electrical schematics to locate and restore supply power to the ECU A-095.
4. Check the ECU A-095 grounding.
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With the ignition switch in the OFF position, use a multimeter to check for continuity on the vehicle (VE) harness
side:
From To Value
X-911 pin 3, wire 057FZ (BK) chassis ground There should be continuity.
X-911 pin 5, wire 057FE (BK) chassis ground There should be continuity.
X-911 pin 28, wire 057HD (BK) chassis ground There should be continuity.
X-911 pin 52, wire 057HC (BK) chassis ground There should be continuity.
X-911 pin 75, wire 057HE (BK) chassis ground There should be continuity.
B. If there is no continuity for one or more of the checks, refer to the appropriate vehicle service manual and
electrical schematics to locate and restore the grounding circuit to the ECU A-095.
With the ignition switch in the OFF position, use a multimeter to measure the resistance of the CAN connection
on the vehicle (VE) harness side:
From To Value
X-911 pin 46, wire 191 (YE) X-911 pin 47, wire 190 (GN) There should be 120 Ω.
X-911 pin 46, wire 191 (YE) chassis ground There should not be continuity
X-911 pin 47, wire 190 (GN) chassis ground There should not be continuity
From To Value
X-911 pin 46, wire 191 (YE) X-911 pin 47, wire 190 (GN) There should be 120 Ω.
B. If the measured resistances are not correct or one or both of the conductors is grounded, refer to the appropriate
vehicle service manual and electrical schematics to locate and restore the termination resistance to the CAN
circuit.
has been resolved.
operation.
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3877 (DTC 647D) - Supply UB1 short to battery failure

Control Module: ECU
Context:
The Electronic Control Unit (ECU) A-095, monitors the supply UB1 circuit. If the A-095 detects that the UB1 supply
circuit has a short to battery power condition, this fault will occur.
Cause:
The A-095 has detected a short to battery power in the supply UB1 circuit.
1. Faulty supply UB1 circuit, short to battery power condition

Solution:
2. Check the supply UB1 circuit for a short to battery power condition.
The ignition switch must be in OFF position.
From To Value
X-911 pin 50, wire 9250C (BK) All pins in connector X-911 There should be no continuity.
A. If there is continuity at any pin, there is a short to battery power condition in the supply UB1 circuit. Locate and
repair the shorted conductor.
B. If there is no continuity, leave the connector disconnected and continue to Step 3.

3. Check the supply UB1 circuit for a short to ignition battery power condition.
Use a multimeter to perform the following voltage test:
From To Value
X-911 pin 50, wire 9250C (BK) Chassis ground There should be no voltage.
A. If there is voltage, there is a short to ignition battery power in the supply UB1 circuit. Locate and repair the
shorted conductor.
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has been resolved.
operation.
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Control Module: ECU
Context:
Cause:

Solution:
From To Value
X-911 pin 74, wire 6580 (BL) All pins in connector X-911 There should be no continuity.
A. If there is continuity, there is a short circuit condition in the supply UB2 circuit. Locate and repair the shorted
conductor.

From To Value
X-911 pin 74, wire 6580 (BL) Chassis ground There should be no voltage.
shorted conductor.
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has been resolved.
operation.
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Control Module: ECU
Context:
Cause:

Solution:
From To Value
X-911 pin 27, wire 6570A (BL) All pins in connector X-911 There should be no continuity.
conductor.

From To Value
shorted conductor.
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has been resolved.
operation.
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3880 (DTC 6A7D) - Actuator relay 3 circuit short to battery failure

Context:
The Electronic Control Unit (ECU) A-9000, monitors the supply for the optional Selective Catalytic Reduction (SCR)
relay circuit. If the A-9000 detects that the supply circuit has a short to battery power condition, this fault will occur.
Cause:
The A-9000 has detected a short to battery power in the supply circuit.
1. Faulty supply circuit, short to battery power condition.

Solution:
A. If the fault is present and active, continue with 2.
2. Check the supply circuit for a short to battery power condition.
The key must be in OFF position.
From To Value
A. If there is continuity, there is a short circuit condition in the supply circuit. Locate and repair the shorted con-
ductor.

3. Check the supply circuit for a short to key battery power condition.
The key must be in the ON position.
From To Value
A. If there is voltage, there is a short to key battery power in the supply circuit. Locate and repair the shorted
conductor.
has been resolved.
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operation.
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3881 (DTC 757D) - Supply UB1 circuit short to ground failure

Control Module: ECU
NOTE: Because this fault causes inducement, it is necessary to perform the Engine Restart Counter Reset / Unlock
Inducement configuration with the Electronic Service Tool (EST) before you return the machine to service. See the
corresponding configure menu in the EST.
Context:
circuit has a short to ground condition, this fault will occur.
Cause:
The A-095 has detected a short to ground in the supply UB1 circuit.
1. Faulty supply UB1 circuit, short to ground condition

Solution:
2. Check the supply UB1 circuit for a short to ground condition.
From To Value
X-911 pin 50, wire 9250C (BK) All pins in connector X-911 There should be no continuity.
conductor.

Use a multimeter to perform the following continuity test:
From To Value
X-911 pin 50, wire 9250C (BK) Chassis ground There should be no continuity.
A. If there is continuity, there is a short to ground in the supply UB1 circuit. Locate and repair the shorted con-
ductor.
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has been resolved.
operation.
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3882 (DTC 777D) - Supply UB2 short to ground failure

Control Module: ECU
Context:
Cause:
The A-095 has detected a short to ground in the supply UB2 circuit.

Solution:
From To Value
X-911 pin 74, wire 6580 (BL) All pins in connector X-911 There should be no continuity.
conductor.

From To Value
X-911 pin 74, wire 6580 (BL) Chassis ground There should be no continuity.
ductor.
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has been resolved.
operation.
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3883 (DTC 797D) - Supply UB3 short to ground failure

Control Module: ECU
NOTE: Because this fault causes inducement, it is necessary to perform the SCR Fault Repair Verification Test once
the fault has been resolved. See the corresponding configure menu in the Electronic Service Tool (EST).
Inducement configuration with the EST before you return the machine to service. See the corresponding configure
menu in the EST.
Context:
The Engine Control Unit (ECU) A-095, monitors the supply UB3 circuit. If the ECU A-095 detects that the UB3 supply
Cause:
The ECU A-095 has detected a short to ground in the supply UB3 circuit.

2. Faulty ECU A-095, software
Solution:
Disconnect connector X-911 from the ECU A-095.
From To Value
X-911 pin 27, wire 6570A (BL) All pins in connector X-911 There should be no continuity.
conductor.

From To Value
X-911 pin 27, wire 6570A (BL) Chassis ground There should be no continuity.
ductor.
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has been resolved.
operation.
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3903 (DTC 1A15) - Fuel temperature is too high

Control Module: ECU
Context:
The Electronic Control Unit (ECU) A-095 monitors the fuel temperature sensor B-017. If the A-095 detects a fuel
temperature higher than 90 °C (194 °F), this fault will occur.
Cause:
The A-095 has detected a fuel temperature greater than 90 °C (194 °F).
1. Faulty fuel cooling, clogged (if equipped)

2. High ambient temperature
3. Faulty B-017, internal failure
4. Faulty B-017, wiring
Solution:
2. Verify the status of the following possible related faults:
3015 (DTC 1C15) – Fuel temperature sensor voltage is higher than expected
A. If the faults is active, diagnose it first, and then return to this fault, 3903 (DTC 1A15) – Fuel temperature is
too high.

3. Check the B-017 signal circuit for a short circuit condition.
From To Value
X-917 pin 12 (OR) All pins in connector X-917 There should be no continuity.
A. If there is continuity, there is a short circuit condition in the B-017 signal circuit. Locate and repair the shorted
conductor.

4. Check the B-017 for a short to ignition power condition.
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From To Value
X-917 pin 12 (OR) Chassis ground There should be no voltage.
A. If there is voltage, there is a short to ignition power condition in the B-017 signal circuit. Locate and repair the
shorted conductor.

5. Replace the B-017.
Use the EST to verify the status of 3903 (DTC 1A15) – Fuel temperature is too high.
has been resolved.
operation.
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3905 (DTC 8814) - Intake air heater ECU driver has an

over-temperature error
Control Module: ECU
Context:
The Engine Control Unit (ECU) A-095 monitors the intake air heater relay K-023 control circuit for an over temperature
condition. If an over temperature condition is detected, this fault will occur.
Cause:
The ECU A-095 has detected an over temperature condition in the K-023 control circuit.
1. Faulty K-023, coil

2. Faulty K-023 control circuit, short to high source condition
Solution:
2. Check the status of the following possible related faults:
3154 (DTC 6A14) – Intake air heater actuator is shorted to battery voltage
A. If the fault is active, diagnose them first and then return to this fault, 3905 (DTC 8814) – Intake air heater ECU
driver has an over-temperature error.

3. Check the K-023 coil for an internal failure.
Remove the K-023.
Use a multimeter to perform the following resistance test:
From To Value
X-215 pin 1 X-215 pin 2 The coil resistance should be
between 70 – 130 Ω.
A. If the value is not within the specified value, the K-023 has failed internally. Replace the K-023.
B. If the value is within the specified range, leave the K-023 disconnected and continue to Step 4.
4. Check the K-023 signal circuit for a short to high source condition.
From To Value
X-911 pin 83, wire 6586 (VT) X-911 pin 74, wire 6580 (BL) There should be no continuity.
X-911 pin 83, wire 6586 (VT) All other pins There should be no continuity.
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A. If there is continuity, there is a short circuit condition in the K-023 signal circuit.
B. If there is no continuity, leave X-911 disconnected and continue to Step 5.

5. Check the K-023 for a short to ignition power condition.
From To Value
X-911 pin 83, wire 6586 (VT) Chassis ground There should be no voltage.
A. If there is voltage, there is a short to ignition power condition in the K-023 signal circuit.
has been resolved.
operation.
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3911 (DTC 6455) - Fuel metering unit is shorted to battery voltage

at the high side
Control Module: ECU
Context:
The Electronic Control Unit (ECU) A-095 monitors the fuel metering unit Y-011 high side driver circuit for a short to
battery power condition. If the A-095 detects a short to battery power, this fault will occur.
Cause:
The A-095 has detected a short to battery power in the Y-011 high side driver circuit.
1. Faulty Y-011, internal failure

2. Faulty Y-011 wiring, short to battery power condition
Solution:
2. Check the Y-011 for an internal short.
Disconnect the Y-011 connector X-833.
Use a multimeter to perform the following resistance check:
From To Value
X-833 pin 1 X-833 pin 2 The value should be between 2.8 –
3.2 Ω (2.8 – 3.2 Ω).
A. If the value is in the specified range, leave the connector X-833 disconnected and continue to Step 3.
B. If the value is not in the specified range, the Y-011 has failed internally. Replace the Y-011 then perform the
Replacement of the Rail Pressure Metering Unit - Reset ECU Data. See the corresponding configure menu in
the Electronic Service Tool (EST).
3. Check the Y-011 high side driver circuit for a short to battery power condition.
From To Value
X-917 pin 58 (YE/GN) All pins in connector X-917 There should be no continuity.
A. If there is continuity, there is a short circuit condition in the Y-011 high side driver circuit. Locate and repair the
shorted conductor.
B. If there is no continuity, leave both connectors disconnected and continue to Step 4.

4. Check the Y-011 high side driver circuit for a short to ignition power condition.
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From To Value
X-917 pin 58 (YE/GN) Chassis ground There should be no voltage.
A. If there is voltage, there is a short to ignition power condition in the Y-011 high side driver circuit. Locate and
repair the shorted conductor.
has been resolved.
operation.
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3912 (DTC 7555) - Fuel metering unit is shorted to ground at the

high side
1. Operating in higher than normal ambient pressure conditions.

2. Faulty fuel injectors, internal leakage or blockage.
3. Faulty fuel pressure sensor B-015 wiring or internal failure.
4. Faulty fuel metering unit Y-011 wiring or internal failure.
5. Faulty high pressure pump, feeding efficiency low.
6. Faulty charge gear pump, pressure too high.
7. Faulty A-095 software.
Solution:
1. Use the Electronic Service Tool (EST) to check for the following related faults that may have caused this fault to
occur. If any of the listed faults are active, diagnose them first and then return to this fault, 3141 (DTC 4465) –
Fuel pump pressure has exceeded desired pressure limits.
3107 (DTC 6655) – Fuel metering unit is shorted to battery voltage at the low side
3912 (DTC 7555) – Fuel metering unit is shorted to ground at the high side
3735 (DTC 8355) – Fuel metering unit has an over-temperature error
3137 (DTC 5255) – Fuel metering unit has an open load error
3910 (DTC 4155) – Fuel metering unit intermittent electrical connection failure
3112 (DTC 1425) – Fuel rail pressure sensor voltage is higher than expected
3808 (DTC 3C65) – High pressure pump fuel delivery quantity at low idle is too high
3176 (DTC 3B65) – High pressure pump fuel delivery quantity in over run exceeds a maximum threshold
3301 (DTC 1565) – Fuel rail pressure has exceeded maximum negative deviation limits
3293 (DTC 2265) – Fuel rail pressure has exceeded maximum positive deviation limits
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3916 (DTC 1745) - Fuel pressure relief valve has reached maximum
allowed open time
Control Module: ECU
Context:
The Engine Control Unit (ECU) A-057 monitors the fuel Pressure Relief Valve (PRV). If the ECU A-057 determines
that the PRV has been open for too long, this fault will occur. The PRV opening duration is monitored by the ECU
A-057 and stored in the EEPROM during after run. This fault is for informational purposes only. If this fault is active,
other fuel system faults may be active that caused this fault to occur. For more information regarding fuel system
troubleshooting, see Fuel injection system - Troubleshooting (10.218).
Cause:
The ECU A-057 has determined that the PRV has reached its maximum allowed open time.
1. Faulty PRV, stuck open or worn.

2. Faulty fuel back-flow, clogged or damaged.
4. Faulty rail pressure sensor B-015, internal failure.
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3936 (DTC E52D) - ECU internal: error sensor supplies voltage

tracker
Control Module: ECU
Context:
The Electronic Control Unit (ECU) A-095 monitors the external voltage tracker for the A-095 internal 5 V supply. If the
A-095 determines that the voltage is too high or too low, this fault will occur.
Solution:
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3964 (DTC 125D) - ECU temperature sensor 2 is too high

Control Module: ECU
Context:
The Electronic Control Unit (ECU) A-095 monitors A-095 internal temperature by the use of two internal temperature
sensors. If temperature sensor 2 monitors a temperature greater than 175 °C (347 °F), this fault will occur.
Cause:
The A-095 temperature sensor 2 has monitored a temperature greater than 175 °C (347 °F).
Solution:
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3965 (DTC 245D) - ECU temperature sensor 2 is too low

Control Module: ECU
Context:
The Engine Control Unit (ECU) temperature is less than -60 °C (-76 °F) .
Cause:
The internal ECU temperature is less than normal.
1. Low ambient temperatures

2. Faulty ECU A-095
Solution:
1. Verify that the fault code is active.
Connect the Electronic Service Tool (EST) to the service tool connector.
To check for fault codes: Start and operate the machine.
A. If the fault code 3965 (DTC 245D) – ECU temperature sensor 2 is too low is not recorded again, go to Step
3 to check for an intermittent condition.
B. If the fault code 3965 (DTC 245D) – ECU temperature sensor 2 is too low is recorded again, go to Step 2.
2. Verify the ambient temperature.
Verify the ambient temperature. The ambient temperature should be warmer than -60 °C (-76 °F).
A. If the ambient temperature is colder than -60 °C (-76 °F), bring the machine inside and allow it to warm up.
Return to Step 1 to confirm elimination of the fault.
B. If the ambient temperature is warmer than -60 °C (-76 °F), go to Step 3.

3. Verify that the wiring and connectors are free of damage.
Verify the minus battery connections from the battery to the frame are tight and secure.
Verify the connections from the chassis ground to the ECU A-095 are tight and secure.
Verify the connections from the battery to the ECU A-095 are tight and secure.
Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment from the battery to the ECU
A-095.
A. The harness is not damaged and all connections are secure. Temporarily replace the ECU A-095 and retest.
Return to Step 1 to confirm elimination of the fault.
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.
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3966 (DTC 165D) - ECU temperature sensor voltage is higher than

expected
Control Module: ECU
Context:
The Electronic Control Unit (ECU) A-095 monitors the A-095 temperature sensor, which is internal to the A-095, for
a voltage higher than expected condition. If the A-095 detects a voltage greater than 3.46 V for a period greater than
500 ms in the temperature sensor circuit, this fault will occur.
Solution:
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3967 (DTC 275D) - ECU temperature sensor voltage is lower than

expected
Control Module: ECU
Context:
The Electronic Control Unit (ECU) A-095 monitors the A-095 temperature sensor, which is internal to the A-095, for
a voltage lower than expected condition. If the A-095 detects a voltage less than 383 mV for a period greater than
500 ms in the temperature sensor circuit, this fault will occur.
Solution:
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4113 - Logical error at gear range signal

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check the cables from the TCU to the FNR switch.

2. Check the connectors from the TCU to the FNR switch.
3. Check the FNR switch.
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4114 - Logical error at direction select signal

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

3. Check the FNR switch signal combinations.
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4116 - Logical error at park brake status

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check the cables from the TCU to the instrument cluster connector 2 pin 6.
2. Check park brake switch.
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4117 - Logic error at direction select signal 2

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

3. Check the FNR switch signal combinations.
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4119 - Short circuit to ground at ride control

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check the cables from the TCU to the ride control relay.
2. Check the connectors from the TCU to the ride control relay.
3. Check the ride control relay.
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4120 - Short circuit to battery voltage at ride control

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
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4121 - Open circuit at ride control

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
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4133 - Short circuit to battery voltage or open circuit at transmission

sump temperature sensor input
[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check the connectors.

2. Check the temperature sensor.
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4134 - Short circuit to ground at transmission sump temperature

sensor input
[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check the cables from TCU to the sensor.

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4135 - Short circuit to battery voltage or open circuit at retarder/

torque converter temperature sensor input
[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

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4136 - Short circuit to ground at retarder/ torque converter

temperature sensor input
[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

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4137 - Short circuit to battery voltage or open circuit at parking

brake sensor input
[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

3. Check the parking brake sensor.
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4145 - Short circuit to battery voltage or open circuit at engine

speed input
[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check the parking brake fuse.

2. Check the parking brake relay.
3. Check the parking brake solenoid.
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4146 - Short circuit to ground at engine speed input

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check the parking brake fuse.

2. Check the parking brake relay.
3. Check the parking brake solenoid.
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4147 - Logical error at engine speed input

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

3. Check the speed sensor.
4. This fault code is reset after power up of the TCU. It is also reset if the signal is above zero speed threshold.
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4148 - Short circuit to battery voltage or open circuit at turbine

speed input
[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

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4149 - Short circuit to ground at turbine speed input

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

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4150 - Logical error at turbine speed input

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

4. This fault code is reset after power up of the TCU
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4151 - Short circuit to battery voltage or open circuit at internal

speed input
[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

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4152 - Short circuit to ground at internal speed input

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

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4153 - Logical error at internal speed input

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

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4154 - Short circuit to battery voltage or open circuit at output

speed input
[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

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4155 - Short circuit to ground at output speed input

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

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4156 - Logical error at output speed input

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

4. This fault code is reset after power up of the TCU.
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4158 - Output speed zero, doesn't fit to other speed signals

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check the sensor signal of the output speed sensor.

2. Check the connector connected to the output speed.
3. Check the cable from the TCU to the sensor.
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4160 - Gear range restriction signal

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check the cluster controller.

2. Check wire of CAN-Bus.
3. Check the cable to the cluster controller.
48050419D 06/10/2017
55.11 [55.DTC] / 364
4161 - Short circuit to battery voltage at load sensor input

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check the cable from TCU to the sensor

3. Check the load sensor.
4. Check the assembly tolerances of load sensor.
48050419D 06/10/2017
55.11 [55.DTC] / 365
4162 - Short circuit to ground open circuit at load sensor input

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check the cable from TCU to the sensor.

3. Check the load sensor.
4. Check the assembly tolerances of load sensor.
48050419D 06/10/2017
55.11 [55.DTC] / 366
4163 - DCT1 timeout

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
48050419D 06/10/2017
55.11 [55.DTC] / 367
4164 - Engine configuration timeout

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check engine controller.

3. Check cable to engine controller.
48050419D 06/10/2017
55.11 [55.DTC] / 368
4165 - EEC1 timeout

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

48050419D 06/10/2017
55.11 [55.DTC] / 369
4166 - EEC3 timeout

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

48050419D 06/10/2017
55.11 [55.DTC] / 370
4167 - Short circuit to battery at converter chutch

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check the cable from TCU to the valve.

2. Check the regulator resistance.
48050419D 06/10/2017
55.11 [55.DTC] / 371
4168 - Short circuit to ground at converter chutch

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

48050419D 06/10/2017
55.11 [55.DTC] / 372
4169 - Open circuit at converter clutch

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

48050419D 06/10/2017
55.11 [55.DTC] / 373
4170 - Slippage at converter lockup clutch

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check pressure at converter lockup clutch.

2. Check main pressure in the system.
3. Check sensor gap at engine speed sensor.
4. Check sensor gap at turbine speed sensor.
5. Check signal at engine speed sensor.
6. Check signal at turbine speed sensor.
7. Replace clutch.
48050419D 06/10/2017
55.11 [55.DTC] / 374
4171 - Short circuit to battery voltage at display output

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check the cable from TCU to the display.

2. Check the connectors at the display.
3. Change display.
48050419D 06/10/2017
55.11 [55.DTC] / 375
4172 - Short circuit to ground at display output

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check the cable from TCU to the display.

2. Check the connectors at the display.
3. Change display.
48050419D 06/10/2017
55.11 [55.DTC] / 376
4173 - Engine torque can signal is defective

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

48050419D 06/10/2017
55.11 [55.DTC] / 377
4174 - Reference engine torque can signal is defective

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

48050419D 06/10/2017
55.11 [55.DTC] / 378
4175 - Actual engine torque can signal is defective

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

48050419D 06/10/2017
55.11 [55.DTC] / 379
4176 - No friction torque can signal is defective

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

48050419D 06/10/2017
55.11 [55.DTC] / 380
4177 - EEC2 timeout

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

48050419D 06/10/2017
55.11 [55.DTC] / 381
4185 - Test mode signal

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

48050419D 06/10/2017
55.11 [55.DTC] / 382
4186 - Invalid park brake status (CAN)

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

48050419D 06/10/2017
55.11 [55.DTC] / 383
4209 - Short circuit to battery voltage at clutch K1

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check the cable from the TCU to the transmission control valve.
2. Check the connectors from the TCU to the transmission control valve.
4. Check internal wire harness of the transmission control valve.
48050419D 06/10/2017
55.11 [55.DTC] / 384
4210 - Short circuit to ground at clutch K1

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 385
4211 - Open circuit at clutch K1

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 386

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 387

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 388

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 389

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 390

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 391

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 392

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 393

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 394

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 395
4228 - Short circuit to battery voltage at clutch KV

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 396
4229 - Short circuit to ground at clutch KV

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 397
4230 - Open circuit at clutch KV

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 398
4231 - Short circuit to battery voltage at clutch KR

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 399
4232 - Short circuit to ground at clutch KR

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 400
4233 - Open circuit at clutch KR

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 401
4241 - Short circuit to ground at relay reverse warning alarm

Solution:
1. Check the cable from the TCU to the backup alarm relay.
2. Check the connectors from the backup alarm relay to TCU.
3. Check the resistance of backup alarm relay circuit.
48050419D 06/10/2017
55.11 [55.DTC] / 402
4242 - Short circuit to battery voltage at relay reverse warning alarm

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 403
4243 - Open circuit at relay reverse warning alarm

Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 404
4273 - Slippage at clutch K1

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check pressure at clutch K1.

3. Check signal at internal speed sensor.
4. Check signal at output speed sensor.
5. Replace clutch.
48050419D 06/10/2017
55.11 [55.DTC] / 405

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

5. Replace clutch.
48050419D 06/10/2017
55.11 [55.DTC] / 406

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

5. Replace clutch.
48050419D 06/10/2017
55.11 [55.DTC] / 407

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

5. Replace clutch.
48050419D 06/10/2017
55.11 [55.DTC] / 408
4277 - Slippage at clutch KV

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check pressure at clutch kV..

5. Replace clutch.
48050419D 06/10/2017
55.11 [55.DTC] / 409
4278 - Slippage at clutch KR

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check pressure at clutch KR.

5. Replace clutch.
48050419D 06/10/2017
55.11 [55.DTC] / 410
4279 - Overtemp sump

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. A critical stop function warning has occurred.

2. Red stop indicator comes on and continuous buzzer sounds.
3. Stop machine and perform required service on the critical area.
4. Cool down machine.
5. Check oil level.
6. Check temperature sensor.
48050419D 06/10/2017
55.11 [55.DTC] / 411
4282 - Differential pressure oil filter

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check oil filter.

2. Check wiring from TCU to filter maintenance switch.
3. Check filter maintenance switch (measure resistance).
48050419D 06/10/2017
55.11 [55.DTC] / 412
4291 - Overtemp converter output

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. A critical stop function warning has occurred.

2. Red stop indicator comes on and continuous buzzer sounds.
3. Stop machine and perform required service on the critical area.
4. Cool down machine.
5. Check oil level.
6. Check temperature sensor.
48050419D 06/10/2017
55.11 [55.DTC] / 413
4292 - Short circuit to ground at joystick status indicator

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check the cables from the TCU to the joystick.

2. Check the connectors from the TCU to the joystick.
3. Check the resistance of the joystick.
48050419D 06/10/2017
55.11 [55.DTC] / 414
4293 - Short circuit to battery voltage at joystick status indicator

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

48050419D 06/10/2017
55.11 [55.DTC] / 415
4294 - Open circuit at joystick status indicator

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

48050419D 06/10/2017
55.11 [55.DTC] / 416
4305 - Short circuit to battery voltage at power supply for sensors

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check the cables from the sensors TCU.

2. Check the connectors from the sensors to the TCU.
48050419D 06/10/2017
55.11 [55.DTC] / 417
4306 - Short circuit to ground at power supply for sensors

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check the cables from the sensors TCU.

2. Check the connectors from the sensors to the TCU.
48050419D 06/10/2017
55.11 [55.DTC] / 418
4307 - Low voltage at battery

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check batteries.
2. Check B+ wires from batteries to TCU.
3. Check voltage at TCU connector pin 45
48050419D 06/10/2017
55.11 [55.DTC] / 419
4308 - High voltage at battery

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check batteries.
2. Check B+ wires from batteries to TCU.
3. Check voltage at TCU connector pin 45.
48050419D 06/10/2017
55.11 [55.DTC] / 420
4309 - Error at valve power supply VPS1

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check fuse A2.

2. Check cable from control valve to TCU.
3. Check connectors from control valve to TCU.
4. Replace clutch.
48050419D 06/10/2017
55.11 [55.DTC] / 421
4310 - Error valve power supply VPS2

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check fuse A2.

2. Check cable from control valve to TCU.
3. Check connectors from control valve to TCU.
4. Replace TCU.
48050419D 06/10/2017
55.11 [55.DTC] / 422
4325 - VehicleID#1 timeout

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Check CAN bus (CAN H and CAN L) wiring to TCU.

2. Check continuity between CAN H and L at TCU and at AIC CN1 connector.
3. Check resistance between CAN H and L.
4. Check TCU connector condition.
5. Replace TCU and check if the problem is solved.
48050419D 06/10/2017
55.11 [55.DTC] / 423
4337 - General EEPROM fault

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Replace the TCU.
48050419D 06/10/2017
55.11 [55.DTC] / 424
4338 - Configuration lost

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Reprogram the correct configuration for the vehicle.
48050419D 06/10/2017
55.11 [55.DTC] / 425
4339 - Application error

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Replace the TCU.
48050419D 06/10/2017
55.11 [55.DTC] / 426
4341 - Clutch failure during AEB

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Do the transmission clutch calibration procedure.
48050419D 06/10/2017
55.11 [55.DTC] / 427
4342 - Clutch adjustment data lost

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
1. Do the transmission clutch calibration procedure.
48050419D 06/10/2017
55.11 [55.DTC] / 428
4346 - Time Out of CAN Message "Gear Range Select" from AWD
[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

2. Check FWD controller.
48050419D 06/10/2017
55.11 [55.DTC] / 429
4347 - Time Out of CAN Message "AWD Status" from AWD

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:

48050419D 06/10/2017
55.11 [55.DTC] / 430
4348 - CAN Message "AWD Status" contains invalid data

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 431
4349 - Short circuit to ground at DLM transversal output

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
48050419D 06/10/2017
55.11 [55.DTC] / 432
4350 - Short circuit to battery voltage at DLM transversal output

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
48050419D 06/10/2017
55.11 [55.DTC] / 433
4351 - Short circuit to battery voltage at DLM indicator lamp output

[HBZN0845VCAF01093 - ]
[HBZN0885PCAF00871 - ]
48050419D 06/10/2017
55.11 [55.DTC] / 434
4352 - Open circuit DLM indicator lamp output

[HBZN0845VCAF01093 - ]
48050419D 06/10/2017
55.11 [55.DTC] / 435
4900 - Solenoid 1 open circuit

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Open or short to ground in Solenoid 1 circuit from output pin J3-A3 to return pin J3-B1.
48050419D 06/10/2017
55.11 [55.DTC] / 436

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Open or short to ground in Solenoid 2 circuit from output pin J3-B2 to return pin J3-B3.
48050419D 06/10/2017
55.11 [55.DTC] / 437

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Open or short to ground in Solenoid 3 circuit from output pin J3-C1 to return pin J3-C2.
48050419D 06/10/2017
55.11 [55.DTC] / 438

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Open or short to ground in Solenoid 4 circuit from output pin J3-C3 to return pin J3-D1.
48050419D 06/10/2017
55.11 [55.DTC] / 439
4904 - Solenoid A open circuit

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Open or short to ground in Solenoid A circuit from output pin J3-D2 to return pin J3-D3.
48050419D 06/10/2017
55.11 [55.DTC] / 440
4905 - Solenoid B open circuit

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Open or short to ground in Solenoid B circuit from output pin J3-E1 to return pin J3-E2.
48050419D 06/10/2017
55.11 [55.DTC] / 441
4906 - Solenoid C open circuit

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Open or short to ground in Solenoid C circuit from output pin J3-E3 to return pin J3-F1.
48050419D 06/10/2017
55.11 [55.DTC] / 442
4907 - Solenoid D open circuit

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Open or short to ground in Solenoid D circuit from output pin J3-F2 to return pin J3-F3.
48050419D 06/10/2017
55.11 [55.DTC] / 443
4908 - Driver open circuit

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Open or short to ground in circuit from output pin J3-G1 to return pin J3-G2.
48050419D 06/10/2017
55.11 [55.DTC] / 444
4909 - Torque Converter lockup open circuit

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Open or short to ground in Torque Converter Lock Up circuit from output pin J3-G3 to return pin J3-H1.
48050419D 06/10/2017
55.11 [55.DTC] / 445
4910 - Solenoid 1 Short circuit

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Short to positive in Solenoid 1 circuit from output pin J3-A3 to return pin J3-B1.
48050419D 06/10/2017
55.11 [55.DTC] / 446

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Short to positive in Solenoid 2 circuit from output pin J3-B2 to return pin J3-B3.
48050419D 06/10/2017
55.11 [55.DTC] / 447

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Short to positive in Solenoid 3 circuit from output pin J3-C1 to return pin J3-C2.
48050419D 06/10/2017
55.11 [55.DTC] / 448

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Short to positive in Solenoid 4 circuit from output pin J3-C3 to return pin J3-D1.
48050419D 06/10/2017
55.11 [55.DTC] / 449
4914 - Solenoid A Short circuit

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Short to positive in Solenoid A circuit from output pin J3-D2 to return pin J3-D3.
48050419D 06/10/2017
55.11 [55.DTC] / 450
4915 - Solenoid B Short circuit

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Short to positive in Solenoid B circuit from output pin J3-E1 to return pin J3-E2.
48050419D 06/10/2017
55.11 [55.DTC] / 451
4916 - Solenoid C Short circuit

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Short to positive in Solenoid C circuit from output pin J3-E3 to return pin J3-F1.
48050419D 06/10/2017
55.11 [55.DTC] / 452
4917 - Solenoid D Short circuit

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Short to positive in Solenoid D circuit from output pin J3-F2 to return pin J3-F3.
48050419D 06/10/2017
55.11 [55.DTC] / 453
4918 - Driver Short circuit

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Short to positive in circuit from output pin J3-G1 to return pin J3-G2.
48050419D 06/10/2017
55.11 [55.DTC] / 454
4919 - Torque Converter Lockup Short circuit

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Short to positive in Torque Converter Lock Up circuit from output pin J3-G3 to return pin J3-H1.
48050419D 06/10/2017
55.11 [55.DTC] / 455
4920 - Request for undefined shift being made

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Not field serviceable.
48050419D 06/10/2017
55.11 [55.DTC] / 456
4921 - Power up in gear

[HBZN0845VBAF00184 - ]
-]
Solution:
1. ECU has not seen a legal Neutral (input pin J2-A1) since initial power up of system.
48050419D 06/10/2017
55.11 [55.DTC] / 457
4922 - Bottom of clutch input is passive

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Application does not utilize inching. Input pin J1-K2 must be connected to system voltage.
48050419D 06/10/2017
55.11 [55.DTC] / 458
4923 - Park and NOT Park values match

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Handle signal is park but PARK PRESSURE (input pin J2-B3) is passive.
48050419D 06/10/2017
55.11 [55.DTC] / 459
4924 - Park Status and Gear Input are not compatible

[HBZN0845VBAF00184 - ]
-]
Solution:
1. PARK (input pin J2-B3) active and REVERSE (input pin J1-J2) passive.
2. PARK passive and REVERSE passive.
3. PARK passive and REVERSE active.
48050419D 06/10/2017
55.11 [55.DTC] / 460
4925 - Upshit and Downshift both active

[HBZN0845VBAF00184 - ]
-]
Solution:
1. UPSHIFT (input pin J1-H2) and DOWNSHIFT (input pin J1-H3) are both active.
48050419D 06/10/2017
55.11 [55.DTC] / 461
4926 - variable need gear has taken on invalid value

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Variable NeedGear has taken on an invalid value. Not field serviceable.
48050419D 06/10/2017
55.11 [55.DTC] / 462
4927 - Start went active

[HBZN0845VBAF00184 - ]
-]
Solution:
1. START (input pin J2-B2) went active disabling internal solenoid power.
48050419D 06/10/2017
55.11 [55.DTC] / 463
4928 - Valve driver supply voltage too low

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Valve driver supply voltage (pin J3-A1) too low.

2. Must be above 8 volts on a 12 volt system or above 17 volts on a 24 volt system.
48050419D 06/10/2017
55.11 [55.DTC] / 464
4929 - illegal or undefined vehicle mode code

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Drill mode (input pin J2-B1) active and transport (input pin J2-C3) passive.
2. Drill mode input passive and transport input active.
48050419D 06/10/2017
55.11 [55.DTC] / 465
4930 - Inching voltage low but bottom of clutch is open

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Inching pot is missing or disconnected. Solution – Verify inching pot is connected properly.
2. Faulty wiring between Bottom of Clutch switch and ecu. Solution – Verify wiring and connections betw.
48050419D 06/10/2017
55.11 [55.DTC] / 466
4931 - seat switch and neutral are both passive

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Seat switch (input pin J2-C3) passive and NEUTRAL (input pin J2-A1) active.
2. Seat switch active and NEUTRAL passive. 3. Seat switch active and NEUTRAL active.
48050419D 06/10/2017
55.11 [55.DTC] / 467
4932 - Engine speed is at or near manufacturers warranty void level

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Engine speed is at or near manufacturers warranty void level.
48050419D 06/10/2017
55.11 [55.DTC] / 468
4934 - illegal wheel mode change out of neutral

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Illegal wheel mode change out of neutral.
48050419D 06/10/2017
55.11 [55.DTC] / 469
4935 - sump temperature too low for calibration

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Warm transmission to above 50 degrees F.
48050419D 06/10/2017
55.11 [55.DTC] / 470
4936 - Engine speed too high for calibration

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Raise engine speed above 1500 rpm, specifically 1600 rpm.
48050419D 06/10/2017
55.11 [55.DTC] / 471
4937 - Engine speed too low for calibration

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Raise engine speed above 1500 rpm, specifically 1600 rpm.
48050419D 06/10/2017
55.11 [55.DTC] / 472
4938 - Output speed sensed during calibration

[HBZN0845VBAF00184 - ]
-]
Cause:
Vehicle physically moves during calibration.
Solution:
1. Check park brake for proper adjustment.

NOTE: Do not disconnect output MPU if vehicle is moving during calibration. Vehicle movement is unacceptabl
48050419D 06/10/2017
55.11 [55.DTC] / 473
4939 - no cylinder speed during calibration

[HBZN0845VBAF00184 - ]
-]
Cause:
1. Cylinder MPU disconnected.

2. Controlling valve is not functioning properly (slow or no response).
Solution:
1. Check MPU wiring harness connections.

2. Replace valve 1 and/or valve 3.
48050419D 06/10/2017
55.11 [55.DTC] / 474
4940 - incorrect FWD/REV cylinder ratio

[HBZN0845VBAF00184 - ]
-]
Cause:
Oil temperature too cold (converter driven units only).
Solution:
1. Increase oil temperature and retry. If problem remains at sump temps above 120 degrees F, try step 2.
2. Controlling valve is not functioning properly.
48050419D 06/10/2017
55.11 [55.DTC] / 475
4941 - Cylinder speed will not drop below start count speed
[HBZN0845VBAF00184 - ]
-]
Solution:
1. Retry calibrating three more times. Take note of the message being displayed previous to the error. If the display
reads: 1. C1H or C2H then excessive drag is emanating from the REV clutches.
48050419D 06/10/2017
55.11 [55.DTC] / 476
4942 - hold clutch exceeds 90 psi

[HBZN0845VBAF00184 - ]
-]
Context:
Take note of the message being displayed previous to the error. If the display reads:
Cause:
C3F or C4F - Holding clutch valve not performing properly.
Solution:
1. Replace valve 1 (F1) and retry.
48050419D 06/10/2017
55.11 [55.DTC] / 477
4943 - Fast fill 1 exceeds 300 ms

[HBZN0845VBAF00184 - ]
-]
Cause:
Valve 1 (F1) is not performing properly.
Solution:
1. Replace valve 1.
48050419D 06/10/2017
55.11 [55.DTC] / 478

[HBZN0845VBAF00184 - ]
-]
Cause:
Valve 2 (F2) is not performing properly.
Solution:
1. Replace valve 2.
48050419D 06/10/2017
55.11 [55.DTC] / 479

[HBZN0845VBAF00184 - ]
-]
Cause:
Valve 3 (R1) is not performing properly.
Solution:
1. Replace valve 3.
48050419D 06/10/2017
55.11 [55.DTC] / 480

[HBZN0845VBAF00184 - ]
-]
Cause:
Valve A is not performing properly.
Solution:
1. Replace valve A.
48050419D 06/10/2017
55.11 [55.DTC] / 481
4947 - Fast fill A exceeds 300 ms

[HBZN0845VBAF00184 - ]
-]
Cause:
Valve A is not performing properly.
Solution:
1. Replace valve A.
48050419D 06/10/2017
55.11 [55.DTC] / 482
4948 - Fast fill B exceeds 300 ms

[HBZN0845VBAF00184 - ]
-]
Cause:
Valve B is not performing properly.
Solution:
1. Replace valve B.
48050419D 06/10/2017
55.11 [55.DTC] / 483
4949 - Fast fill C exceeds 300 ms

[HBZN0845VBAF00184 - ]
-]
Cause:
Valve D is not performing properly.
Solution:
1. Replace valve D.
48050419D 06/10/2017
55.11 [55.DTC] / 484
4950 - Fast fill D exceeds 300 ms

[HBZN0845VBAF00184 - ]
-]
Cause:
Valve D is not performing properly.
Solution:
1. Replace valve D.
48050419D 06/10/2017
55.11 [55.DTC] / 485
4951 - Calibrating without park brake set

[HBZN0845VBAF00184 - ]
-]
Cause:
1. Park brake is not set.

2. Park brake inputs are not functioning properly.
Solution:
1. Set park brake.

2. Check park brake switches and wiring.
48050419D 06/10/2017
55.11 [55.DTC] / 486
4952 - Analog inching voltage too low

[HBZN0845VBAF00184 - ]
-]
Cause:
1. Faulty wiring causing open pot supply voltage or analog input between inching pot and ecu.
2. Faulty inching pot. Solution : Replace
Solution:
1. Repair wiring and/or connections between inching pot and ecu.
48050419D 06/10/2017
55.11 [55.DTC] / 487
4953 - Temperature sensor circuit shorted or open.

Solution:
1. Temperature sensor circuit (J1-C3 or J1-D1 ) shorted or open.
48050419D 06/10/2017
55.11 [55.DTC] / 488
4954 - Analog inching voltage too high

[HBZN0845VBAF00184 - ]
-]
Cause:
Analog inching voltage (J1-F3 ) too high.
Solution:
1. Faulty wiring causing open pot gnd or short to analog input between inching pot and ecu. Solution – Repair wiring
and/or connections between inching pot and ecu.
2. Faulty inching pot. Solution – Replace inching pot.
48050419D 06/10/2017
55.11 [55.DTC] / 489
4955 - Engine MPU SC or OC

[HBZN0845VBAF00184 - ]
-]
48050419D 06/10/2017
55.11 [55.DTC] / 490
4956 - Output MPU SC or OC

[HBZN0845VBAF00184 - ]
-]
48050419D 06/10/2017
55.11 [55.DTC] / 491
4957 - Cannot get shift constants from EEPROM

[HBZN0845VBAF00184 - ]
-]
NOTE: Not a field serviceable error.
48050419D 06/10/2017
55.11 [55.DTC] / 492
4958 - Group 1 enable low; should be high

[HBZN0845VBAF00184 - ]
-]
48050419D 06/10/2017
55.11 [55.DTC] / 493

[HBZN0845VBAF00184 - ]
-]
48050419D 06/10/2017
55.11 [55.DTC] / 494

[HBZN0845VBAF00184 - ]
-]
48050419D 06/10/2017
55.11 [55.DTC] / 495
4963 - Engine controller not communicating

[HBZN0845VBAF00184 - ]
-]
NOTE: Pointer in capcom20 gets too big.

Not a field serviceable error.
48050419D 06/10/2017
55.11 [55.DTC] / 496
4964 - AWD controller not communicating

[HBZN0845VBAF00184 - ]
-]
48050419D 06/10/2017
55.11 [55.DTC] / 497
4965 - Transmission controll not equipped for AWD control

[HBZN0845VBAF00184 - ]
-]
NOTE: Attempt to use non FWD controller on machine equipped with FWD.
48050419D 06/10/2017
55.11 [55.DTC] / 498
4967 - Sump temperature too high

[HBZN0845VBAF00184 - ]
-]
Context:
Sump temperature too high.
48050419D 06/10/2017
55.11 [55.DTC] / 499
4968 - Slippage in clutch

[HBZN0845VBAF00184 - ]
-]
Context:
Unexpected slippage in active speed clutch.
48050419D 06/10/2017
55.11 [55.DTC] / 500

[HBZN0845VBAF00184 - ]
-]
Context:
Driver 13 cannot get up to requested current.
Solution:
1. Open or short to ground in circuit from output pin J3-J3 to return pin J3-K1.
48050419D 06/10/2017
55.11 [55.DTC] / 501
4970 - Driver SC
[HBZN0845VBAF00184 - ]
-]
Context:
Driver 13 cannot get down to requested current.
Solution:
1. Short to positive in circuit from output pin J3-J3 to return pin J3-K1.
48050419D 06/10/2017
55.11 [55.DTC] / 502
4971 - Variable need gear has taken on invalid value

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Invalid 5 bit selector code from shift handle.
48050419D 06/10/2017
55.11 [55.DTC] / 503

[HBZN0845VBAF00184 - ]
-]
Solution:
1. FORWARD (input pin J1-J1) and REVERSE (input pin J1-J2) are both active.
48050419D 06/10/2017
55.11 [55.DTC] / 504

[HBZN0845VBAF00184 - ]
-]
Cause:
NEUTRAL and REVERSE inputs are both active.
Solution:
1. NEUTRAL (input pin J2-A1) active and REVERSE (input pin J1-J2) passive.
2. NEUTRAL passive and REVERSE active.
48050419D 06/10/2017
55.11 [55.DTC] / 505

[HBZN0845VBAF00184 - ]
-]
Cause:
NEUTRAL and FORWARD inputs are both active.
Solution:
1. NEUTRAL (input pin J2-A1) active and FORWARD (input pin J1-J1) passive.
2. NEUTRAL passive and FORWARD active.
48050419D 06/10/2017
55.11 [55.DTC] / 506

[HBZN0845VBAF00184 - ]
-]
Solution:
1. FORWARD (input pin J1-J1) NEUTRAL (input pin J2-A1) and REVERSE (input pin J1-J2) are all passive.
48050419D 06/10/2017
55.11 [55.DTC] / 507
4976 - Driver short circuit

[HBZN0845VBAF00184 - ]
-]
Context:
Solution:
1. Short to positive in circuit from output pin J3-J1 to return pin J3-J2.
48050419D 06/10/2017
55.11 [55.DTC] / 508
4977 - Driver short circuit

[HBZN0845VBAF00184 - ]
-]
Context:
Solution:
1. Short to positive in circuit from output pin J3-H2 to return pin J3-H3.
48050419D 06/10/2017
55.11 [55.DTC] / 509

[HBZN0845VBAF00184 - ]
-]
Context:
Solution:
1. Open or short to ground in circuit from output pin J3-J1 to return pin J3-J2.
48050419D 06/10/2017
55.11 [55.DTC] / 510

[HBZN0845VBAF00184 - ]
-]
Context:
Solution:
1. Open or short to ground in circuit from output pin J3-H2 to return pin J3-H3.
48050419D 06/10/2017
55.11 [55.DTC] / 511
4980 - illegal wheel mode change out of neutral

[HBZN0845VBAF00184 - ]
-]
Context:
WHEELS-UP and WHEELS-DOWN are both active.
Legal conditions are:
Solution:
1. WHEELS-UP (input on J2-C3) active and WHLS-DWN (input on J2-B1) passive.

2. WHEELS-UP passive and WHEELS-DOWN active.
3. WHEELS-UP passive and WHEELS-DOWN passive.
48050419D 06/10/2017
55.11 [55.DTC] / 512

[HBZN0845VBAF00184 - ]
-]
Context:
PARK and FORWARD are both active.
Solution:
1. PARK (input pin J2-B3) active and FORWARD (input pin J1-J1) passive.
2. PARK passive and FORWARD passive.
3. PARK passive and FORWARD active.
48050419D 06/10/2017
55.11 [55.DTC] / 513

[HBZN0845VBAF00184 - ]
-]
Context:
PARK is active but NEUTRAL is passive.
Solution:
1. PARK (input pin J2-B3) active and NEUTRAL (input pin J2-A1) active.
2. PARK passive and NEUTRAL passive.
48050419D 06/10/2017
55.11 [55.DTC] / 514

[HBZN0845VBAF00184 - ]
-]
Context:
PARK is active but Neutral is passive.
Solution:
1. PARK (input pin J2-B3) active and Neutral (input pin J2-A1) active.
2. PARK passive and Neutral active.
3. PARK passive and Neutral passive.
48050419D 06/10/2017
55.11 [55.DTC] / 515

[HBZN0845VBAF00184 - ]
-]
Context:
NOT PARK and NEUTRAL are both passive.
Solution:
1. NOT PARK (input pin J1-K1) active and NEUTRAL (input pin J2-A1) passive.
2. NOT PARK passive and NEUTRAL active.
48050419D 06/10/2017
55.11 [55.DTC] / 516

[HBZN0845VBAF00184 - ]
-]
Context:
PARK and NOT PARK are both active.
Solution:
1. PARK (input pin J2-B3) passive and NOT PARK (input pin J1-K1) active.
2. PARK active and NOT PARK passive.
48050419D 06/10/2017
55.11 [55.DTC] / 517

[HBZN0845VBAF00184 - ]
-]
Solution:
1. PARK (input pin J2-B3) passive and NOT PARK (input pin J1-K1) active.
2. PARK active and NOT PARK passive.
48050419D 06/10/2017
55.11 [55.DTC] / 518

[HBZN0845VBAF00184 - ]
-]
Solution:
1. NOT PARK (input pin J1-K1) active and PARK (input pin J2-B3) passive.
2. NOT PARK passive and PARK active.
48050419D 06/10/2017
55.11 [55.DTC] / 519

[HBZN0845VBAF00184 - ]
-]
Solution:
1. NOT PARK (input pin J1-K1) active and PARK (input pin J2-B3) passive.
2. NOT PARK passive and PARK active.
48050419D 06/10/2017
55.11 [55.DTC] / 520
4989 - Slippage in clutch

[HBZN0845VBAF00184 - ]
-]
Context:
Unexpected slippage in active directional clutch.
48050419D 06/10/2017
55.11 [55.DTC] / 521
4990 - group 1 enable low; should be high

[HBZN0845VBAF00184 - ]
-]
Context:
48050419D 06/10/2017
55.11 [55.DTC] / 522

[HBZN0845VBAF00184 - ]
-]
Context:
48050419D 06/10/2017
55.11 [55.DTC] / 523

[HBZN0845VBAF00184 - ]
-]
Context:
48050419D 06/10/2017
55.11 [55.DTC] / 524
4993 - hold clutch exceeds 90 psi

[HBZN0845VBAF00184 - ]
-]
Cause:
Valve being calibrated is not performing properly.
Solution:
1. Replace valve being calibrated at time of error.
48050419D 06/10/2017
55.11 [55.DTC] / 525
4994 - incorrect FWD/REV cylinder ratio

[HBZN0845VBAF00184 - ]
-]
Cause:
Oil temperature too cold (converter driven units only)
Solution:
1. Increase oil temperature and retry. If problem remains at sump temps above 120 degrees F, try step 2.
Controlling valve is not functioning.
48050419D 06/10/2017
55.11 [55.DTC] / 526
5160 - AWD Controller detects Yellow Warning

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Check error code using the EST tool checking the AWD error code list.
48050419D 06/10/2017
55.11 [55.DTC] / 527
5161 - AWD Controller detects Red Warning

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Check error code using the EST tool checking the AWD error code list.
48050419D 06/10/2017
55.11 [55.DTC] / 528
5301 - No connection at CAN Bus number 1

[HBZN0845VBAF00184 - ]
-]
Context:
CAN Bus #1 is not connected.
Solution:
1. Check harness of CAN Bus #1 (EHC pin 26: CAN low; EHC pin 27: CAN high).
2. Check resistance between CAN high and CAN low at power off for being 60±5Ω.
48050419D 06/10/2017
55.11 [55.DTC] / 529
5308 - Ignition is switched on but no EEC1 message

Context:
Ignition is switched on but no EEC1 message (CAN ID 0x0CF00400) from Engine Controller Unit (ECU) is received.
Solution:
1. Check harness for CAN Bus #1 for connection of Engine Controller Unit (ECU).
2. Check harness for ignition connection to ECU
3. Check harness for ignition connection to EHC.
4. Check if right ECU version is installed.
48050419D 06/10/2017
55.11 [55.DTC] / 530
5311 - Ignition is switched on but no EEC2 message

Context:
Ignition is switched on but no EEC2 message from Engine Controller Unit (ECU) is received.
Solution:
1. Check harness for CAN Bus #1 for connection of Engine Controller Unit (ECU).
2. Check harness for ignition connection to ECU.
3. Check harness for ignition connection to EHC.
4. Check if right ECU version is installed.
48050419D 06/10/2017
55.11 [55.DTC] / 531
5314 - Engine is running but no ETC1 message

NOTE: Restart engine before checking error again.
Context:
Engine is running but no ETC1 message from Transmission Controller Unit (TCU) is received.
Solution:
1. Check harness for CAN Bus #1 for connection of Transmission Controller Unit (TCU).
2. Check if right TCU version is installed.
48050419D 06/10/2017
55.11 [55.DTC] / 532
5317 - Engine is running but no ETC2 message

Context:
Engine is running but no ETC2 message from Transmission Controller Unit (TCU) is received.
Solution:
1. Check harness for CAN Bus #1 for connection of Transmission Controller Unit (TCU).
2. Check if right TCU version is installed.
48050419D 06/10/2017
55.11 [55.DTC] / 533
5320 - Ignition is switched on but no AIC1 message

Context:
Ignition is switched on but no AIC1 (0x18FEB017) message from Advanced Instrument Cluster (AIC2) is received.
Solution:
1. Check harness for CAN Bus #1 for connection of Advanced Instrument Cluster (AIC2).
2. Check if right AIC2 version is installed.
3. Check if right AIC2 Software version is installed (1.9.0.0 or superior)
48050419D 06/10/2017
55.11 [55.DTC] / 534
5323 - Wrong engine speed

[HBZN0845VBAF00184 - ]
-]
Context:
Engine rpm value from CAN message EEC1 sent by Engine Controller Unit (ECU) with CAN ID 0x0CF00400 exceeds
the limit of 4000 rpm or is 0xFE00 (=error).
Solution:
1. Check Engine Controller Unit (ECU) for any errors.

2. Check rpm sensor of engine if possible.
48050419D 06/10/2017
55.11 [55.DTC] / 535
5324 - Wrong pedal position

[HBZN0845VBAF00184 - ]
-]
Context:
Accelerator pedal position value from CAN message EEC2 sent by Engine Controller Unit (ECU) with CAN ID
0x0CF00300 exceeds the limit of 100% or is 0xFE (=error).
Solution:
1. Check Engine Controller Unit (ECU) for any errors.

2. Check accelerator pedal potentiometers for any errors.
48050419D 06/10/2017
55.11 [55.DTC] / 536
5328 - Output shaft speed above maximum

[HBZN0845VBAF00184 - ]
-]
Context:
Transmission output speed value from CAN message ETC1 sent by Transmission Controller Unit (TCU) with CAN ID
0x00F00203 exceeds the limit of 5000 rpm.
Solution:
1. Check Transmission Controller Unit (TCU) for any errors.

2. Check rpm sensor of transmission output shaft if possible.
48050419D 06/10/2017
55.11 [55.DTC] / 537
5331 - Open circuit at pilot dump valve of AWD pump

[HBZN0845VBAF00184 - ]
-]
Context:
An open circuit at pilot dump valve of AWD pump was detected while engine is running.
Solution:
1. Check connector of pilot dump valve (MS) at AWD pump.

2. Check harness from EHC pin 59 to connector of pilot dump valve (MS) at AWD pump.
3. Check resistance of pilot dump valve solenoid (Ms) at AWD pump for being < 200Ω.
48050419D 06/10/2017
55.11 [55.DTC] / 538
5332 - Short circuit to ground at pilot dump valve of AWD pump

[HBZN0845VBAF00184 - ]
-]
Context:
A short circuit to ground at pilot dump valve of AWD pump was detected.
Solution:

3. Check resistance of pilot dump valve solenoid (MS) at AWD pump for being > 5Ω.
48050419D 06/10/2017
55.11 [55.DTC] / 539
5333 - Short circuit to power at pilot dump valve of AWD pump

[HBZN0845VBAF00184 - ]
-]
Context:
A short circuit to power supply at pilot dump valve of AWD pump was detected.
Solution:

3. Check resistance of pilot dump valve solenoid (MS) at AWD pump for being > 5Ω
48050419D 06/10/2017
55.11 [55.DTC] / 540
5341 - Open circuit at pilot valve on forward direction of AWD pump

[HBZN0845VBAF00184 - ]
-]
Context:
An open circuit at pilot valve for forward direction at AWD pump was detected while engine is running.
Solution:
1. Check connector of pilot valve (MY) at AWD pump.

2. Check harness from EHC pin 48 to connector of pilot valve (MY) at AWD pump.
3. Check resistance of pilot valve solenoid (MY) at AWD pump for being < 200Ω.
48050419D 06/10/2017
55.11 [55.DTC] / 541
5342 - Short circuit to ground at pilot valve on forward direction

of AWD pump
[HBZN0845VBAF00184 - ]
-]
Context:
A short circuit to ground at pilot valve for forward direction at AWD pump was detected.
Solution:

3. Check resistance of pilot valve solenoid (MY) at AWD pump for being > 5Ω.
48050419D 06/10/2017
55.11 [55.DTC] / 542
5343 - Short circuit to power at pilot valve on forward direction

of AWD pump
[HBZN0845VBAF00184 - ]
-]
ATTENTION: Do not operate machine.
Context:
A short circuit to power at pilot valve for forward direction at AWD pump was detected.
Solution:

3. Check resistance of pilot valve solenoid (MY) at AWD pump for being > 5Ω.
48050419D 06/10/2017
55.11 [55.DTC] / 543
5344 - Wrong current level at pilot valve on forward direction of

AWD pump
[HBZN0845VBAF00184 - ]
-]
Context:
Actual current of pilot valve for forward direction at AWD pump is different to commanded current.
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 544
5347 - Control software failure at pilot valve on forward direction

of AWD pump
[HBZN0845VBAF00184 - ]
-]
Context:
An internal error at current output for supplying pilot valve for forward direction at AWD pump was detected while
engine is running.
Solution:
1. Error might not be caused by hardware problems. Please contact Service.
48050419D 06/10/2017
55.11 [55.DTC] / 545
5351 - Open circuit at pilot valve on reverse direction of AWD pump

[HBZN0845VBAF00184 - ]
-]
Context:
An open circuit at pilot valve for reverse direction at AWD pump was detected while engine is running.
Solution:
1. Check connector of pilot valve (MZ) at AWD pump.

2. Check harness from EHC pin 10 to connector of pilot valve (MZ) at AWD pump.
3. Check resistance of pilot valve solenoid (MZ) at AWD pump for being < 200Ω.
48050419D 06/10/2017
55.11 [55.DTC] / 546
5352 - Short circuit to ground at pilot valve on reverse direction

of AWD pump
[HBZN0845VBAF00184 - ]
-]
Context:
A short circuit to ground at pilot valve for reverse direction at AWD pump was detected.
Solution:

3. Check resistance of pilot valve solenoid (MZ) at AWD pump for being > 5Ω.
48050419D 06/10/2017
55.11 [55.DTC] / 547
5353 - Short circuit to power at pilot valve on reverse direction of

AWD pump
[HBZN0845VBAF00184 - ]
-]
Context:
A short circuit to power at pilot valve for reverse direction at AWD pump was detected.
Solution:

3. Check resistance of pilot valve solenoid (MZ) at AWD pump for being > 5Ω.
48050419D 06/10/2017
55.11 [55.DTC] / 548
5354 - Wrong current level at pilot valve on reverse direction of

AWD pump
[HBZN0845VBAF00184 - ]
-]
Context:
Actual current of pilot valve for reverse direction of AWD pump is different to commanded current.
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 549
5357 - Control software failure at pilot valve on reverse direction

of AWD pump
[HBZN0845VBAF00184 - ]
-]
Context:
An internal error at current output for supplying pilot valve for reverse direction at AWD pump was detected while
engine is running.
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 550
5361 - Open circuit at pilot valve on left front wheel motor

[HBZN0845VBAF00184 - ]
-]
Context:
An open circuit at pilot valve of front left hydraulic motor was detected while engine is running.
Solution:
1. Check connector of pilot valve (MLE) at front left hydraulic motor.

2. Check harness from EHC pin 57 to connector of pilot valve (MLE) at front left hydraulic motor.
3. Check resistance of pilot valve solenoid (MLE) at left hydraulic motor for being < 200Ω.
48050419D 06/10/2017
55.11 [55.DTC] / 551
5362 - Short circuit to ground at pilot valve on left front wheel motor
[HBZN0845VBAF00184 - ]
-]
Context:
A short circuit to ground at pilot valve of front left hydraulic motor was detected.
Solution:

2. Check harness from EHC pin 57 to connector of pilot valve (MLE) at front left hydraulic motor
3. Check resistance of pilot valve solenoid (MLE) at front left hydraulic motor for being > 5Ω.
48050419D 06/10/2017
55.11 [55.DTC] / 552
5363 - Short circuit to power at pilot valve on left front wheel motor
[HBZN0845VBAF00184 - ]
-]
Context:
A short circuit to power at pilot valve of front left hydraulic motor was detected.
Solution:

2. Check harness from EHC pin 57 to connector of pilot valve (MLE) at front left hydraulic motor.
3. Check resistance of pilot valve solenoid (MLE) at front left hydraulic motor for being > 5Ω.
48050419D 06/10/2017
55.11 [55.DTC] / 553
5364 - Wrong current level at pilot valve on left front wheel motor
[HBZN0845VBAF00184 - ]
-]
Context:
Actual current at pilot valve of front left hydraulic motor is different to commanded current.
Solution:
1. Check harness from EHC pin 57 to connector of pilot valve (MLE) of front left hydraulic motor.
48050419D 06/10/2017
55.11 [55.DTC] / 554
5367 - Control software failure at pilot valve on left front wheel

motor
[HBZN0845VBAF00184 - ]
-]
Context:
An internal error at current output for supplying pilot valve of front left hydraulic motor was detected while engine is
running.
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 555
5371 - Open circuit at pilot valve on right front wheel motor

[HBZN0845VBAF00184 - ]
-]
Context:
An open circuit at pilot valve of front right hydraulic motor was detected while engine is running.
Solution:
1. Check connector of pilot valve (MRI) at front right hydraulic motor.

2. Check harness from EHC pin 4 to connector of pilot valve (MRI) at front right hydraulic motor.
3. Check resistance of pilot valve solenoid (MRI) at right hydraulic motor for being < 200Ω.
48050419D 06/10/2017
55.11 [55.DTC] / 556
5372 - Short circuit to ground at pilot valve on right front wheel

motor
[HBZN0845VBAF00184 - ]
-]
Context:
A short circuit to ground at pilot valve of front right hydraulic motor was detected.
Solution:

3. Check resistance of pilot valve solenoid (MRI) at front right hydraulic motor for being > 5Ω.
48050419D 06/10/2017
55.11 [55.DTC] / 557
5373 - Short circuit to power at pilot valve on right front wheel motor
[HBZN0845VBAF00184 - ]
-]
Context:
A short circuit to power at pilot valve of front right hydraulic motor was detected.
Solution:

3. Check resistance of pilot valve solenoid (MRI) at front right hydraulic motor for being > 5Ω.
48050419D 06/10/2017
55.11 [55.DTC] / 558
5374 - Wrong current level at pilot valve on right front wheel motor
[HBZN0845VBAF00184 - ]
-]
Context:
Actual current at pilot valve of front right hydraulic motor is different to commanded current.
Solution:
1. Check harness from EHC pin 4 to connector of pilot valve (MRI) of right hydraulic motor.
48050419D 06/10/2017
55.11 [55.DTC] / 559
5377 - Control software failure at pilot valve on right front wheel

motor
[HBZN0845VBAF00184 - ]
-]
Context:
An internal error at current output for supplying pilot valve of front right hydraulic motor was detected while engine is
running.
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 560
5379 - Comparison error of rear axle rpm and CAN value TCU ETC1
[HBZN0845VBAF00184 - ]
-]
Context:
Difference between rpm sensor mounted at the rear axle related to the value of CAN message ETC1 sent by TCU is
greater than 500rpm.
Solution:
1. Check harness from EHC pin 34 to connector of rear axle rpm sensor.
2. Check distance of rear axle rpm sensor to the toothed wheel disk.
3. Check rear frequency value at message DIAG_INP_03 sent by EHC with ID 0x00FFC82E at CAN Bus #1 for being
reasonable (see ES-BI017 Grader CAN Spec document for further information.
4. Check transmission output speed value at message ETC1 sent by TCU with ID 0x00F00203 at CAN Bus #1 for
being reasonable (see ES-BI017 Grader CAN Spec document for further information.
5. Check rpm sensor of transmission output shaft if possible.
48050419D 06/10/2017
55.11 [55.DTC] / 561
5381 - Open circuit at PIN 2 on left front wheel speed sensor

[HBZN0845VBAF00184 - ]
-]
Context:
An open circuit at channel A of front left wheel speed sensor was detected while engine is running.
Solution:
1. Check connector of left front wheel speed sensor.

2. Check harness from EHC pin 38 to connector of left front wheel speed sensor pin 2.
48050419D 06/10/2017
55.11 [55.DTC] / 562
5382 - Short circuit to ground at PIN 2 on left front wheel speed

sensor
[HBZN0845VBAF00184 - ]
-]
Context:
A short circuit to ground at channel A of front left wheel speed sensor was detected.
Solution:

48050419D 06/10/2017
55.11 [55.DTC] / 563
5383 - Short circuit to power at PIN 2 on left front wheel speed

sensor
[HBZN0845VBAF00184 - ]
-]
Context:
A short circuit to power at channel A of front left wheel speed sensor was detected.
Solution:

48050419D 06/10/2017
55.11 [55.DTC] / 564
5384 - Open circuit at PIN 4 on left front wheel speed sensor

[HBZN0845VBAF00184 - ]
-]
Context:
An open circuit at channel B of front left wheel speed sensor was detected while engine is running.
Solution:

48050419D 06/10/2017
55.11 [55.DTC] / 565
5385 - Short circuit to ground at PIN 4 on left front wheel speed

sensor
[HBZN0845VBAF00184 - ]
-]
Context:
A short circuit to ground at channel B of front left wheel speed sensor was detected.
Solution:
1. Check connector of left front wheel speed sensor pin 4.

48050419D 06/10/2017
55.11 [55.DTC] / 566
5386 - Short circuit to power at PIN 4 on left front wheel speed

sensor
[HBZN0845VBAF00184 - ]
-]
Context:
A short circuit to power at channel B of front left wheel speed sensor was detected.
Solution:
1. Check connector of left front wheel speed sensor pin 4.

48050419D 06/10/2017
55.11 [55.DTC] / 567
5387 - Open circuit at power connection PIN 1 on left front wheel

speed sensor
[HBZN0845VBAF00184 - ]
-]
Context:
An open circuit at power supply connection of front left wheel speed sensor was detected while engine is running.
Solution:

2. Check harness from time relay K_TIME pin 87 to connector of left front wheel speed sensor pin 1.
48050419D 06/10/2017
55.11 [55.DTC] / 568
5388 - Open circuit at ground connection PIN 3 on left front wheel

speed sensor
[HBZN0845VBAF00184 - ]
-]
Context:
An open circuit at ground connection of front left wheel speed sensor was detected while engine is running.
Solution:

3. Check harness from left front wheel speed sensor pin 3 to EHC pin 1 for having resistance of 40±2Ω.
48050419D 06/10/2017
55.11 [55.DTC] / 569
5389 - Open circuit at resistor ground connection on left front

wheel speed sensor
[HBZN0845VBAF00184 - ]
-]
Context:
An open circuit at resistor ground connection of front left wheel speed sensor was detected while engine is running.
Solution:

3. Check fuse F27.
48050419D 06/10/2017
55.11 [55.DTC] / 570
5390 - Different frequencies at PIN 2/4 on left front wheel speed

sensor
[HBZN0845VBAF00184 - ]
-]
Context:
Difference of channel A and channel B of front left wheel speed sensor is too high.
Solution:
1. Check harness from EHC pin 38 to connector of front left wheel speed sensor pin 2 for loose connection.
3. Replace front left wheel speed sensor.
48050419D 06/10/2017
55.11 [55.DTC] / 571
5391 - Direction failure on left front wheel speed sensor

[HBZN0845VBAF00184 - ]
-]
Context:
Direction information can not be determined by channel A and B of front left wheel speed sensor while engine is
running.
Solution:
3. Check mounting position of front left wheel speed sensor.
48050419D 06/10/2017
55.11 [55.DTC] / 572
5392 - Wrong input signals on left front wheel speed sensor

[HBZN0845VBAF00184 - ]
-]
Context:
An internal error was detected when reading in frequency inputs of front left wheel speed sensor.
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 573
5393 - Revolutions on left front wheel speed sensor above

maximum
[HBZN0845VBAF00184 - ]
-]
Context:
Measured frequency of front left wheel speed sensor exceeds the maximum measurable speed.
Solution:
1. Check power supply of front left wheel speed sensor at sensor connector pin 1 for being constant.
48050419D 06/10/2017
55.11 [55.DTC] / 574
5401 - Open circuit at PIN 2 on right front wheel speed sensor

[HBZN0845VBAF00184 - ]
-]
Context:
An open circuit at channel A of front right wheel speed sensor was detected while engine is running.
Solution:
1. Check connector of right front wheel speed sensor.

2. Check harness from EHC pin 42 to connector of right front wheel speed sensor pin 2.
48050419D 06/10/2017
55.11 [55.DTC] / 575
5402 - Short circuit to ground at PIN 2 on right front wheel speed

sensor
[HBZN0845VBAF00184 - ]
-]
Context:
A short circuit to ground at channel A of front right wheel speed sensor was detected.
Solution:

48050419D 06/10/2017
55.11 [55.DTC] / 576
5403 - Short circuit to power at PIN 2 on right front wheel speed

sensor
[HBZN0845VBAF00184 - ]
-]
Context:
A short circuit to power at channel A of front right wheel speed sensor was detected.
Solution:

48050419D 06/10/2017
55.11 [55.DTC] / 577
5404 - Open circuit at PIN 4 on right front wheel speed sensor

[HBZN0845VBAF00184 - ]
-]
Context:
An open circuit at channel B of front right wheel speed sensor was detected while engine is running.
Solution:

48050419D 06/10/2017
55.11 [55.DTC] / 578
5405 - Short circuit to ground at PIN 4 on right front wheel speed

sensor
[HBZN0845VBAF00184 - ]
-]
Context:
A short circuit to ground at channel B of front right wheel speed sensor was detected.
Solution:

48050419D 06/10/2017
55.11 [55.DTC] / 579
5406 - Short circuit to power at PIN 4 on right front wheel speed

sensor
[HBZN0845VBAF00184 - ]
-]
Context:
A short circuit to power at channel B of front right wheel speed sensor was detected.
Solution:

48050419D 06/10/2017
55.11 [55.DTC] / 580
5407 - Open circuit at power connection PIN 1 on right front wheel

speed sensor
[HBZN0845VBAF00184 - ]
-]
Context:
An open circuit at power supply connection of front right wheel speed sensor was detected while engine is running.
Solution:

2. Check harness from time relay K_TIME pin 87 to connector of right front wheel speed sensor pin 1.
48050419D 06/10/2017
55.11 [55.DTC] / 581
5408 - Open circuit at ground connection PIN 3 on right front wheel

speed sensor
[HBZN0845VBAF00184 - ]
-]
Context:
An open circuit at ground connection of front right wheel speed sensor was detected while engine is running.
Solution:

3. Check harness from right front wheel speed sensor pin 3 to EHC pin 1 for having resistance of 40±2Ω.
48050419D 06/10/2017
55.11 [55.DTC] / 582
5409 - Open circuit at resistor ground connection on right front

wheel speed sensor
[HBZN0845VBAF00184 - ]
-]
Context:
An open circuit at resistor ground connection of front right wheel speed sensor was detected while engine is running
Solution:

3. Check fuse F27.
48050419D 06/10/2017
55.11 [55.DTC] / 583
5410 - Different frequencies at PIN 2/4 on right front wheel speed

sensor
[HBZN0845VBAF00184 - ]
-]
Context:
Difference of channel A and channel B of front right wheel speed sensor is too high.
Solution:
1. Check harness from EHC pin 42 to connector of front right wheel speed sensor pin 2 for loose connection.
3. Replace front right wheel speed sensor.
48050419D 06/10/2017
55.11 [55.DTC] / 584
5411 - Direction failure on right front wheel speed sensor

[HBZN0845VBAF00184 - ]
-]
Context:
Direction information can not be determined by channel A and B of front right wheel speed sensor while engine is
running.
Solution:
3. Check mounting position of front right wheel speed sensor.
48050419D 06/10/2017
55.11 [55.DTC] / 585
5412 - Wrong input signals on right front wheel speed sensor

[HBZN0845VBAF00184 - ]
-]
Context:
An internal error was detected when reading in frequency inputs of front right wheel speed sensor.
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 586
5413 - Revolutions on right front wheel speed sensor above

maximum
[HBZN0845VBAF00184 - ]
-]
Context:
Measured frequency of front right wheel speed sensor exceeds the maximum measurable speed.
Solution:
1. Check power supply of front right wheel speed sensor at sensor connector pin 1 for being constant.
48050419D 06/10/2017
55.11 [55.DTC] / 587
5421 - Open circuit at forward pressure sensor

[HBZN0845VBAF00184 - ]
-]
Context:
An open circuit at forward pressure sensor was detected while engine is running.
Solution:
1. Check connector of forward pressure sensor.

2. Check harness from EHC pin 6 to connector of forward pressure sensor pin 1.
3. Check fuse F25.
48050419D 06/10/2017
55.11 [55.DTC] / 588
5422 - Short circuit to power at forward pressure sensor

[HBZN0845VBAF00184 - ]
-]
Context:
A short circuit to power at forward pressure sensor was detected.
Solution:
1. Check connector of forward pressure sensor

2. Check harness from EHC pin 6 to connector of forward pressure sensor pin 1.
48050419D 06/10/2017
55.11 [55.DTC] / 589
5426 - Return line pressure at pump port A above allowed value

[HBZN0845VBAF00184 - ]
-]
Context:
Return line pressure exceeds maximum when driving machine reverse.
Solution:
1. Check current of forward pressure sensor pin 1) for having reasonable current values (4..20mA = 1..450bar) when
ignition is on or engine is running.
2. Check forward pressure sensor being connected to EHC pin 6 and reverse pressure sensor being connected to
EHC pin 7.
48050419D 06/10/2017
55.11 [55.DTC] / 590
5427 - Forward pressure sensor test failed

[HBZN0845VBAF00184 - ]
-]
Context:
Forward pressure sensor shows pressure exceeding 10.40bar when trying to activate AWD system.
Solution:
1. Check current of forward pressure sensor pin 1 for having reasonable current values (4.20mA = 1.450bar) when
ignition is on or engine is running.
48050419D 06/10/2017
55.11 [55.DTC] / 591
5431 - Open circuit at reverse pressure sensor

[HBZN0845VBAF00184 - ]
-]
Context:
An open circuit at reverse pressure sensor was detected while engine is running.
Solution:
1. Check connector of reverse pressure sensor.

2. Check harness from EHC pin 7 to connector of reverse pressure sensor pin 1.
3. Check fuse F25.
48050419D 06/10/2017
55.11 [55.DTC] / 592
5432 - Short circuit to power at reverse pressure sensor

[HBZN0845VBAF00184 - ]
-]
Context:
A short circuit to power at reverse pressure sensor was detected.
Solution:
1. heck connector of reverse pressure sensor.

2. Check harness from EHC pin 7 to connector of reverse pressure sensor pin 1.
48050419D 06/10/2017
55.11 [55.DTC] / 593
5436 - Return line pressure at pump port B above allowed value

[HBZN0845VBAF00184 - ]
-]
Context:
Return line pressure exceeds maximum when driving machine forward
Solution:
1. Check current of reverse pressure sensor pin 1 for having reasonable current values (4..20mA = 1..450bar) when
ignition is on and/or engine is running.
2. Check forward pressure sensor being connected to EHC pin 6 and reverse pressure sensor being connected to
EHC pin 7.
48050419D 06/10/2017
55.11 [55.DTC] / 594
5437 - Return line pressure exceeds maximum when driving

machine forward
[HBZN0845VBAF00184 - ]
-]
Context:
Reverse pressure sensor shows pressure exceeding 10..40bar when trying to activate AWD system.
Solution:
1. Check current of reverse pressure sensor pin 1 for having reasonable current values (4..20mA = 1..450bar) when
ignition is on and/or engine is running.
48050419D 06/10/2017
55.11 [55.DTC] / 595
5440 - Sensor test at reverse pressure sensor failed

[HBZN0845VBAF00184 - ]
-]
Context:
Forward pressure sensor shows pressure exceeding 10..40bar when activating AWD system.
Solution:
1. Check fuse F21.

2. Check power supply of drive behavior module pin 6.
3. Check module pin 7 being connected to CAN high and module pin 8 being connected to CAN low of CAN Bus #1.
48050419D 06/10/2017
55.11 [55.DTC] / 596
5442 - AWD mode key not available on drive behavior module C6

[HBZN0845VBAF00184 - ]
-]
Context:
Right key of drive behavior module can not be found.
Solution:
1. Check if correct drive behavior module is installed.
48050419D 06/10/2017
55.11 [55.DTC] / 597
5443 - Incorrect status of AWD mode key on drive behavior module

C6
[HBZN0845VBAF00184 - ]
-]
Context:
Internal key state error occurred when reading right key of drive behavior module.
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 598
5445 - Creep mode key not available on drive behavior module C6

[HBZN0845VBAF00184 - ]
-]
Context:
Left key of drive behavior module can not be found.
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 599
5446 - Incorrect status of creep mode key on drive behavior module

C6
[HBZN0845VBAF00184 - ]
-]
Context:
Internal key state error occurred when reading left key of drive behavior module.
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 600
5448 - Encoder button not available on drive behavior module C6

[HBZN0845VBAF00184 - ]
-]
Context:
Encoder button of drive behavior module can not be found.
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 601
5451 - Drive behavior encoder not available on module C6

[HBZN0845VBAF00184 - ]
-]
Context:
Encoder drive behavior module can not be found.
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 602
5452 - Incorrect status of drive behavior encoder on module C6

[HBZN0845VBAF00184 - ]
-]
Context:
Internal encoder state error occurred when reading encoder of drive behavior module.
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 603
5459 - Logical error at brake pressure switches ZR1 and VG1

[HBZN0845VBAF00184 - ]
-]
Context:
Brake pressure switches do not show same state when ignition was turned on.
Solution:
1. Push and release again brake pedal and restart ignition.

2. Check connectors of brake pressure switches.
3. Check harness of brake pressure switches at EHC pin 17 and pin 19.
48050419D 06/10/2017
55.11 [55.DTC] / 604
5461 - Open circuit at neutral contact of accelerator pedal

[HBZN0845VBAF00184 - ]
-]
ATTENTION: Accelerator pedal is a low side switch.
Context:
An open circuit at neutral contact of accelerator pedal was detected while engine is running.
Solution:
1. Check connector of accelerator pedal.

2. Check harness from EHC pin 36 to accelerator pedal connector pin D.
3. Use diagnostic part of Grader Desk or EST software to locate any unreasonable switch states or sensor values.
48050419D 06/10/2017
55.11 [55.DTC] / 605
5463 - Short circuit to ground at neutral contact of accelerator pedal

[HBZN0845VBAF00184 - ]
-]
ATTENTION: Accelerator pedal is a low side switch.

NOTE: Both switch states need to be detected correctly to reset error.
Context:
A short circuit to ground at neutral contact of accelerator pedal was detected.
Solution:
1. Check connector of accelerator pedal.

2. Check harness from EHC pin 36 to accelerator pedal connector pin D.
48050419D 06/10/2017
55.11 [55.DTC] / 606
5467 - Short circuit to power at FNR switch of gear shift unit

[HBZN0845VBAF00184 - ]
-]
NOTE: Neutral state needs to be detected correctly for resetting error.
Context:
More than one contact of F or N or R connections is active.
Solution:
1. Check connector of FNR switch.

2. Check EHC pin 14 being connected to FNR switch pin C.
3. Check EHC pin 15 being connected to FNR switch pin G.
4. Check EHC pin 16 being connected to FNR switch pin F.
48050419D 06/10/2017
55.11 [55.DTC] / 607
5469 - Logical error at FNR switch of gear shift unit

[HBZN0845VBAF00184 - ]
-]
Context:
Two of the FNR contacts are active.
Solution:
1. Check connector of FNR switch.

2. Check EHC pin 14 being connected to FNR switch pin C.
3. Check EHC pin 15 being connected to FNR switch pin G.
4. Check EHC pin 16 being connected to FNR switch pin F.
48050419D 06/10/2017
55.11 [55.DTC] / 608
5474 - Logical error at machine code plug

[HBZN0845VBAF00184 - ]
-]
Context:
Wrong machine code plug is installed at machine
Solution:
1. Check code plug located at drive behavior module.
48050419D 06/10/2017
55.11 [55.DTC] / 609
5475 - Wrong signal on digital input of machine code plug

[HBZN0845VBAF00184 - ]
-]
Context:
Some Digital inputs of code plug are connected with low side logic.
Solution:
1. Check code plug located at drive behavior module.
48050419D 06/10/2017
55.11 [55.DTC] / 610
5487 - Configuration incomplete

[HBZN0845VBAF00184 - ]
-]
Solution:
1. Use configuration part of Grader Desk or EST software to check machine configuration before operating machine.
2. Check if front wheel type is set correctly.
3. Check if rear wheel type is set correctly.
4. Check if transmission type is set correctly.
48050419D 06/10/2017
55.11 [55.DTC] / 611
5491 - Calibration of pump forward direction not complete

[HBZN0845VBAF00184 - ]
-]
Context:
Calibration of pilot valve solenoid of AWD pump for driving in forward direction was not calibrated successfully.
Solution:
1. Use calibration part of Grader Desk or EST software to run calibration before operating machine.
48050419D 06/10/2017
55.11 [55.DTC] / 612
5492 - Calibration of pump reverse direction not complete

[HBZN0845VBAF00184 - ]
-]
Context:
Calibration of pilot valve solenoid of AWD pump for driving in reverse direction was not calibrated successfully.
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 613
5493 - Calibration of left front wheel motor not complete

[HBZN0845VBAF00184 - ]
-]
Context:
Calibration of pilot valve solenoid of left hydraulic motor was not calibrated successfully.
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 614
5494 - Calibration of right front wheel motor not complete

[HBZN0845VBAF00184 - ]
-]
Context:
Calibration of pilot valve solenoid of right hydraulic motor was not calibrated successfully.
Solution:
48050419D 06/10/2017
55.11 [55.DTC] / 615
5495 - Low Voltage at 2nd ignition input of controller

[HBZN0845VBAF00184 - ]
-]
Context:
Redundant ignition input at EHC is not active.
Solution:
1. Restart engine before checking error again.

Check fuse F26.
2. Check harness from time relay K_TIME pin 87 to EHC pin 18.
48050419D 06/10/2017
55.11 [55.DTC] / 616
5497 - No charge pressure

[HBZN0845VBAF00184 - ]
-]
Context:
System pressure is lower than 10bar but the engine is running.
Solution:
1. Restart engine before checking error again.

Check charge pump for running properly.
2. Check all hoses and pipes of AWD system for any leakage.
3. Check fuse F25.
48050419D 06/10/2017
55.11 [55.DTC] / 617
5498 - Too high pressure at both hydraulic lines

[HBZN0845VBAF00184 - ]
-]
Context:
High pressure is detected at both hydraulic lines while engine is running.
Solution:
1. Use diagnostic part of Grader Desk or EST software to check pressure values from both pressure sensors.
2. Check hydrostatic pump and motors for internal leakage.
3. Check integrated flushing valve of hydraulic motors for being installed properly.
48050419D 06/10/2017
55.11 [55.DTC] / 618
9121 - Logical error when retreiving flash data

Cause:
AIC internal error.
Solution:
1. Reboot AIC (turn OFF and ON again).

2. If the error persists, re-program AIC software with the Service Tool.
3. If the error persists, replace AIC.
48050419D 06/10/2017
55.11 [55.DTC] / 619

Cause:
AIC internal error.
Solution:

48050419D 06/10/2017
55.11 [55.DTC] / 620

Cause:
AIC internal error.
Solution:

48050419D 06/10/2017
55.11 [55.DTC] / 621

Cause:
AIC internal error.
Solution:

48050419D 06/10/2017
55.11 [55.DTC] / 622
9128 - CAN timed out during operation

Cause:
CAN timed out during operation
Solution:
1. If error is permanent or repeats often, check CAN wiring harness and connections on the CAN bus circuits.
48050419D 06/10/2017
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Cause:
Solution:
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Cause:
Solution:
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Solution:
1. Check CAN bus (CAN H and CAN L) wiring continuity between machine's controllers.
3. Check AIC connectors (CN1 and CN2) condition.
4. Check Keypad connector.
5. Check AIC SW version (1.2.0.0 or above).
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9133 - Never started receiving message

Solution:
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Solution:
4. Check Keypad connector
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Solution:
4. Check Keypad connector.
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9160 - Hour Meter Failure - Both copies are wrong

Solution:
1. CAN communication interrupted during normal operation.

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9161 - Hour Meter Failure - one of two copies are wrong

Solution:

2. Faulty reading from component
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9162 - Hour Meter Failure - Pre-crank And After-crank Checks Are

Wrong
Solution:

2. Faulty reading from component
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9173 - Configuration Error - Engine Selection

Solution:
1. Reset the machine model through the config menu selecting the correct engine.
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9174 - Configuration Error - Transmission Selection

Solution:
1. Reset the machine model through the config menu selecting the correct transmission.
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9175 - Configuration Error - AWD selection

Solution:
1. Reset the machine model through the config menu selecting the correctly if the machine ia a AWD modeln.
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9176 - Configuration Error - not set

Solution:
1. Reset the machine model through the config menu selecting the correct transmission.
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19001 (DTC 1361) - Battery voltage is higher than expected

Control Module: ECU
Context:
The Electronic Control Unit (ECU) A-095 monitors battery voltage. If the A-095 determines that battery voltage has
exceeded 35.7 V , this fault will occur.
Cause:
Battery voltage is greater than 35.7 V.
1. Faulty charging system

Solution:
The engine must be running.
From To Value
Battery (+) terminal Battery (–) terminal There should be approximately 12 V
A. If there is not approximately 12 V, continue to Step 3.
B. If there is approximately 12 V, check the ECU A-095 for the appropriate software and re-flash, if necessary.
3. Check the charging system for proper operation.
A. If the charging system is not functioning properly, repair the charging system as necessary.
B. If the charging system is functioning properly, check the ECU A-095 for the appropriate software and re-flash,
if necessary.
has been resolved.
operation.
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19002 (DTC 2461) - Battery voltage is lower than expected

Control Module: ECU
Context:
The Electronic Control Unit (ECU) A-095 monitors battery voltage. If the A-095 determines that battery is less than
5.4 V, this fault will occur.
Cause:
Battery voltage is less than 5.4 V.
1. Faulty Battery
2. Faulty A-095 supply wiring
3. Faulty charging system
Solution:
From To Value
Battery (+) terminal Battery (–) terminal There should be approximately 12 V
A. If there is not approximately 12 V, Charge the battery and then perform load test on the battery. If the battery
passes the load test, continue to Step 3. If the battery fails the load test, continue to Step 5.
B. If there is approximately 12 V, continue to Step 3.

3. Check the voltage supply to the A-095.
The ignition switch must be in the ON position for voltage and OFF position for continuity.
Use a multimeter to perform the following wiring checks:
From To Value
X-911 pin 73, wire 6408F (GN) Chassis ground There should be approximately 12 V
X-911 pin 49, wire 6408E (GN) Chassis ground There should be approximately 12 V
X-911 pin 25, wire 6408C (GN) Chassis ground There should be approximately 12 V
X-911 pin 1, wire 6408B (GN) Chassis ground There should be approximately 12 V
X-911 pin 26, wire 6408D (GN) Chassis ground There should be approximately 12 V
X-911 pin 3, wire 057FZ (BK) Chassis ground There should be continuity.
X-911 pin 28, wire 057HD (BK) Chassis ground There should be continuity.
X-911 pin 75, wire 057HE (BK) Chassis ground There should be continuity.
X-911 pin 5, wire 057FE (BK) Chassis ground There should be continuity.
X-911 pin 52, wire 057HC (BK) Chassis ground There should be continuity.
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A. If the specified values are measured, continue to Step 4.
B. If the specified values are not measured, there is a failure in the A-095 supply wiring. Locate and repair the
failed conductor.
4. Check the charging system for proper operation.
A. If the charging system is not functioning properly, repair the charging system as necessary.
B. If the charging system is functioning properly, continue to Step 5.

5. Replace the battery.
Use the Electronic Service Tool (EST) to verify the status of this fault, 19002 (DTC 2461) – Battery voltage is
lower than expected.
A. If the fault has been resolved, perform a parasitic draw test to measure excessive current draw from the battery.
If an excessive draw is found, locate and repair as necessary and then return the machine to service..
has been resolved.
operation.
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19071 (DTC 2DDA) - SCR catalyst efficiency lower than first NOx
production threshold level
Control Module: ECU
NOTE: Because this fault causes inducement, it is necessary to perform the SCR Fault Repair Verification Test once
the fault has been resolved. See the corresponding configure menu in the Electronic Service Tool (EST).
Inducement configuration with the EST before you return the machine to service. See the corresponding configure
menu in the EST.
Context:
For information regarding the functional operation of the Selective Catalytic Reduction (SCR) system refer to the
appropriate manual. The instantaneous SCR catalyst efficiency is obtained from the Diesel Oxidation Catalyst (DOC)
upstream NOx sensor A-085 and the SCR downstream NOx sensor A-084. When the Engine Control Unit (ECU)
A-095 determines that the SCR catalyst efficiency is lower than expected, this fault occurs.
Cause:
The ECU A-095 calculated that the SCR catalyst efficiency is lower than expected.
1. Faulty SCR downstream NOx sensor A-084, measures too high values
2. Faulty DOC upstream NOx sensor A-085, measures too high values
3. Faulty NH3 sensor B-077, measures too high values
4. Faulty DEF/AdBlue® quality sensor B-076, measures too high values with too low DEF/AdBlue® concentration
at the same time
5. Faulty DEF/AdBlue® mixture concentration, too low
6. Faulty DEF/AdBlue® injection quantity, too low
7. Faulty DOC and Mixing chamber assembly, catalyst contamination or damage or mixing chamber damage
8. Faulty SCR assembly, catalyst contamination or damage
Solution:
1. Check for related faults.
Use the Electronic Service Tool (EST) to check for the presence of SCR Downstream NOx sensor A-084 fault
3528 (DTC 319E) – Downstream NOx sensor values are not plausible or DOC upstream NOx sensor A-085
fault 19062 (DTC E98E) – Upstream NOx sensor values are not plausible.
A. If either 3528 (DTC 319E) – Downstream NOx sensor values are not plausible or 19062 (DTC E98E) –
Upstream NOx sensor values are not plausible is present, resolve the relevant fault. Then determine if
fault 19071 (DTC 2DDA) – SCR catalyst efficiency lower than first NOx production threshold level is
also resolved.
B. If neither 3528 (DTC 319E) – Downstream NOx sensor values are not plausible nor 19062 (DTC E98E) –
Upstream NOx sensor values are not plausible is present, continue with Step 2.
Use the EST to check for the presence of SCR downstream NOx sensor A-084 fault 19422 (DTC 43CE) – Down-
stream NOx sensor signal is stuck at a constant value or NH3 sensor B-077 fault 3170 (DTC 38CB) – NH3
sensor signal is not changing.
A. If either 19422 (DTC 43CE) – Downstream NOx sensor signal is stuck at a constant value or 3170 (DTC
38CB) – NH3 sensor signal is not changing is present, resolve the relevant fault. Then determine if fault
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19071 (DTC 2DDA) – SCR catalyst efficiency lower than first NOx production threshold level is also
resolved.
B. If neither 19422 (DTC 43CE) – Downstream NOx sensor signal is stuck at a constant value nor 3170
(DTC 38CB) – NH3 sensor signal is not changing is present, continue with Step 3.
Use the EST to check for the presence of DEF/AdBlue® quality sensor B-076 fault 19140 (DTC 4BCA) – DEF/
AdBlue concentration is out of range or 19159 (DTC 144E) – DEF/AdBlue quality sensor internal failure
(concentration value is higher than expected) or 19160 (DTC 254E) – DEF/AdBlue quality sensor internal
failure (concentration value is lower than expected).
A. If either 19140 (DTC 4BCA) – DEF/AdBlue concentration is out of range or 19159 (DTC 144E) – DEF/
AdBlue quality sensor internal failure (concentration value is higher than expected) or 19160 (DTC
254E) – DEF/AdBlue quality sensor internal failure (concentration value is lower than expected) is
present, resolve the relevant fault. Then determine if fault 19071 (DTC 2DDA) – SCR catalyst efficiency
lower than first NOx production threshold level is also resolved.
B. If neither 19140 (DTC 4BCA) – DEF/AdBlue concentration is out of range nor 19159 (DTC 144E) – DEF/
AdBlue quality sensor internal failure (concentration value is higher than expected) nor 19160 (DTC
254E) – DEF/AdBlue quality sensor internal failure (concentration value is lower than expected) is
present, continue with Step 4.
4. Check the DEF/AdBlue® level and the DEF/AdBlue® mixture concentration.
Visually determine that the DEF/AdBlue® quality sensor B-076 is sufficiently immersed.
Use a refractometer to determine the concentration level of the DEF/AdBlue® mixture.
There should be 28.75 – 36.25% mixture concentration.
A. If there is an insufficient level of DEF/AdBlue® to adequately cover the DEF/AdBlue® quality sensor B-076 or
if the DEF/AdBlue® mixture concentration is not between 28.75 – 36.25%, drain the DEF/AdBlue® tank. Then
remove, inspect and clean, if necessary, the DEF/AdBlue® quality sensor B-076 to assure the DEF/AdBlue®
quality sensor B-076 cover holes are free of debris. Then fill the DEF/AdBlue® tank with properly concentrated
DEF/AdBlue® mixture.
B. If there is a sufficient level of DEF/AdBlue® to adequately cover the DEF/AdBlue® quality sensor B-076 and
the DEF/AdBlue® mixture concentration is between 28.75 – 36.25%, continue with Step 5.
5. Check dosing module Y-046 for deposits.
Remove the dosing module Y-046 and check for large deposits that would inhibit injection.
There should be no blockage.
A. If significant blockage does exist, repair or replace the dosing module Y-046, as required.
B. If significant blockage is not visible, do not install the dosing module Y-046 and continue with Step 6.
6. Check DEF/AdBlue® system for pressure, leaks and quantity.
Orient the dosing module Y-046 and a piece of cardboard to a location that would allow capture of a produced
spray pattern.
Use the EST and follow the on-screen instructions to perform a Urea Dosing System Test (UDST).
During the UDST record DEF/AdBlue® system pressure and capture the injection pattern on the cardboard.
Also, visually check for any DEF/AdBlue® system leakage.
There should be 9.00 – 11.00 bar (130.50 – 159.50 psi) before injection, a uniform spray pattern, and no leakage.
A. If the pressure is out of specification or the pattern is not uniform or leakage is seen, clean, repair or replace
system components, as required.
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B. If the pressure is within specification, the spray pattern is uniform, and leakage is not seen, do not install the
dosing module Y-046 and continue with Step 7.
7. Check the condition of the DEF/AdBlue® mixing chamber.
Visually inspect the DEF/AdBlue® and exhaust gas mixing chamber, through the dosing module Y-046 mounting
hole, for large deposits or damage.
A. If large deposits or damage is discovered, clean, repair or replace the DOC assembly, as required. If DOC
assembly is replaced, use EST to perform the Replacement of Catalyst - Reset ECU Data configuration. See
the corresponding configure menu in the EST.
B. If large deposits or damage is not discovered, install the dosing module Y-046 and continue with Step 8.
8. Check the condition of the DOC catalyst.
Remove the DOC upstream exhaust gas temperature sensor B-074.
Visually inspect the catalyst, through the DOC upstream exhaust gas temperature sensor B-074 mounting hole,
for substrate contamination or damage.
There should be no contamination or damage.
A. If substrate contamination or damage exists, replace the DOC assembly. Then use EST to perform the Re-
placement of Catalyst - Reset ECU Data configuration. See the corresponding configure menu in the EST.
B. If substrate contamination or damage does not exist, continue with Step 9.

9. Check the condition of the SCR catalyst.
Remove the SCR upstream exhaust gas temperature sensor B-070.
Visually inspect the catalyst, through the SCR upstream exhaust gas temperature sensor B-070 mounting hole,
for substrate contamination and damage.
There should be no contamination or damage.
A. If substrate contamination or damage exists, replace the SCR assembly. Then use EST to perform the Re-
placement of Catalyst - Reset ECU Data configuration. See the corresponding configure menu in the EST.
B. If substrate contamination or damage does not exist, continue with Step 10.
10. Replace the SCR downstream NOx sensor A-084.
Then use the EST to perform the Replacement of the Nox Downstream Sensor - Reset ECU Data configuration.
See the corresponding configure menu in the EST.
Then check to see if fault 19071 (DTC 2DDA) – SCR catalyst efficiency lower than first NOx production
threshold level is resolved.
A. If the fault is resolved, use the EST to perform the Engine Restart Counter Reset / Unlock Inducement config-
uration. See the corresponding configure menu in the EST. Then perform the SCR Fault Repair Verification
Test, see the corresponding configure menu in the EST. Then return the machine to service.
B. If the fault is not resolved, continue with Step 11.

11. Check the ECU A-095 software.
Use the EST to check for the appropriate ECU A-095 software.
A. If the ECU A-095 is not running appropriate software, use the EST to re-flash the ECU.
B. If the ECU A-095 is currently running appropriate software, use the EST to retrieve stored engine data, then
use ASIST to escalate a concern.
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19323 (DTC 94FB) - External engine shutdown request received

Control Module: ECU
Context:
This fault is for informational purposes and requires no action other than the resolution of the, external to the Engine
Control Unit (ECU) A-095, request for engine shutdown.
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19434 (DTC E26D) - ECU internal failure - EEPROM erase error

Control Module: ECU
Context:
The Electronic Control Unit (ECU) A-095 has the capability of reading and writing values to flash or EEPROM. The
A-095 monitors the reading and writing capability of this function. If the A-095 determines that flash memory can not
be performed, this fault will occur.
Solution:
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19435 (DTC E36D) - ECU internal failure - EEPROM read error

Control Module: ECU
Context:
A-095 monitors the reading and writing capability of this function. If the A-095 determines that at least three memory
blocks can not be read during this monitoring, this fault will occur.
Solution:
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19436 (DTC E46D) - ECU internal failure - EEPROM write error

Control Module: ECU
Context:
A-095 monitors the reading and writing capability of this function. If the A-095 determines that if one memory block
can not be written at least three times during this monitoring, this fault will occur.
Solution:
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Index
FAULT CODES - DTC

1310 - Hydraulic Filter Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1311 - Engine Air Filter Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1312 - Hydraulic Oil Temperature Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1313 - Hydraulic Oil Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1314 - Transmission Oil Temperature Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1315 - Transmission Oil Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1316 - Brake Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1317 - Steering Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1318 - Engine Coolant Temperature Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1319 - Engine Coolant Temperature High - Critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1320 - Engine Oil Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1321 - Engine Oil Pressure Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1322 - Engine Oil Pressure Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1323 - Battery Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1324 - Battery Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1325 - Engine Oil Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1326 - Coolant Level Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1331 - Electrical Charging System Voltage Too Low - Critical Level . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1332 - Water Detected In Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1333 - Engine Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1334 - Intake Manifold Temperature High - Critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1335 - Brake Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1346 - Engine Coolant Temperature Sensor Failure Out of Range High . . . . . . . . . . . . . . . . . . . . . . . 39
1347 - Engine Coolant Temperature Sensor Failure Short Circuit to Ground . . . . . . . . . . . . . . . . . . . 40
1348 - Engine Coolant Temperature Sensor Failure Out of Range Low . . . . . . . . . . . . . . . . . . . . . . . . 41
1351 - Voltmeter Input and Key Switch Input not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1353 - Engine Oil Pressure Sensor Failure Out of Range High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1354 - Engine Oil Pressure Sensor Failure Out of Range Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1355 - Transmission Oil Pressure Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1356 - Transmission Oil Pressure Sensor OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1358 - Fan Control Valve short to ground OR open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1359 - Fan Control Valve short to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1360 - OC/ SC to Bat. at Hydraulic Oil Temperature. Sensor Severity: yellow . . . . . . . . . . . . . . . . . . 49
1361 - SC to GND. at Hydraulic Oil Temperature. Sensor Severity: yellow . . . . . . . . . . . . . . . . . . . . . 50
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1364 - Intake Manifold Temperature Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
19001 (DTC 1361) - Battery voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 637
19002 (DTC 2461) - Battery voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 638
19071 (DTC 2DDA) - SCR catalyst efficiency lower than first NOx production threshold level . . . . . 640
19323 (DTC 94FB) - External engine shutdown request received . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643
19434 (DTC E26D) - ECU internal failure - EEPROM erase error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644
19435 (DTC E36D) - ECU internal failure - EEPROM read error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645
19436 (DTC E46D) - ECU internal failure - EEPROM write error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646
3000 - ZF power curves adjustable via CAN, TSC1 CAN interface disabled VCM2EDC . . . . . . . . . 52
3001 - Foot Throttle Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3002 - Foot Throttle Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3003 - Foot Throttle Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3004 - Foot Throttle Sensor - No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3005 (DTC 4B84) - Air filter clog or circuit failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3006 - Coolant Temperature Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3007 - Coolant Temperature Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . 60
3008 - Coolant Temperature Sensor - Signal Below Range Minimun . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3009 - Coolant Temperature Sensor - (via CAN) Null . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3010 - Air Intake Temperature Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . 63
3011 - Air Intake Temperature Sensor - Signal Above Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . 64
3012 - Air Intake Temperature Sensor - Signal Above Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . 65
3014 (DTC 4C84) - Air filter clog or circuit failure present for a long time . . . . . . . . . . . . . . . . . . . . . . . 68
3014 (DTC 4C84) - Air filter clog or circuit failure present for a long time . . . . . . . . . . . . . . . . . . . . . . . 66
3015 - Fuel Temperature Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3016 - Fuel Temperature Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3019 - Boost Pressure Sensor - Signal Above Range Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3021 - Boost Pressure Sensor - (via CAN) Null . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3022 - Boost Pressure Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3023 - Atmospheric Pressure Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3024 - Atmospheric Pressure Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . 76
3025 - Atmospheric Pressure Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . 77
3028 - OIL PRESSURE SENSOR LOW VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3029 - Oil Pressure Sensor - Short Circuit To Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3030 - Oil Pressure Sensor - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3031 - Oil Pressure Sensor - ADC Conversion Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3032 - Oil Pressure Sensor - Pressure Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3033 - Oil temperature sensor - signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3034 - Oil Temperature Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3035 - Oil Temperature Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3036 - Oil Temperature Sensor - CAN Transmission Disturbed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3037 - Boost Pressure Sensor - Signal Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3047 - High Pressure Pump Relay - Short Circuit to Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
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3048 - High Pressure Pump Relay - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3051 - Battery Voltage to ECM too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3052 - Battery Voltage to ECM too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3059 - ECM Afterrun was Interrupted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3060 - Cylinder 1 - Unclassifiable Error In Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3061 - Cylinder 1 - Injector Cable Short Circuit (Low Side To Battery) . . . . . . . . . . . . . . . . . . . . . . . . . 94
3062 - Cylinder1 - Signal Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3063 - Cylinder1 - Injector Cable Shortcircuit (High Side to Low Side) . . . . . . . . . . . . . . . . . . . . . . . . . 96
3074 - Cylinder 6 - Signal Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3075 - Cylinder 6 - Injector Cable Shortcircuit (High Side to Low Side) . . . . . . . . . . . . . . . . . . . . . . . . 108
3088 - Crankshaft sensor lost synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3089 - Crankshaft Sensor - Defective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3090 - Camshaft Sensor - Lost Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3091 - Camshaft Sensor Phase Synchronization Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3092 - Offset Between Camshaft and Crankshaft - Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3093 - Offset Between Camshaft And Crankshaft - Outside Boundaries . . . . . . . . . . . . . . . . . . . . . . . 122
3095 - Operating with Camshaft Sensor Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3096 (DTC 951B) - CAN A Bus off failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3102 - Rail Pressure Sensor CP3 - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3104 - Rail Pressure Relief Valve - Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3105 - Rail Pressure Relief Valve - Pressure Shock Requested . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3106 - Rail Pressure Relief Valve - Did Not Open After Pressure Shock . . . . . . . . . . . . . . . . . . . . . . . 129
3107 - Metering unit output short circuit to battery on low side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3108 - Metering Unit - Shortcircuit to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
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3110 - Rail Pressure Sensor Offset Monitoring - Signal Above Range Maximum . . . . . . . . . . . . . . . . 132
3111 - Rail Pressure Sensor Offset Monitoring - Signal Below Range Minimum . . . . . . . . . . . . . . . . . 133
3112 - Rail Pressure Sensor CP3 - Signal Above Maximum Range . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3113 - Main relay 1 (high pressure pump) - short to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3114 - Grid heater battery switch relay short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3118 - ECM 12V sensor supply voltage high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
3119 - ECM 12V sensor supply voltage low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3131 - Grid Heater Always Switched On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3137 - Metering Unit - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3138 - Metering Unit - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
3141 - Set point of fuel volume flow through metering unit is lower than calculated limit . . . . . . . . . . 142
3146 (DTC 4415) - Water in fuel detected or water in fuel circuit failure . . . . . . . . . . . . . . . . . . . . . . . . 143
3147 - Oil Temperature Sensor - Signal Above Normal Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3154 - Grid Heater Relay - Short Circuit To Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
3155 - Grid Heater Relay - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
3156 - Grid Heater Relay - No Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3176 - Fuel delivery exceeded threshold for pressure in overrun mode . . . . . . . . . . . . . . . . . . . . . . . . 149
3178 - Timeout of CAN Message BC2EDC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3179 - Timeout of CAN Message BC2EDC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
3180 - Time-out Of CAN Message VCM2EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
3188 - Cylinder 1 - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
3210 - Bank 1 - General Short Circuit On Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
3211 - Bank 1 - Injector Cable Short Circuit Low Side To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
3212 - Bank 1 - No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
3213 - Bank 1 - Unclassifiable Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3218 - Bank 2 - General Short Circuit On Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
3219 - Bank 2 - Injector Cable Short Circuit Low Side To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
3220 - Bank 2 No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3221 - Bank 2 - Unclassifiable Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3227 - Injection Processor Error - Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3228 - Injection Processor Error - Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3229 - Injection processor error - stop engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
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55.11 [55.DTC] / 650
3235 (DTC F936) - Exceeded the number of injections for a given engine speed . . . . . . . . . . . . . . . 175
3236 (DTC F836) - Number of injections is limited by system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3237 (DTC 1636) - Number of desired injections exceeds threshold . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3238 - Communication error of CJ940 processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
3242 - Recovery which is locked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
3243 - Recovery which is suppressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3244 - Recovery which is visible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
3245 - Communication supervision Watchdog/controller-Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3246 - Redundant shutoff paths during initial. / ECU HW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
3247 - Redundant shutoff paths during initial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
3248 - Redundant shutoff paths during initial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
3249 - TPU monitoring - Time deviation between TPU and system not plausible . . . . . . . . . . . . . . . . 187
3250 - ECU Software Varian Dataset failure - Dataset not valid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
3251 - Dataset - Requested Variant Could Not Be Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
3252 - Controller Watchdog - SPI Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
3253 - Error status ADC monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3258 - High side power - short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3259 - High side power - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3260 - Low side power - open load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
3261 - Shortcircuit to Battery or Excessive Temperature at Low Side Power Stage . . . . . . . . . . . . . . 198
3262 - Shortcircuit to Ground at Low Side Power Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
3265 - Energising time exceeds limit of overrun monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
3266 - Plausibility Error in Engine Speed Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3278 - Supply voltage CJ940 upper limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3279 - Supply voltage CJ940 lower limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3280 - Sensor Supply Voltage 1 - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3281 - Sensor Supply Voltage 1 - Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3290 - Turbo Compound Monitoring - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
3293 (DTC 2265) - Fuel rail pressure has exceeded maximum positive deviation limits . . . . . . . . . . 211
3301 (DTC 1565) - Fuel rail pressure has exceeded maximum negative deviation limits . . . . . . . . . 212
3305 (DTC 2765) - Fuel rail pressure has exceeded minimum limit . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
3309 (DTC 1865) - Fuel rail pressure has exceeded maximum limit . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
3315 - Minimum Number of Injections Not Reached - Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
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55.11 [55.DTC] / 651
3361 (DTC E16D) - There was an error during Write/Read EEPROM operation . . . . . . . . . . . . . . . . 219
3362 (DTC E1FD) - ECU internal failure - Fuel calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
3363 - Atmospheric Pressure Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
3368 (DTC F6EF) - Torque limitation caused by performance limiter . . . . . . . . . . . . . . . . . . . . . . . . . . 222
3370 (DTC F2EF) - Strong torque limitation from engine protection active . . . . . . . . . . . . . . . . . . . . . 223
3371 (DTC F3EF) - Strong torque limitation from injection system active . . . . . . . . . . . . . . . . . . . . . . 224
3403 (DTC 8A22) - Starter relay low side ECU driver circuit over temperature failure . . . . . . . . . . . . 225
3443 (DTC F3A2) - Torque limitation due to excessive coolant temperature . . . . . . . . . . . . . . . . . . . . 227
3444 (DTC F4A2) - Torque limitation due to excessive exhaust gas temperature . . . . . . . . . . . . . . . 228
3445 (DTC F5A2) - Torque limitation due to excessive fuel temperature . . . . . . . . . . . . . . . . . . . . . . . 229
3446 (DTC F6A2) - Torque limitation due to excessive intake air temperature . . . . . . . . . . . . . . . . . . 230
3447 (DTC F7A2) - Torque limitation due to excessive oil temperature . . . . . . . . . . . . . . . . . . . . . . . . 231
3448 (DTC F8A2) - Torque limitation due to turbocharger protection after start . . . . . . . . . . . . . . . . . 232
3449 (DTC E812) - ECU internal failure - Calculated engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
3457 (DTC 1374) - Intake manifold temperature sensor voltage is higher than expected . . . . . . . . . 234
3459 (DTC 1BD3) - Oil temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
3460 (DTC 2CD3) - Oil temperature too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
3461 (DTC E69D) - ECU internal failure - Timeout in the shut off path test error . . . . . . . . . . . . . . . . 240
3462 (DTC E79D) - ECU internal failure - Overvoltage monitoring error . . . . . . . . . . . . . . . . . . . . . . . 241
3491 (DTC F176) - Missing adjustment value programming for injector in cylinder 1 . . . . . . . . . . . . 242
3501 (DTC ED1D) - ECU internal failure - Software resets in DSM 0 . . . . . . . . . . . . . . . . . . . . . . . . . . 248
3502 (DTC EE1D) - ECU internal failure - Software resets in DSM 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 249
3507 (DTC 4761) - Engine cranked for too long or key switch failure . . . . . . . . . . . . . . . . . . . . . . . . . . 250
3508 (DTC FAEF) - Torque limitation active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
3581 (DTC FD8F) - Torque limitation is active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
3594 (DTC F7EF) - Torque limitation caused by SCR catalyst protection . . . . . . . . . . . . . . . . . . . . . . 254
3616 (DTC F1EF) - Torque limitation caused by turbo charger protection . . . . . . . . . . . . . . . . . . . . . . 255
3638 (DTC F4EF) - Torque limitation caused by engine brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
3652 (DTC 911B) - CAN A Bus off passive failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
3680 (DTC E536) - Engine speed limitation via fuel injection cut off is active . . . . . . . . . . . . . . . . . . . 259
3699 (DTC E56D) - ECU EEPROM memory failure - EEPData1 block . . . . . . . . . . . . . . . . . . . . . . . . 260
3703 (DTC 2B36) - The minimum rail pressure value necessary to allow fuel injection has not been
reached . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
3735 (DTC 8355) - Fuel metering unit has an over-temperature error . . . . . . . . . . . . . . . . . . . . . . . . . 262
3738 (DTC E71D) - ECU internal failure - ROM error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
3739 (DTC E13D) - ECU internal failure - Loss of synchronization to MM from CPU . . . . . . . . . . . . 265
48050419D 06/10/2017
55.11 [55.DTC] / 652
3740 (DTC E23D) - ECU internal failure - ECU shutdown test failure . . . . . . . . . . . . . . . . . . . . . . . . . . 266
3741 (DTC E33D) - ECU internal failure - Wrong set response time . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
3742 (DTC E43D) - ECU internal failure - SPI errors during MoCSOP execution . . . . . . . . . . . . . . . . 268
3743 (DTC E53D) - ECU internal failure - Undervoltage monitoring error . . . . . . . . . . . . . . . . . . . . . . 269
3745 (DTC E63D) - ECU internal failure - WDA is not working correctly . . . . . . . . . . . . . . . . . . . . . . . 270
3746 (DTC E73D) - ECU internal failure - Alarm task period error . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
3747 (DTC E83D) - ECU internal failure - Positive test failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
3749 (DTC E5B1) - ECU internal failure - Accelerator pedal position sensor . . . . . . . . . . . . . . . . . . . 273
3750 (DTC EC36) - ECU internal failure - Fuel injection energizing time is not plausible . . . . . . . . . 274
3751 (DTC ED36) - ECU internal failure - Fuel injection energizing phase is not plausible . . . . . . . 275
3752 (DTC EE36) - Fuel injection correction has exceeded a minimum limit . . . . . . . . . . . . . . . . . . . 276
3753 (DTC E5DD) - ECU internal failure - Injection quantity correction . . . . . . . . . . . . . . . . . . . . . . . . 277
3754 (DTC E6DD) - ECU internal failure - Rail pressure plausibility . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
3755 (DTC E7DD) - ECU internal failure - Torque request comparison . . . . . . . . . . . . . . . . . . . . . . . . 279
3756 (DTC E1DD) - ECU internal failure - Post injection quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
3757 (DTC E2DD) - ECU internal failure - Post injection shut-off failure . . . . . . . . . . . . . . . . . . . . . . . 281
3758 (DTC E3DD) - Post injection efficiency failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
3759 (DTC E8DD) - ECU internal failure - Torque request due to fuel pressure exceeds maximum
torque limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
3760 (DTC E9DD) - ECU internal failure - Torque request due to air control exceeds maximum torque
limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
3761 (DTC EADD) - ECU internal failure - Torque request exceeds maximum torque limit . . . . . . . 285
3762 (DTC EBDD) - ECU 5 volt supply voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . 286
3763 (DTC ECDD) - ECU 5 volt supply voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . 287
3764 (DTC F561) - ECU after run power interruption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
3767 (DTC E81D) - ECU internal failure - 'WDA active' reported due to errors in query/response
communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
3768 (DTC E91D) - ECU internal failure - 'ABE active' reported due to undervoltage detection . . . 292
3769 (DTC EA1D) - ECU internal failure - 'ABE active' reported due to overvoltage detection . . . . 293
3770 (DTC EB1D) - ECU internal failure - 'WDA/ABE active' reported . . . . . . . . . . . . . . . . . . . . . . . . . 294
3799 (DTC F345) - Fuel pressure relief valve is forced to open, perform pressure shock . . . . . . . . . 295
3805 (DTC 1D85) - Maximum rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
3808 (DTC 3C65) - High pressure pump fuel delivery quantity at low idle is too high . . . . . . . . . . . . 297
3810 (DTC 4125) - Rail pressure sensor value is intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
3811 (DTC E22D) - ECU internal failure - Sensor 5 volt supply 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
3812 (DTC 115D) - ECU temperature sensor 1 is too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
3813 (DTC 235D) - ECU temperature sensor 1 is too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
3814 (DTC E55D) - ECU temperature sensor error detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
3856 - Coolant Temperature does not rise as expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
3870 (DTC 936B) - CAN communication failure between vehicle controller and ECU - BC2ECU1
message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
3877 (DTC 647D) - Supply UB1 short to battery failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
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3880 (DTC 6A7D) - Actuator relay 3 circuit short to battery failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
3881 (DTC 757D) - Supply UB1 circuit short to ground failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
3882 (DTC 777D) - Supply UB2 short to ground failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
3883 (DTC 797D) - Supply UB3 short to ground failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
3903 (DTC 1A15) - Fuel temperature is too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
3905 (DTC 8814) - Intake air heater ECU driver has an over-temperature error . . . . . . . . . . . . . . . . 328
3911 (DTC 6455) - Fuel metering unit is shorted to battery voltage at the high side . . . . . . . . . . . . . 330
3912 (DTC 7555) - Fuel metering unit is shorted to ground at the high side . . . . . . . . . . . . . . . . . . . . 332
3916 (DTC 1745) - Fuel pressure relief valve has reached maximum allowed open time . . . . . . . . . 333
3936 (DTC E52D) - ECU internal: error sensor supplies voltage tracker . . . . . . . . . . . . . . . . . . . . . . . 334
3964 (DTC 125D) - ECU temperature sensor 2 is too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
3965 (DTC 245D) - ECU temperature sensor 2 is too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
3966 (DTC 165D) - ECU temperature sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . 337
3967 (DTC 275D) - ECU temperature sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . 338
4113 - Logical error at gear range signal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
4114 - Logical error at direction select signal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
4116 - Logical error at park brake status (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
4117 - Logic error at direction select signal 2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
4119 - Short circuit to ground at ride control (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
4120 - Short circuit to battery voltage at ride control (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
4121 - Open circuit at ride control (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
4133 - Short circuit to battery voltage or open circuit at transmission sump temperature sensor input
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
4134 - Short circuit to ground at transmission sump temperature sensor input (*) . . . . . . . . . . . . . . . 347
4135 - Short circuit to battery voltage or open circuit at retarder/ torque converter temperature sensor
input (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
4136 - Short circuit to ground at retarder/ torque converter temperature sensor input (*) . . . . . . . . . 349
4137 - Short circuit to battery voltage or open circuit at parking brake sensor input (*) . . . . . . . . . . . 350
4145 - Short circuit to battery voltage or open circuit at engine speed input (*) . . . . . . . . . . . . . . . . . . 351
4146 - Short circuit to ground at engine speed input (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
4147 - Logical error at engine speed input (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
4148 - Short circuit to battery voltage or open circuit at turbine speed input (*) . . . . . . . . . . . . . . . . . 354
4149 - Short circuit to ground at turbine speed input (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
4150 - Logical error at turbine speed input (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
4151 - Short circuit to battery voltage or open circuit at internal speed input (*) . . . . . . . . . . . . . . . . . 357
4152 - Short circuit to ground at internal speed input (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
4153 - Logical error at internal speed input (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
4154 - Short circuit to battery voltage or open circuit at output speed input (*) . . . . . . . . . . . . . . . . . . 360
4155 - Short circuit to ground at output speed input (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
4156 - Logical error at output speed input (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
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4158 - Output speed zero, doesn't fit to other speed signals (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
4160 - Gear range restriction signal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
4161 - Short circuit to battery voltage at load sensor input (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
4162 - Short circuit to ground open circuit at load sensor input (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
4163 - DCT1 timeout (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
4164 - Engine configuration timeout (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
4165 - EEC1 timeout (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
4166 - EEC3 timeout (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
4167 - Short circuit to battery at converter chutch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
4168 - Short circuit to ground at converter chutch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
4169 - Open circuit at converter clutch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
4170 - Slippage at converter lockup clutch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
4171 - Short circuit to battery voltage at display output (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
4172 - Short circuit to ground at display output (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
4173 - Engine torque can signal is defective (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
4174 - Reference engine torque can signal is defective (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
4175 - Actual engine torque can signal is defective (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
4176 - No friction torque can signal is defective (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
4177 - EEC2 timeout (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
4185 - Test mode signal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
4186 - Invalid park brake status (CAN) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
4209 - Short circuit to battery voltage at clutch K1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
4210 - Short circuit to ground at clutch K1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
4211 - Open circuit at clutch K1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
4228 - Short circuit to battery voltage at clutch KV (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
4229 - Short circuit to ground at clutch KV (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
4230 - Open circuit at clutch KV (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
4231 - Short circuit to battery voltage at clutch KR (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
4232 - Short circuit to ground at clutch KR (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
4233 - Open circuit at clutch KR (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
4241 - Short circuit to ground at relay reverse warning alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
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4242 - Short circuit to battery voltage at relay reverse warning alarm (*) . . . . . . . . . . . . . . . . . . . . . . . 403
4243 - Open circuit at relay reverse warning alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
4273 - Slippage at clutch K1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
4277 - Slippage at clutch KV (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
4278 - Slippage at clutch KR (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
4279 - Overtemp sump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
4282 - Differential pressure oil filter (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
4291 - Overtemp converter output (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
4292 - Short circuit to ground at joystick status indicator (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
4293 - Short circuit to battery voltage at joystick status indicator (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
4294 - Open circuit at joystick status indicator (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
4305 - Short circuit to battery voltage at power supply for sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . 417
4306 - Short circuit to ground at power supply for sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
4307 - Low voltage at battery (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
4308 - High voltage at battery (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
4309 - Error at valve power supply VPS1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
4310 - Error valve power supply VPS2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
4325 - VehicleID#1 timeout (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
4337 - General EEPROM fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
4338 - Configuration lost (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
4339 - Application error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
4341 - Clutch failure during AEB (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
4342 - Clutch adjustment data lost (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
4346 - Time Out of CAN Message "Gear Range Select" from AWD (*) . . . . . . . . . . . . . . . . . . . . . . . . 429
4347 - Time Out of CAN Message "AWD Status" from AWD (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
4348 - CAN Message "AWD Status" contains invalid data (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
4349 - Short circuit to ground at DLM transversal output (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
4350 - Short circuit to battery voltage at DLM transversal output (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
4351 - Short circuit to battery voltage at DLM indicator lamp output (*) . . . . . . . . . . . . . . . . . . . . . . . . 434
4352 - Open circuit DLM indicator lamp output (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
4900 - Solenoid 1 open circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
4904 - Solenoid A open circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
4905 - Solenoid B open circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
4906 - Solenoid C open circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
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4907 - Solenoid D open circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
4908 - Driver open circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
4909 - Torque Converter lockup open circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
4910 - Solenoid 1 Short circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
4914 - Solenoid A Short circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
4915 - Solenoid B Short circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
4916 - Solenoid C Short circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
4917 - Solenoid D Short circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
4918 - Driver Short circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
4919 - Torque Converter Lockup Short circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
4920 - Request for undefined shift being made (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
4921 - Power up in gear (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
4922 - Bottom of clutch input is passive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
4923 - Park and NOT Park values match (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
4924 - Park Status and Gear Input are not compatible (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
4925 - Upshit and Downshift both active (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
4926 - variable need gear has taken on invalid value (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
4927 - Start went active (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
4928 - Valve driver supply voltage too low (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
4929 - illegal or undefined vehicle mode code (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
4930 - Inching voltage low but bottom of clutch is open (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
4931 - seat switch and neutral are both passive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
4932 - Engine speed is at or near manufacturers warranty void level (*) . . . . . . . . . . . . . . . . . . . . . . . 468
4934 - illegal wheel mode change out of neutral (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
4935 - sump temperature too low for calibration (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
4936 - Engine speed too high for calibration (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
4937 - Engine speed too low for calibration (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
4938 - Output speed sensed during calibration (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
4939 - no cylinder speed during calibration (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
4940 - incorrect FWD/REV cylinder ratio (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
4941 - Cylinder speed will not drop below start count speed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476
4942 - hold clutch exceeds 90 psi (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477
4943 - Fast fill 1 exceeds 300 ms (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
4947 - Fast fill A exceeds 300 ms (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
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4948 - Fast fill B exceeds 300 ms (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
4949 - Fast fill C exceeds 300 ms (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
4950 - Fast fill D exceeds 300 ms (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
4951 - Calibrating without park brake set (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
4952 - Analog inching voltage too low (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
4953 - Temperature sensor circuit shorted or open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488
4954 - Analog inching voltage too high (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489
4955 - Engine MPU SC or OC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
4956 - Output MPU SC or OC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491
4957 - Cannot get shift constants from EEPROM (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
4958 - Group 1 enable low; should be high (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
4963 - Engine controller not communicating (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
4964 - AWD controller not communicating (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
4965 - Transmission controll not equipped for AWD control (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
4967 - Sump temperature too high (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
4968 - Slippage in clutch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
4970 - Driver SC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
4971 - Variable need gear has taken on invalid value (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
4976 - Driver short circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
4977 - Driver short circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
4980 - illegal wheel mode change out of neutral (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
4989 - Slippage in clutch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
4990 - group 1 enable low; should be high (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
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4993 - hold clutch exceeds 90 psi (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
4994 - incorrect FWD/REV cylinder ratio (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
5160 - AWD Controller detects Yellow Warning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
5161 - AWD Controller detects Red Warning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528
5301 - No connection at CAN Bus number 1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529
5308 - Ignition is switched on but no EEC1 message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
5311 - Ignition is switched on but no EEC2 message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531
5314 - Engine is running but no ETC1 message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
5317 - Engine is running but no ETC2 message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
5320 - Ignition is switched on but no AIC1 message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534
5323 - Wrong engine speed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535
5324 - Wrong pedal position (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
5328 - Output shaft speed above maximum (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537
5331 - Open circuit at pilot dump valve of AWD pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
5332 - Short circuit to ground at pilot dump valve of AWD pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
5333 - Short circuit to power at pilot dump valve of AWD pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540
5341 - Open circuit at pilot valve on forward direction of AWD pump (*) . . . . . . . . . . . . . . . . . . . . . . . 541
5342 - Short circuit to ground at pilot valve on forward direction of AWD pump (*) . . . . . . . . . . . . . . . 542
5343 - Short circuit to power at pilot valve on forward direction of AWD pump (*) . . . . . . . . . . . . . . . 543
5344 - Wrong current level at pilot valve on forward direction of AWD pump (*) . . . . . . . . . . . . . . . . . 544
5347 - Control software failure at pilot valve on forward direction of AWD pump (*) . . . . . . . . . . . . . . 545
5351 - Open circuit at pilot valve on reverse direction of AWD pump (*) . . . . . . . . . . . . . . . . . . . . . . . 546
5352 - Short circuit to ground at pilot valve on reverse direction of AWD pump (*) . . . . . . . . . . . . . . . 547
5353 - Short circuit to power at pilot valve on reverse direction of AWD pump (*) . . . . . . . . . . . . . . . 548
5354 - Wrong current level at pilot valve on reverse direction of AWD pump (*) . . . . . . . . . . . . . . . . . 549
5357 - Control software failure at pilot valve on reverse direction of AWD pump (*) . . . . . . . . . . . . . . 550
5361 - Open circuit at pilot valve on left front wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551
5362 - Short circuit to ground at pilot valve on left front wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . 552
5363 - Short circuit to power at pilot valve on left front wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . 553
5364 - Wrong current level at pilot valve on left front wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 554
5367 - Control software failure at pilot valve on left front wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . 555
5371 - Open circuit at pilot valve on right front wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
5372 - Short circuit to ground at pilot valve on right front wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . 557
5373 - Short circuit to power at pilot valve on right front wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . 558
5374 - Wrong current level at pilot valve on right front wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . 559
5377 - Control software failure at pilot valve on right front wheel motor (*) . . . . . . . . . . . . . . . . . . . . . 560
5379 - Comparison error of rear axle rpm and CAN value TCU ETC1 (*) . . . . . . . . . . . . . . . . . . . . . . 561
5381 - Open circuit at PIN 2 on left front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562
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5382 - Short circuit to ground at PIN 2 on left front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . 563
5383 - Short circuit to power at PIN 2 on left front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . 564
5384 - Open circuit at PIN 4 on left front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565
5385 - Short circuit to ground at PIN 4 on left front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . 566
5386 - Short circuit to power at PIN 4 on left front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . 567
5387 - Open circuit at power connection PIN 1 on left front wheel speed sensor (*) . . . . . . . . . . . . . 568
5388 - Open circuit at ground connection PIN 3 on left front wheel speed sensor (*) . . . . . . . . . . . . 569
5389 - Open circuit at resistor ground connection on left front wheel speed sensor (*) . . . . . . . . . . . 570
5390 - Different frequencies at PIN 2/4 on left front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . 571
5391 - Direction failure on left front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
5392 - Wrong input signals on left front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573
5393 - Revolutions on left front wheel speed sensor above maximum (*) . . . . . . . . . . . . . . . . . . . . . . 574
5401 - Open circuit at PIN 2 on right front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575
5402 - Short circuit to ground at PIN 2 on right front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . 576
5403 - Short circuit to power at PIN 2 on right front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . 577
5404 - Open circuit at PIN 4 on right front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
5405 - Short circuit to ground at PIN 4 on right front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . 579
5406 - Short circuit to power at PIN 4 on right front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . 580
5407 - Open circuit at power connection PIN 1 on right front wheel speed sensor (*) . . . . . . . . . . . . 581
5408 - Open circuit at ground connection PIN 3 on right front wheel speed sensor (*) . . . . . . . . . . . 582
5409 - Open circuit at resistor ground connection on right front wheel speed sensor (*) . . . . . . . . . . 583
5410 - Different frequencies at PIN 2/4 on right front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . 584
5411 - Direction failure on right front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585
5412 - Wrong input signals on right front wheel speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586
5413 - Revolutions on right front wheel speed sensor above maximum (*) . . . . . . . . . . . . . . . . . . . . . 587
5421 - Open circuit at forward pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588
5422 - Short circuit to power at forward pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589
5426 - Return line pressure at pump port A above allowed value (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 590
5427 - Forward pressure sensor test failed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591
5431 - Open circuit at reverse pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592
5432 - Short circuit to power at reverse pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593
5436 - Return line pressure at pump port B above allowed value (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 594
5437 - Return line pressure exceeds maximum when driving machine forward (*) . . . . . . . . . . . . . . 595
5440 - Sensor test at reverse pressure sensor failed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596
5442 - AWD mode key not available on drive behavior module C6 (*) . . . . . . . . . . . . . . . . . . . . . . . . . 597
5443 - Incorrect status of AWD mode key on drive behavior module C6 (*) . . . . . . . . . . . . . . . . . . . . 598
5445 - Creep mode key not available on drive behavior module C6 (*) . . . . . . . . . . . . . . . . . . . . . . . . 599
5446 - Incorrect status of creep mode key on drive behavior module C6 (*) . . . . . . . . . . . . . . . . . . . . 600
5448 - Encoder button not available on drive behavior module C6 (*) . . . . . . . . . . . . . . . . . . . . . . . . . 601
5451 - Drive behavior encoder not available on module C6 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
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5452 - Incorrect status of drive behavior encoder on module C6 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
5459 - Logical error at brake pressure switches ZR1 and VG1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
5461 - Open circuit at neutral contact of accelerator pedal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
5463 - Short circuit to ground at neutral contact of accelerator pedal (*) . . . . . . . . . . . . . . . . . . . . . . . 606
5467 - Short circuit to power at FNR switch of gear shift unit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
5469 - Logical error at FNR switch of gear shift unit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
5474 - Logical error at machine code plug (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
5475 - Wrong signal on digital input of machine code plug (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
5487 - Configuration incomplete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
5491 - Calibration of pump forward direction not complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
5492 - Calibration of pump reverse direction not complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613
5493 - Calibration of left front wheel motor not complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614
5494 - Calibration of right front wheel motor not complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615
5495 - Low Voltage at 2nd ignition input of controller (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
5497 - No charge pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
5498 - Too high pressure at both hydraulic lines (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
9121 - Logical error when retreiving flash data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
9128 - CAN timed out during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623
9133 - Never started receiving message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627
9160 - Hour Meter Failure - Both copies are wrong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630
9161 - Hour Meter Failure - one of two copies are wrong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631
9162 - Hour Meter Failure - Pre-crank And After-crank Checks Are Wrong . . . . . . . . . . . . . . . . . . . . . 632
9173 - Configuration Error - Engine Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633
9174 - Configuration Error - Transmission Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634
9175 - Configuration Error - AWD selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635
9176 - Configuration Error - not set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636
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PRINTED IN BRAZIL
48050419D 06/10/2017
EN
SERVICE MANUAL
Dozer blade and arm

48050419D 06/10/2017
86
Contents
Dozer blade and arm - 86
[86.110] Dozer blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.1
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Contents
Dozer blade - 110
FUNCTIONAL DATA
Dozer blade
- Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Dozer blade
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Dozer blade and arm - Dozer blade
Dozer blade - Exploded view

845B
865B
885B
LAIL11MG2072F0A 1
1. Front Blade 6. Screw 11. Nut

2. Bushing 7. Knife 12. Arm
3. Flat washer 8. Screw 13. Spacer
4. Cotter pin 9. Nut 14. Flat washer
5. Nut 10. Screw 15. Screw
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Dozer blade and arm - Dozer blade
Dozer blade - Assemble

845B
865B
885B
Front Blade
The mounting process of the front blade is similar to
that of the front scarifier. To mount the replaceable and
reversible cutting blades, tighten the nuts with a torque
of 290 – 310 kgm.
LAIL11MG1894A0A 1
LAIL11MG2072F0A 2
1. Front Blade 6. Screw 11. Nut

2. Bushing 7. Knife 12. Arm
3. Flat washer 8. Screw 13. Spacer
4. Cotter pin 9. Nut 14. Flat washer
5. Nut 10. Screw 15. Screw
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Index
Dozer blade - 110

Dozer blade - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dozer blade - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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SERVICE MANUAL
Tools

48050419D 06/10/2017
89
Contents
Tools - 89
[89.128] Ripper assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.1
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Contents
Tools - 89
TECHNICAL DATA
Ripper assembly
Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Ripper assembly
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Tools - Ripper assembly
Ripper assembly - Dimension

845B
865B
885B
Rear Ripper
LAIL11MG0217G0A 1
A. Internal diameter of the support: 70.100 – 70.174 mm (2.7598 – 2.7628 in)

B. Internal diameter of the arm: 60.000 – 60.046 mm (2.3622 – 2.3640 in)
C. Internal diameter of the frame: 50.080 – 50.180 mm (1.9717 – 1.9756 in)
D. Bush outer diameter: 60.07 – 60.10 mm (2.3650 – 2.3661 in)
Bush inner diameter: 50.195 – 50.18 mm (1.9762 – 1.9756 in)
E. External diameter of the bolt: 59.954 – 60.000 mm (2.3604 – 2.3622 in)
F. External diameter of the bolt: 49.961 – 50.000 mm (1.9670 – 1.9685 in)
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Ripper assembly - Assemble

845B
Rear Ripper
1. Assemble the link plates of the connecting rods and the
tray on the rear frame.
2. Assemble the rear tray with the connecting rods of the
linkage and the tray on the rear plate.
3. Mount the cylinder in the bearing and tighten the bolts.
4. Connect the tubes and the hoses to the guided check
valve.
5. Install the ripper teeth on the rear tray with their respec-
tive screws and cotter pins.
6. The claws of the ripper teeth are replaceable. To re-
place them, remove the spring lock screw. LAIL11MG0222A0A 1
7. Try to note down the mounting angle to prevent break-

ing the claws.
LAIL11MG1709A0A 2
LAIL11MG1710A0A 3
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Ripper assembly - Assemble

865B
885B
Rear Ripper
1. Assemble the link plates of the connecting rods and the
tray on the rear frame.
2. Assemble the rear tray with the connecting rods of the
linkage and the tray on the rear plate.
3. Mount the cylinder in the bearing and tighten the bolts.
4. Connect the tubes and the hoses to the guided check
valve.
5. Install the ripper teeth on the rear tray with their respec-
tive screws and cotter pins.
6. Note that there are scarifier teeth in addition to the rip-
per teeth. LAIL11MG0222A0A 1
7. The claws of the ripper teeth are replaceable. To re-

place them, remove the spring lock screw.
8. The scarifier replacement process is similar to that of
the front. To replace the ripper teeth it is necessary to
remove the elastic lock pins.
9. Try to note down the mounting angle to prevent break-
ing the claws.
LAIL11MG1709A0A 2
LAIL11MG1710A0A 3
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Index
Tools - 89

Ripper assembly - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Ripper assembly - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Ripper assembly - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN BRAZIL
48050419D 06/10/2017
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SPECIAL TOOL INDEX
Genuine Reference PAGE

380100284 [Snap Ring Powered rear axle - Special tools 27.1 / 4
Installer]
380100286 [Hub Lifting Tool] Powered rear axle - Special tools 27.1 / 4
380100287 [Seal Installer] Powered rear axle - Special tools 27.1 / 4
380100285 [Hub Spring Powered rear axle - Special tools 27.1 / 4
Compressor]
Installer]
Installer]
Installer]
380100285 [Hub Spring Powered rear axle - Special tools 27.1 / 10
Compressor]
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Service Manual

845B Direct drive transmission, Tier 3, made in Brazil [HBZN0845VBAF00184

Product Market Product Engine

[21.135] Powershift transmission external controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2

[21.105] Powershift transmission hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3

[21.155] Powershift transmission internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4

[21.700] Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5

[21.900] Hydraulic pump drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.6

Front axle system ....................................................................... 25

[25.400] Non-powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2

Rear axle system........................................................................ 27

[27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2

[27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3

Brakes and controls .................................................................... 33

Frames and ballasting ................................................................. 39

[39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.2

Cab climate control ..................................................................... 50

[50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.3

Electrical systems ....................................................................... 55

[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2

[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3

[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4

[55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5

[55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6

[55.024] Transmission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7

[55.051] Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls. . . . . . . . . . . . . . . . . . . 55.8

[55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . . . 55.9

[55.020] Transmission speed sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10

[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11

Dozer blade and arm................................................................... 86

Safety rules - Batteries (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(*) See content for specific models

Safety rules - Batteries

Variable displacement pump - Safety rules

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT

Torque - Minimum tightening torques for normal assembly

METRIC NON-FLANGED HARDWARE

METRIC FLANGED HARDWARE

Metric Hex head and carriage bolts, classes 5.6 and up

Metric Hex nuts and locknuts, classes 05 and up

INCH NON-FLANGED HARDWARE

INCH FLANGED HARDWARE

Inch Bolts and free-spinning nuts

SAE Grade Identification

Inch Lock Nuts, All Metal (Three optional methods)

Maintenance chart and Lubrication

Maintenance chart and Lubrication

SERVICE POINTS A B C D AND F

SERVICE POINTS A B C D AND F

Maintenance chart and Lubrication

Engine Cooling System

Power Rear Axle

Tandem and Brakes

Circle Turn Gear Reducer

Engine Cooling System

Power Rear Axle

Tandem and Brakes

Circle Turn Gear Reducer

Engine Cooling System

Power Rear Axle

Tandem and Brakes

Circle Turn Gear Reducer

Front Wheel Reducer