Motor Grader: 836C 836C AWD 856C 856C AWD Stage IV

SERVICE MANUAL
836C
836C 836C AWD
836C AWD 856C
856C 856C AWD
856C AWD Stage IV
Motor Grader Motor Grader
1/1 SERVICE MANUAL

Part number 47829048B
Part number 47829048B

English
June 2016
© 2016 CNH Industrial Italia S.p.A. All Rights Reserved.
SERVICE MANUAL
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
EN
Link Product / Engine
Product Market Product Engine

836C Europe F4HFE6133*B003
836C AWD Europe F4HFE6133*B003
856C Europe F4HFE613Y*B003
856C AWD Europe F4HFE613Y*B003
47829048B 15/06/2016
Contents
INTRODUCTION
Engine....................................................................................... 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
[10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
[10.501] Exhaust Gas Recirculation (EGR) exhaust treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
Transmission.............................................................................. 21
[21.113] Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
[21.135] Powershift transmission external controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2
[21.105] Powershift transmission lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3
[21.155] Powershift transmission internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4
[21.700] Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5
Front axle system ....................................................................... 25

[25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1
[25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2
Rear axle system........................................................................ 27

[27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1
[27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2
[27.600] Tandem axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3
[27.650] Chain drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.4
Hydrostatic drive......................................................................... 29
[29.204] Reservoir, cooler, and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.1
[29.218] Pump and motor components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.2
Brakes and controls .................................................................... 33

[33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1
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[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2
Hydraulic systems....................................................................... 35
[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1
[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2
[35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3
[35.102] Pump control valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4
[35.105] Charge pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5
[35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6
[35.354] Hydraulic central joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7
[35.739] Swing arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8
[35.741] Dozer blade cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9
[35.742] Ripper hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10
[35.310] Distributor and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.11
Frames and ballasting ................................................................. 39

[39.100] Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1
Steering..................................................................................... 41
[41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1
[41.206] Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2
[41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3
Wheels ...................................................................................... 44
[44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1
[44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2
Cab climate control ..................................................................... 50

[50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1
Electrical systems ....................................................................... 55

[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1
[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
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[55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.988] Selective Catalytic Reduction (SCR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
[55.989] Exhaust Gas Recirculation (EGR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5
[55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
[55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7
[55.530] Camera. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8
[55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9
[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10
Dozer blade and arm................................................................... 86

[86.110] Dozer blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.1
[86.112] Moldboard blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.2
Tools ......................................................................................... 89
[89.128] Ripper assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.1
Platform, cab, bodywork, and decals ............................................. 90

[90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1
[90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2
[90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3
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47829048B 15/06/2016
INTRODUCTION
47829048B 15/06/2016
1
Contents
INTRODUCTION
Foreword - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Safety rules (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Torque - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Torque - Standard torque data for hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Basic instructions - Shop and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Basic instructions - Precaution for disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Basic instructions - Electrical equipment precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Basic instructions - Hydraulic contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Basic instructions - Biodiesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Product identification - Machine orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
(*) See content for specific models

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INTRODUCTION
Foreword - Important notice regarding equipment servicing

All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel,
strictly complying with the instructions given, and using, whenever possible, the special tools.
Anyone who performs repair and maintenance operations without complying with the procedures provided herein
shall be responsible for any subsequent damages.
The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or
local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manu-
facturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer.
In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case
of damages caused by parts and/or components not approved by the manufacturer.
The manufacturer reserves the right to make improvements in design and changes in specifications at any time without
notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and
illustrative material herein are as accurate as known at time of publication but are subject to change without notice.
In case of questions, refer to your CASE CONSTRUCTION Sales and Service Networks.
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INTRODUCTION
Safety rules
800C WE
Personal safety
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible death or injury.
Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special in-
structions. These precautions are intended for the personal safety of you and those working with you.
Read and understand all the safety messages in this manual before you operate or service the machine.
DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT

IN DEATH OR SERIOUS INJURY.
Machine safety
NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage.
Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or
property damage. The word Notice is used to address practices not related to personal safety.
Information
NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual.
Throughout this manual you will find the word Note followed by additional information about a step, procedure, or
other information in the manual. The word Note is not intended to address personal safety or property damage.
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INTRODUCTION
Personal safety
Carefully read this Manual before proceeding with main-
tenance, repairs, refuelling or other machine operations.
Repairs have to be carried out only by authorized and in-

structed staff; specific precautions have to be taken when
grinding, welding or when using mallets or heavy ham-
mers.
Not authorized persons are not allowed to repair or carry

out maintenance on this machine. Do not carry out any
work on the equipment without prior authorization.
Ask your employer about the safety instructions in force

and safety equipment.
TULI12WEX2004AA 1
Nobody should be allowed in the cab during machine

maintenance unless he is a qualified operator helping
with the maintenance work.
If it is necessary to move the equipment to carry out re-

pairs or maintenance, do not lift or lower the equipment
from any other position than the operator’s seat.
Never carry out any operation on the machine when the
engine is running, except when specifically indicated.
Stop the engine and ensure that all pressure is relieved

from hydraulic circuits before removing caps, covers,
valves, etc.
All repair and maintenance operations should be carried

out with the greatest care and attention.
Service stairs and platforms used in a workshop or in the

field should be built in compliance with the safety rules in
force.
Any functional disorders, especially those affecting the

safety of the machine, should therefore be rectified im-
mediately.
DANGER
Unexpected movement!
Make sure parking brake is applied. Secure
machine with wheel chocks.
Failure to comply will result in death or serious
injury.
D0013A
Before performing any work on the machine, attach a

maintenance in progress tag. This tag can be applied on
the dashboard, on the cab door, or at any other well visi-
ble place.
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INTRODUCTION
Emergency
Be prepared for emergencies. Always keep a fire extin-
guisher and first aid kit readily available. Ensure that the
fire extinguisher is serviced in accordance with the man-
ufacturer’s instructions.
SMIL12WEX0174AA 2
Equipment
Wear close fitting clothing and safety equipment appropri-
ate for the job:
• Safety helmet
• Safety shoes
• Heavy gloves
• Reflective clothing
• Wet weather clothing
If working conditions require, the following personal safety

equipment should be on hand:
3
• Respirators (or dust proof masks) TULI12WEX2008AA
• Ear plugs or acoustic ears protections

• Goggles with lateral shield or masks for eyes protection
Do not wear rings, wristwatches, jewels, unbuttoned or

flapping clothing such as ties, torn clothes, scarves, open
jackets or shirts with open zips which could get caught into
moving parts.
Engine - Radiator
Never leave the engine running in enclosed spaces with-
out proper ventilation which is able to evacuate toxic ex-
haust gases. Keep the exhaust manifold and tube free
from combustible materials.
Do not refuel with the engine running, especially if hot, as

this increases fire hazard in case of fuel spillage.
Never attempt to check or adjust the belts when the en-

gine is running.
Never lubricate the machine with the engine running.
TULI12WEX2009AA 4
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INTRODUCTION
Pay attention to rotating components and do not allow

to anyone to approach these areas to avoid becoming
entangled.
Hands, clothing or tools getting caught in the fan blades

or transmission belts, can cause amputations, violent
hemorrages and generate conditions of grave danger.
For this reason avoid touching or approaching all rotating
or moving parts.
A surging spray of the coolant from the radiator can cause

serious burns and scalds.
Before checking the coolant level, shut-off the engine

TULI12WEX2010AA 5
and allow machine to cool down the radiator and hoses.
Slowly unscrew the cap to release any residual pressure.
If it is necessary to remove the cap while engine is hot,
wear safety clothes and equipment, then loosen the cap
slowly to relieve the pressure gradually.
When checking the fuel, oil and coolant levels, use lights
and lamps explicitly designated as explosion proof. If
these types of lamps are not use, fires or explosions may
occur.
TULI12WEX2011AA 6
Hydraulic systems
Jets of fluids under pressure can penetrate the skin caus-
ing serious injuries.
Avoid this hazard by relieving pressure before disconnect-

ing hydraulic or other lines.
Relieve the residual pressure by moving the hydraulic

control levers several times.
Tighten all connections before applying pressure.
To protect the eyes wear a facial shield or safety goggles.
Protect your hands and body from possible jets of fluids

7
under pressure. TULI12WEX2012AA
Swallowing hydraulic oil is a severe health hazard.
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INTRODUCTION
When hydraulic oil has been swallowed, avoid vomiting,

but consult a doctor or go to a hospital.
If an accident occurs, see a doctor familiar with this type

of injury immediately.
Any fluid penetrating the skin must be removed within few

hours to avoid serious infections.
Flammable splashes may originate because of heating

near lines with fluids under pressure, resulting in serious
burns. Do not weld or use torches near lines containing
fluids or other flammable materials.
TULI12WEX2013AA 8
Lines under pressure can accidentally be pierced when
the heat expands beyond the area immediately heated.
Arrange for temporary fire resistant shields to protect

hoses or other components during welding or torch use.
Have any visible leakage repaired immediately.
Discharged oil pollutes the environment. Soak up any

oil that has spilled with a proper binding agent. Sweep
up binding agent and dispose of it separately from other
waste.
Never search for leakages with fingers; instead, use a

piece of cardboard and always wear goggles.
Never repair a damaged line; always replace it. Replace

hydraulic hoses immediately on detecting any damaged
or moist areas.
Always store hydraulic oil in the original containers.
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INTRODUCTION
Hoses and tubes

Always replace hoses and tubes if the cone end or the
end connections on the hose are damaged.
When installing a new hose, loosely connect each end

and make sure the hose takes up the correct position be-
fore tightening the connections. Clamps should be tight-
ened sufficiently to hold the hose without crushing and to
prevent chafing.
After hose replacement to a moving component, check

that the hose does not foul by moving the component
through the complete range of travel. Be sure any hose
which has been installed is not kinked or twisted.
TULI12WEX2014AA 9
Hose connections which are damaged, dented, crushed
or leaking, restrict oil flow and the productivity of the com-
ponents being served. Connectors which show signs of
movement from the original position have failed and will
ultimately separate completely.
A hose with a frayed outer sheath will allow water penetra-

tion. Concealed corrosion of the wire reinforcement could
subsequently occur along the hose length with resultant
hose failure.
Ballooning of the hose indicates an internal leakage due to

structural failure. This condition rapidly deteriorates and
total hose failure soon occurs.
Kinked, crushed, stretched or deformed hoses generally

suffer internal structural damage which can result in oil
restriction, a reduction in the speed of operation and ulti-
mate hose failure.
Free-moving, unsupported hoses must never be allowed

to touch each other or related working surfaces. This
causes chafing which reduces hose life.
O-rings
Replace O-rings, seal rings and gaskets whenever they
are disassembled.
Never mix new and old seals or O-rings, regardless of

condition. Always lubricate new seal rings and O-rings
with hydraulic oil before installation to relevant seats.
This will prevent the O-rings from rolling over and twisting
during mounting which will jeopardize sealing.
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INTRODUCTION
Battery
Batteries give off explosive gases.
Never handle naked flames and unshielded light sources

near batteries. (No smoking is addressed in next instruc-
tion).
To prevent any risk of explosion, observe the following

instructions:
• When disconnecting the battery cables, always discon-

nect the negative (-) cable first.
• To reconnect the battery cables, always connect the
negative (-) cable last.
TULI12WEX2015AA 10
• Never short-circuit the battery terminals with metal ob-
jects.
• Do not weld, grind or smoke near a battery.
Battery electrolyte causes severe burns. The battery con-

tains sulphuric acid. Avoid any contact with the skin, eyes
or clothing.
Antidote:
• EXTERNAL: Rinse well with water, removing any soiled

clothing.
• INTERNAL: Avoid vomiting. Drink water to rinse your
mouth. Consult a doctor.
• EYES: Rinse abundantly with water for 15 min and con-
sult a doctor.
• When the electrolyte of a battery is frozen, it can ex-
plode if you attempt to charge the battery or if you try to
start the engine using a booster battery. Always keep
the battery charged to prevent the electrolyte freezing.
TULI12WEX2016AA 11
Provide good ventilation when changing a battery or using
a battery in an enclosed space. Always protect your eyes
when working near a battery.
Never set tools down on the battery. They may induce
a short circuit, causing irreparable damage to the battery
and injuring persons.
Never wear metal necklaces, bracelets or watch straps

when working on the battery. The metal parts may induce
a short circuit resulting in burns.
Dispose of used batteries separately from other waste in

the interests of environmental protection.
TULI12WEX2017AA 12
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INTRODUCTION
Flammable liquids
When handling flammable liquids:
• Do not smoke.
• Keep away from unshielded light sources and naked
flames.
Fuels often have a low flash point and are readily ignited.
Never attempt to extinguish burning liquids with water.

Use:
• Dry powder
• Carbon dioxide
TULI12WEX2016AA 13
• Foam
Water used for extinguishing purposes would vaporize in-

stantaneously on contact with burning substances and
spread burning oil, for example, over a wide area. Water
generates short circuits in the electrical system, possibly
producing new hazards.
Stay away from open flames during refilling of hydraulic
oil or fuel.
Fuel or oil spills can cause slipping hazards; thoroughly

contain and clean affected areas.
Always tighten the safety plugs of fuel tank and hydraulic

oil tank firmly.
Never use fuel to clean machine parts that will be exposed

to dirt or debris.
Use a non-inflammable product for cleaning parts.

14
Always perform fuel or oil refilling in well aired and venti- TULI12WEX2018AA
lated areas.
During refuelling hold the pistol firmly and always keep it
in contact with the filler neck until the end of the refuelling,
to avoid arcing due to static electricity.
Do not overfill the tank but leave a space for fuel expan-
sion.
Never refuel when the engine is running.
Take all the necessary safety measures when welding,

grinding or when working near a naked flame.
TULI12WEX2019AA 15
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INTRODUCTION
Tires
Before inflating the tires, always check the condition of
rims and the outer condition of tires to find out the pres-
ence of dents, cuts, tears of reinforcement plies or other
faults. Before inflating a tire, make sure that there are no
nearby persons, then position yourself at tread side.
When inflating tires, ensure tire pressure does not exceed

that prescribed by the tire manufacturer. Ensure that the
pressure of the right tire corresponds to the pressure of
the left tire.
NOTE: The front and rear tire pressures may be different.
Never use reconditioned rims because possible welds,

16
heat treatments or brazings not performed correctly can TULI12WEX2020AA
weaken the wheels and cause following damages or fail-

ures. Deflate the tires before their disassembly.
Before taking out possible jammed objects from the rims,

it is necessary to deflate the tires. Inflate tires by means
of an inflation pistol complete with extension and pressure
control valve.
Cleaning
Clean the exterior of all components before carrying out
any form of repair. Dirt and dust can reduce the efficient
working life of a component and lead to costly replace-
ment.
Solvents should be checked that they are suitable for the

cleaning of components and also that they do not risk the
personal safety of the user.
Dirt, oil, grease and scattered tools are dangerous for peo-
ple, because they can create slipping or tripping hazards.
For machine cleaning, use a jet of warm water or steam

under pressure and commercial detergents. Never use
TULI12WEX2021AA 17
fuel, petroleum or solvents, because they can leave an
oily residue that attracts dust, and solvents (even if weak)
damage the paint and can lead to the information of rust.
Never use water jets or steam on sensors, connectors or

other electric components.
Avoid direct spray of seals and seams to prevent water

penetration inside the cab.
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INTRODUCTION
Waste disposal
Improperly disposing of waste can threaten the environ-
ment.
Each country has its own regulations on this subject. It

is therefore advisable to prepare suitable containers to
collect and store momentarily all solid and fluid materials
that must not be scattered in the environment to avoid
pollution.
At preset intervals these products will be delivered to dis-

posal stations legally recognized and present in this coun-
try.
Hereunder are listed some products of the machine re-

TULI12WEX2022AA 18
quiring disposal:
• Lubricating oil
• Brake system oil
• Coolant mixture, condensation rests and pure an-
tifreeze
• Fuel
• Filter elements, oil and fuel filters
• Filter elements, air filters
• Battery
Also polluting rags, paper, sawdust and gloves must be

disposed in compliance with the same procedures.
Do not use food or beverage containers that may mislead

someone into drinking from them. Do not pour waste onto
the ground, down a drain, or into any water source. Air
conditioning refrigerants escaping into the air can damage
the Earth’s atmosphere. Government regulations may re-
quire a certified air conditioning service centre to recover
and recycle used air conditioning refrigerants. Obtain in-
formation on the proper way to recycle or dispose of waste
from your local environmental or recycling centre, or from
your Dealer.
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INTRODUCTION
Torque - Minimum tightening torques for normal assembly

Use the torques in this chart when special torques are not given. These torques apply to plain and zinc-dichromate
fasteners as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphite lubri-
cants, Molydisulfide greases, or other extreme pressure lubricants are used. A torque range of ± 10 % is acceptable.
Grade 8.8 bolts, nuts, and studs

Size Nm lb ft
4 mm 4 N·m 3 lb ft
5 mm 7 N·m 5 lb ft
6 mm 12 N·m 9 lb ft
10 mm 57 N·m 42 lb ft
12 mm 100 N·m 74 lb ft
14 mm 159 N·m 117 lb ft
16 mm 248 N·m 183 lb ft
18 mm 352 N·m 260 lb ft
20 mm 500 N·m 369 lb ft
22 mm 681 N·m 502 lb ft
24 mm 865 N·m 638 lb ft
27 mm 1262 N·m 931 lb ft
30 mm 1719 N·m 1268 lb ft
36 mm 2999 N·m 2212 lb ft
Markings for Grade 8.8 hardware
Grade 10.9 bolts, nuts and studs

Size Nm lb ft
4 mm 5 N·m 4 lb ft
10 mm 82 N·m 60 lb ft
12 mm 143 N·m 105 lb ft
14 mm 227 N·m 168 lb ft
16 mm 354 N·m 261 lb ft
18 mm 487 N·m 359 lb ft
20 mm 690 N·m 509 lb ft
22 mm 942 N·m 695 lb ft
24 mm 1195 N·m 882 lb ft
27 mm 1749 N·m 1290 lb ft
30 mm 2377 N·m 1753 lb ft
36 mm 4149 N·m 3061 lb ft
Grade 12.9 bolts, nuts, and studs

Torque values specified for grade 10.9 hardware can be used for grade 12.9 hardware.
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INTRODUCTION
Torque - Standard torque data for hydraulics

Use the torques in the charts when special torques are not given.
The torque values are based on catalogue data provided by the hydraulic fitting manufacturers.
If the manufacturer is unknown apply the “Recommended” torque.
NOTE:
a) The torque values are applicable on all carbon steel components in which the external surface is protected with an
appropriate coating (zinc plating). Changes in plating may affect assembly torques.
b) For steel fittings into aluminum or cast iron components the torque may differ (e.g. depending on depth of thread
engagement)!
c) Not applicable if special graphite lubricants, Molydisulfide greases, or other extreme pressure lubricants are used.
The assembly of the fitting and connector shall be carried out without external loads. Screw up hand-tight and then
tighten further with a spanner according to the values mentioned in the tables on the next pages. Ensure that in all
cases the fitting or hose is correctly aligned before tightening onto the corresponding adaptor.
The fitting manufacturers which are not listed on the torque charts shall draw up assembly instructions for the use
of the connectors. These instructions shall include at least the following:
• Details relating to material and quality of suitable tubes
• Details concerning the preparation of the selected tube
• Instructions regarding the assembly of the connector, such as the number of wrenching turns or assembly torque
• Recommendations regarding the tools to be used for assembly
1. Stud connector for ports with elastomeric sealing (Type E)

NOTE:
- The torque chart give recommendations to threaded connectors in steel with a zinc-coated surface.
- For steel fittings into aluminum components the torque is 70 % of the below values.
SS14G152 1
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INTRODUCTION
Stud end with elastomeric sealing (type E) according ISO 9974-2

Series Tube outer Thread size (d) Recommended PARKER VOSS
diameter
Light (L) 6 mm M10 X 1 18 N·m 18 N·m 15 N·m
(13 lb ft) (13 lb ft) (11 lb ft)
Light (L) 8 mm M12 X 1.5 25 N·m 25 N·m 25 N·m
(18 lb ft) (18 lb ft) (18 lb ft)
(33 lb ft) (33 lb ft) (37 lb ft)
(44 lb ft) (41 lb ft) (52 lb ft)
(59 lb ft) (52 lb ft) (66 lb ft)
(92 lb ft) (92 lb ft) (96 lb ft)
(133 lb ft) (133 lb ft) (133 lb ft)
(207 lb ft) (229 lb ft) (170 lb ft)
(295 lb ft) (332 lb ft) (243 lb ft)
(398 lb ft) (398 lb ft) (369 lb ft)

diameter
Light (L) 6 mm G 1/8 A 18 N·m 18 N·m 20 N·m
(13 lb ft) (13 lb ft) (15 lb ft)
(30 lb ft) (26 lb ft) (37 lb ft)
(30 lb ft) (26 lb ft) (37 lb ft)
(59 lb ft) (52 lb ft) (59 lb ft)
(74 lb ft) (66 lb ft) (74 lb ft)
(74 lb ft) (66 lb ft) (74 lb ft)
(133 lb ft) (133 lb ft) (133 lb ft)
Light (L) 28 mm G1A 280 N·m 310 N·m 230 N·m
(207 lb ft) (229 lb ft) (170 lb ft)
Light (L) 35 mm G 1 1/4 A 400 N·m 450 N·m 330 N·m
(295 lb ft) (332 lb ft) (243 lb ft)
Light (L) 42 mm G 1 1/2 A 540 N·m 540 N·m 500 N·m
(398 lb ft) (398 lb ft) (369 lb ft)
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INTRODUCTION

diameter
Heavy (S) 6 mm M12 X 1.5 40 N·m 40 N·m 50 N·m
(30 lb ft) (30 lb ft) (37 lb ft)
(41 lb ft) (30 lb ft) (44 lb ft)
(52 lb ft) (52 lb ft) (59 lb ft)
(66 lb ft) (66 lb ft) (66 lb ft)
(100 lb ft) (100 lb ft) (96 lb ft)
Heavy (S) 20 mm M27 X 2 180 N·m 180 N·m 200 N·m
(133 lb ft) (133 lb ft) (148 lb ft)
(229 lb ft) (229 lb ft) (184 lb ft)
(347 lb ft) (332 lb ft) (369 lb ft)
(413 lb ft) (398 lb ft) (443 lb ft)

diameter
Heavy (S) 6 mm G 1/4 A 50 N·m 40 N·m 60 N·m
(37 lb ft) (30 lb ft) (44 lb ft)
(37 lb ft) (30 lb ft) (44 lb ft)
(59 lb ft) (59 lb ft) (66 lb ft)
(59 lb ft) (59 lb ft) (66 lb ft)
(89 lb ft) (85 lb ft) (111 lb ft)
(133 lb ft) (133 lb ft) (148 lb ft)
Heavy (S) 25 mm G1A 300 N·m 310 N·m 250 N·m
(221 lb ft) (229 lb ft) (184 lb ft)
Heavy (S) 30 mm G 1 1/4 A 470 N·m 450 N·m 500 N·m
(347 lb ft) (332 lb ft) (369 lb ft)
Heavy (S) 38 mm G 1 1/2 A 560 N·m 540 N·m 600 N·m
(413 lb ft) (398 lb ft) (443 lb ft)
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INTRODUCTION
2. 24° cone connectors (DKO) - Metallic tube connections conforming to ISO 8434-1
Assembly:
A. Check that the O-ring is not twisted and that is bedded correctly in the groove of the taper.
B. Lubricate the O-ring lightly with system fluid or compatible lubricant.
C. Keeping the taper aligned, insert it into the cone and press it firmly.
D. Turn the union nut until it is hand-tight.
E. Then use a spanner to finally tighten up the coupling to the specified torque.
SS14G151 2
Position Designation
1 Body
2 Nut
3 DKO-end (including O-ring)
24° cone connectors (DKO) - Metallic tube connections conforming to ISO 8434-1
Tube
Thread
Series outer Recommended ALFAGOMMA FOR PARKER VOSS
size
diameter
Light 6 mm M12 X 1.5 15 - 17 N·m 15 - 20 N·m 13 - 15 N·m 15 - 17 N·m 19 - 21 N·m
(L) (11 - 13 lb ft) (11 - 15 lb ft) (10 - 11 lb ft) (11 - 13 lb ft) (14 - 15 lb ft)
Light 22 mm M30 X 2 100 - 115 N·m 105 - 120 N·m 85 - 105 N·m 110 - 121 N·m 114 - 126 N·m
Light 28 mm M36 X 2 125 - 145 N·m 135 - 150 N·m 120 - 140 N·m 130 - 143 N·m 152 - 168 N·m
Light 35 mm M45 x 2 170 - 215 N·m 250 - 280 N·m 170 - 190 N·m 215 - 237 N·m 238 - 263 N·m
Light 42 mm M52 x 2 260 - 330 N·m 270 - 300 N·m 190 - 230 N·m 330 - 363 N·m 361 - 399 N·m
47829048B 15/06/2016
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INTRODUCTION
24° cone connectors (DKO) - Metallic tube connections conforming to ISO 8434-1
Tube
Thread
Series outer Recommended ALFAGOMMA FOR PARKER VOSS
size
diameter
Heavy 6 mm M14 X 1.5 22 - 28 N·m 25 - 30 N·m 14 - 16 N·m 25 - 28 N·m 24 - 26 N·m
(S) (16 - 21 lb ft) (18 - 22 lb ft) (10 - 12 lb ft) (18 - 21 lb ft) (18 - 19 lb ft)
Heavy 20 mm M30 X 2 100 - 120 N·m 105 - 120 N·m 90 - 110 N·m 120 - 132 N·m 133 - 147 N·m
Heavy 38 mm M52 x 2 260 - 350 N·m 270 - 300 N·m 200 - 245 N·m 350 - 385 N·m 380 - 420 N·m
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INTRODUCTION
3. 4–bolt flange connections conforming to ISO 6162-1 and SAE J518-1 (Code 61) and to
ISO 6162-2 and SAE J518-2 (Code 62):
NOTE:
Torque values according ISO 6162:
– It is important that all screws be lightly torqued before applying the final recommended torque values to avoid break-
ing the split flange clamps or one-piece flange clamps during installation.
– Calculated with a coefficient of friction at 0.17.
SS14G153 3
Position Designation
1 Shape optional
2 O-ring
3 Flange clamp
4 Flanged head
5 Screw
6 Hardened washer
7 Face of port on adapter,
pump, etc.
Assembly:
A. Make sure sealing surfaces are free of burrs, nicks, scratches or any contamination.
B. Lubricate the O-ring lightly with system fluid or compatible lubricant.
C. Position flange and clamp halves.
D. Place lock washers on bolts and bolt through clamp halves.
E. Finger tighten all four bolts making certain the flange and fitting shoulder are started squarely. ALL BOLTS MUST
BE EVENLY TORQUED. Do not tighten any one bolt fully before going on to the next one. Partially tighten each
bolt as shown below and repeat this sequence until all bolts are tightened to the specified torque for that bolt size.
SS14G150 4
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INTRODUCTION
4–bolt flange connections conforming to ISO 6162-1 and SAE J518-1 (Code 61)
At a pressure of 35 - 350 bar (508 - 5075 psi)
Metric screws – Class 10.9
Nominal Nominal Screw Recommended
Dash size size Thread According
ALFAGOMMA PARKER VOSS
size (Drill) (Drill) Metric ISO 6162
Metric d1 Inch d1 d3 (SAE J518)
-8 13 mm 1/2 M8 32 - 35 N·m 20 - 25 N·m 24 - 26 N·m 23 - 25 N·m
(24 - 26 lb ft) (15 - 18 lb ft) (18 - 19 lb ft) (17 - 18 lb ft)
-12 19 mm 3/4 M10 70 - 77 N·m 28 - 40 N·m 50 - 55 N·m 45 - 50 N·m
-16 25 mm 1 M10 70 - 77 N·m 37 - 48 N·m 50 - 55 N·m 45 - 50 N·m
-20 32 mm 1 1/4 M10 70 - 77 N·m 48 - 62 N·m 50 - 55 N·m 45 - 50 N·m
-24 38 mm 1 1/2 M12 130 - 143 N·m 62 - 79 N·m 92 - 101 N·m 77 - 85 N·m
-32 51 mm 2 M12 130 - 143 N·m 73 - 90 N·m 92 - 101 N·m 77 - 85 N·m
-40 64 mm 2 1/2 M12 130 - 143 N·m 107 - 124 N·m 92 - 101 N·m 77 - 85 N·m
-48 76 mm 3 M16 295 - 325 N·m 186 - 203 N·m 210 - 231 N·m 189 - 210 N·m
4–bolt flange connections conforming to ISO 6162-2 and SAE J518-2 (Code 62)
At a pressure of 420 bar (6090 psi)
Metric screws – Class 10.9
Nominal Nominal Screw Recommended
Dash size size Thread According
ALFAGOMMA PARKER VOSS
size (Drill) (Drill) Metric ISO 6162
Metric d1 Inch d1 d3 (SAE J518)
-8 13 mm 1/2 M8 32 - 35 N·m 20 - 25 N·m 24 - 26 N·m 23 - 25 N·m
-12 19 mm 3/4 M10 70 - 77 N·m 34 - 45 N·m 50 - 55 N·m 45 - 50 N·m
-16 25 mm 1 M12 130 - 143 N·m 56 - 68 N·m 92 - 101 N·m 77 - 85 N·m
-20 32 mm 1 1/4 M12 130 - 143 N·m 85 - 102 N·m 130 - 143 N·m 117 - 130 N·m
-24 38 mm 1 1/2 M16 295 - 325 N·m 158 - 181 N·m 210 - 231 N·m 189 - 210 N·m
-32 51 mm 2 M20 550 - 605 N·m 271 - 294 N·m 400 - 440 N·m
(406 - 446 lb ft) (200 - 217 lb ft) (295 - 325 lb ft)
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INTRODUCTION
Special tools
Commercially available tools for disassembly/assembly
Item Figure
Designation
No.
1 Magnet holder
SS12H068 1
2 Dial indicator
SS12H069 2
Final dimensions
3 70 mm (2.8 in)
100 mm (3.9 in)
SS12H070 3
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INTRODUCTION
Item Figure
Designation
No.
Digital depth gauge

4 200 mm (7.9 in)
300 mm (11.8 in)
SS12H071 4
Digital calliper gauge

5
150 mm (5.9 in)
SS12H072 5
Torque wrench
0.6 - 6.0 N·m (0.4 - 4.4 lb ft)
6 1.0 - 12 N·m (0.7 - 8.9 lb ft)
0.23 - 3 N·m (0.2 - 2.2 lb ft)
5.0 - 45 N·m (3.7 - 33.2 lb ft)
SS12H073 6
47829048B 15/06/2016
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INTRODUCTION
Item Figure
Designation
No.
7 Hot air blower
SS12H074 7
Plastic mallet
8
Ø 28.4 mm (1.1 in)
SS12H075 8
9 Lifting strap
SS12H076 9
10 Sling chain
SS12H077 10
47829048B 15/06/2016
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INTRODUCTION
Item Figure
Designation
No.
11 Pry bar
SS12H078 11
12 Hammer puller
SS12H079 12
Set of internal pliers

13
I1-I2-I3-I4
SS12H080 13
Set of internal pliers

14 I11-I21-I31-I41
90 °
SS12H081 14
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INTRODUCTION
Item Figure
Designation
No.
Set of external pliers

15
A1-A2-A3-A4
SS12H082 15
Set of external pliers

16 A01-A02-A03-A04
90 °
SS12H083 16
Two-arm puller
Span 80 mm (3.1 in)
Throat depth 100 mm (3.9 in)
Span 120 mm (4.7 in)
17 Throat depth 175 mm (6.9 in)
Span 350 mm (13.8 in)
Span 380 mm (15.0 in)
SS12H084 17
Span 520 mm (20.5 in)
Throat depth 300 - 500 mm (11.8 - 19.7 in)
Three-armed extractor
Span 85 mm (3.3 in)
18 Throat depth 150 mm (5.9 in)
Span 295 mm (11.6 in)
Span 390 mm (15.4 in)
Span 640 mm (25.2 in)
SS12H085 18
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INTRODUCTION
Basic instructions - Shop and assembly

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

For correct rotating shaft seal installation, proceed as follows:
1. Before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes.
2. Thoroughly clean the shaft and check that the working surface on the shaft is not damaged.
3. Position the sealing lip facing the fluid.
NOTE: With hydrodynamic lips, take into consideration the shaft rotation direction and position the grooves so that
they will move the fluid towards the inner side of the seal.
4. Coat the sealing lip with a thin layer of lubricant (use oil rather than grease). Fill the gap between the sealing lip
and the dust lip on double lip seals with grease.
5. Insert the seal in its seat and press down using a flat punch or seal installation tool. Do not tap the seal with a
hammer or mallet.
6. While you insert the seal, check that the seal is perpendicular to the seat. When the seal settles, make sure that
the seal makes contact with the thrust element, if required.
7. To prevent damage to the seal lip on the shaft, position a protective guard during installation operations.
O-ring seals
Lubricate the O-ring seals before you insert them in the seats. This will prevent the O-ring seals from overturning and
twisting, which would jeopardize sealing efficiency.
Sealing compounds
Apply a sealing compound on the mating surfaces when specified by the procedure. Before you apply the sealing
compound, prepare the surfaces as directed by the product container.
Spare parts
Only use CNH Original Parts or CASE CONSTRUCTION Original Parts.
Only genuine spare parts guarantee the same quality, duration, and safety as original parts, as they are the same
parts that are assembled during standard production. Only CNH Original Parts or CASE CONSTRUCTION Original
Parts can offer this guarantee.
When ordering spare parts, always provide the following information:

• Machine model (commercial name) and Product Identification Number (PIN)
• Part number of the ordered part, which can be found in the parts catalog
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INTRODUCTION
Protecting the electronic and/or electrical systems during charging and welding
To avoid damage to the electronic and/or electrical systems, always observe the following practices:
1. Never make or break any of the charging circuit connections when the engine is running, including the battery
connections.
2. Never short any of the charging components to ground.
3. Always disconnect the ground cable from the battery before arc welding on the machine or on any machine
attachment.
• Position the welder ground clamp as close to the welding area as possible.
• If you weld in close proximity to a computer module, then you should remove the module from the machine.
• Never allow welding cables to lie on, near, or across any electrical wiring or electronic component while you
weld.
4. Always disconnect the negative cable from the battery when charging the battery in the machine with a battery
charger.
NOTICE: If you must weld on the unit, you must disconnect the battery ground cable from the machine battery.
The electronic monitoring system and charging system will be damaged if this is not done.
5. Remove the battery ground cable. Reconnect the cable when you complete welding.
CAUTION
Overhead object hazard!
When the grain tank covers are open, the total machine height is in excess of 5.4 m (17.7 ft). Make
sure the machine has sufficient clearance to pass in all directions. Pay special attention to overhead
obstacles.
Failure to comply could result in minor or moderate injury.
C0001A
Special tools
The special tools that CASE CONSTRUCTION suggests and illustrate in this manual have been specifically re-
searched and designed for use with CASE CONSTRUCTION machines. The special tools are essential for reliable
repair operations. The special tools are accurately built and rigorously tested to offer efficient and long-lasting oper-
ation.
By using these tools, repair personnel will benefit from:

• Operating in optimal technical conditions
• Obtaining the best results
• Saving time and effort
• Working in safe conditions
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INTRODUCTION
Basic instructions - Precaution for disassembly and assembly

Preparations for disassembly
• Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause
machine components to be contaminated during disassembling/assembling, resulting in damage to machine com-
ponents, as well as decreased efficiency in service work.
• Be sure to thoroughly understand all disassembling/assembling procedures beforehand, to help avoid incorrect
disassembling of components as well as personal injury.
• Check and record the items listed below to prevent problems from occurring in the future.
1. The machine model, machine serial number, and hour meter reading.
2. Reason for disassembly (symptoms, failed parts, and causes).
3. Clogging of filters and oil, water or air leaks, if any.
4. Capacities and condition of lubricants.
5. Loose or damaged parts.
• Prepare the necessary tools to be used and the area for disassembling work.
• Wear appropriate clothing, safety shoes, safety helmet, goggles, and clothes with long sleeves.
• Confirm ready access to a first-aid kit and fire extinguisher, as well as appropriate emergency personnel contacts
in the case of a medical accident or fire.
• Before performing any work on the machine, follow lockout/tagout procedures by attaching a “maintenance in
progress tag”. This tag can be applied on the dashboard, on the cab door, or at any other well visible place.
Notify those with access to the machine that you will be performing the maintenance.
Disassembling and assembling hydraulic equipment

• Before removing lines, release the pressure of hydraulic oil tank.
• Drain the oil in removed lines into an appropriate container to prevent oil contamination.
• Protect open connections with plugs or caps to prevent oil from leaking and debris from contaminating the system.
• Thoroughly clean the outside of components before disassembling, and drain hydraulic oil and gear oil before dis-
assembly.
Disassembling hydraulic equipment

• Impaired performance and function of hydraulic equipment after unauthorized service may not be covered under
warranty by the manufacturer. Consult your local dealer for service.
• If it is unavoidably necessary to disassemble and modify, it should be carried out by experts or personnel qualified
through service training.
• Make match mark on parts for reassembling.
• Before disassembling, read instructions in advance, and determine if the service is required to be performed by an
authorized dealer.
• Use appropriate specialty tools and jigs if required.
• If parts can not be removed as specified by the procedure, never force removal. Check for other failures that may
be causing binding or interference.
• Inspect parts for wear and clearance; record the measured values. Replace components if the values fall outside
of the recommended range.
• If an abnormality is detected, repair or replace the parts.
• When removing parts, use appropriate markings or labels to ensure thy can be reinstalled in the correct order and
location without confusion.
• For common parts, pay attention to the quantity and locations of each group of components.
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INTRODUCTION
Reassembling hydraulic equipment

• Clean parts in a well ventilated room.
• Remove residual oil with compressed air, and apply fresh hydraulic oil or gear oil to surfaces before reassembly.
• Replace removed o-rings, back-up rings and oil seals with new ones. Apply gear oil on them before reassembling.
• Thoroughly clean and dry surfaces on which liquid sealant must be reapplied.
• Before assembling, remove rust preventives on new parts.
• Use special tools to fit bearings, bushing and oil seal.
• Assemble parts matching to the marks.
• After completion, check that there is no omission of parts.
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INTRODUCTION
Basic instructions - Electrical equipment precautions

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

• Handle equipment with care so as not to drop it or bump
it.
• Connector should be removed by unlocking while hold-
ing the connector.
• Never disconnect electrical plugs by pulling on the
wires. Always use only the electrical connectors to
make the disconnection.
• Check that connector is connected and locked com-
pletely.
• Engine key off before removing and connecting connec-
tor.
• Engine key off before touching terminals of starter and
alternator.
• Wash machine with care so as not to splash water on
electrical equipment and connector.
• If water has entered a sealed connection, thoroughly
dry both connectors before reconnecting
• Remove battery grounding terminal before beginning
work close to battery and battery relay with tools.
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INTRODUCTION
Basic instructions - Hydraulic contamination

Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination
is any foreign material in the hydraulic oil.
Contamination can enter the hydraulic system in several ways:

• When you drain the oil or disconnect any line
• When you disassemble a component
• From normal wear of the hydraulic components
• From damaged seals or worn seals
• From a damaged component in the hydraulic system
All hydraulic systems operate with some contamination. The design of the components in this hydraulic system per-
mits efficient operation with a small amount of contamination. An increase in this amount of contamination can cause
problems in the hydraulic system.
The following list includes some of these problems:

• Cylinder rod seals that leak
• Control valve spools that do not return to neutral
• Movement of control valve spools is difficult
• Hydraulic oil that becomes too hot
• Pump gears, housing, and other parts that wear rapidly
• Relief valves or check valves held open by dirt
• Quick failure of components that have been repaired
• Slow cycle times are slow. The machine does not have enough power.
If your machine has any of these problems, check the hydraulic oil for contamination.
There are two types of contamination: microscopic and visible.
Microscopic contamination occurs when very fine particles of foreign material are suspended in the hydraulic oil.
These particles are too small to see or feel. Microscopic contamination can be found by identification of the following
problems or by testing in a laboratory.
Examples of problems caused by microscopic contamination:

• Cylinder rod seals that leak
• Control valve spools that do not return to neutral
• The hydraulic system has a high operating temperature
Visible contamination is foreign material that can be found by sight, touch, or odor. Visible contamination can cause
a sudden failure of components.
Examples of problems caused by visible contamination:

• Particles of metal or dirt in the oil
• Air in the oil
• Dark or thick oil
• Oil with an odor of burned oil
• Water in the oil
If you find contamination, use a portable filter to clean the hydraulic system.
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INTRODUCTION
Basic instructions - Biodiesel fuel

Introduction to Fatty Acid Methyl Ester (FAME) biodiesel
FAME biodiesel, called biodiesel fuel in the following section, consists of a family of fuels derived from vegetable oils
treated with methyl esters.
There are two main biodiesel fuel types: Rapeseed Methyl Ester (RME) and Soybean Methyl Ester (SME). RME is a
blend of rapeseed and sunflower methyl ester, and is the preferred crop in Europe. SME is the preferred crop in the
United States.
Biodiesel fuel is a renewable alternative fuel source. Its use and development is promoted worldwide, especially in
Europe and in the United States.
NOTICE: Your emissions control system is compatible with up to 7 % biodiesel fuel (B7). Be aware that the use
of biodiesel fuel that does not comply with the standards mentioned in this section could lead to severe damage to
the engine, fuel system or aftertreatment system of your machine. The use of non-approved fuels may void CASE
CONSTRUCTION Warranty coverage.
Biodiesel can be used to run Tier 4b diesel engines only when blended with standard diesel fuel:
• B7: indicates the blend of 7 % biodiesel and 93 % diesel fuels.
• B20: indicates the blend of 20 % biodiesel and 80 % diesel fuels. Do not use.
Biodiesel fuel has several positive features in comparison with diesel fuel:
• Biodiesel adds lubricity to the fuel, which is beneficial in many circumstances, particularly as sulfur and aromatics
are removed from the fuel.
• Biodiesel has a greater cetane number and burns cleaner.
• Biodiesel produces less particulate matter and reduces smoke emissions.
• Biodiesel is fully biodegradable and non-toxic.
Diesel and biodiesel fuel specifications

Tier 4b diesel fuel specifications are covered by the following:
• EN 590 - Specification of Diesel fuel. (10 ppm sulfur maximum.)
Biodiesel blends are covered by:

• European Diesel Fuel Specification EN 590 allows up to 7 % biodiesel since 2009. European fuel suppliers are
allowed to use up to 7 % biodiesel fuel (B7) to supply the network.
Pure biodiesel blend stock (B100) specification is covered by the following requirements:
• Europe: EN14214 - Automotive fuels. Fatty Acid Methyl Ester (FAME) for diesel engines. Requirements and test
methods.
• DIN V 51606 - German standard for biodiesel.
Before raw oil can be converted into usable biodiesel fuel, it must undergo transesterification to remove glycerides.
During the transesterification process, the oil reacts with an alcohol to separate the glycerine from the fat or vegetable
oil. This process leaves behind two products: methyl ester (the chemical name for biodiesel) and glycerine (a byprod-
uct usually sold for use in soaps or other products).
NOTICE: Biodiesel fuels approved for use in the CASE CONSTRUCTION equipment must be transesterified and
comply with the European Standard EN14214 or the German standard DIN V 51606.
NOTICE: Cold Pressed Biodiesel, Cold Pressed Oil, Straight Vegetable Oil (SVO), or more generally unrefined veg-
etable oils used as motor fuel, are fuels that are normally made from Rapeseed oil or similar high oil content crops.
These kinds of fuel are not transesterified, so they do not fulfil the EN14214 requirements. There is no recognized
quality standard available for these types of fuel. Therefore the use of Cold Pressed Biodiesel, Cold Pressed Oil,
Straight Vegetable Oil (SVO), or more generally unrefined vegetable oils used as motor fuel are NOT APPROVED at
any blend in any CASE CONSTRUCTION product.
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INTRODUCTION
NOTICE: Any engine and fuel injection equipment fitted to a CASE CONSTRUCTION vehicle found to have run with
any blend of NON-APPROVED fuel (fuel not fulfilling the specification described in the requirement EN14214) will no
longer be covered for Warranty by CASE CONSTRUCTION.
Biodiesel fuel usage conditions

You must stringently follow the biodiesel fuel usage conditions. Incorrect application of the biodiesel fuel usage con-
ditions could lead to severe damage to the engine, fuel injection equipment and aftertreatment system.
The main concerns related to operation with biodiesel fuels are:

• Filters and injector blockage caused by poor fuel quality.
• Wear and corrosion of internal components due to water content, which affects lubricity.
• Deterioration of some rubber sealing compounds in the fuel system.
• Biodiesel oxidation, which can lead to the formation of deposits that can harm the fuel injection system.
NOTICE: Any problem in the engine fuel injection equipment associated with non-compliance to the following condi-
tions for biodiesel fuel handling and maintenance will not be covered for Warranty by CASE CONSTRUCTION.
Purchase biodiesel fuel from a trusted supplier who understands the product and maintains acceptable fuel quality.
The use of biodiesel blends up to B7 will not void the CASE CONSTRUCTION warranty as long as the following
conditions for biodiesel fuel handling and maintenance are stringently followed:
Biodiesel fuel must be pre-blended by the supplier. Mixing biodiesel fuels on-site can result in an incorrect mixture
that could damage the engine and/or fuel system.
NOTICE: CASE CONSTRUCTION may void your warranty if the problem is associated with poor fuel quality due to
improper blending. It is the responsibility of the fuel supplier and/or yourself to ensure the right type of fuel and blend
is delivered and used.
Storage
The machine should not be stored for more than 6 months with biodiesel in the fuel system. For longer storage time,
it is strongly suggested that only regular EN 590 or #2 diesel fuel is used.
NOTE: If storage for longer than 6 months is necessary, the engine must be run on regular EN 590 or #2 diesel for a
minimum of 20 hours to flush the biodiesel fuel out of the fuel system prior to storage.
Biodiesel is highly hygroscopic and tends to collect water more than diesel fuel. This increases the risk of algae and
bacteria growth which can cause severe damage to the fuel injection system. Keep the machine fuel tanks and on-site
storage tanks as full as possible to limit the amount of air and water vapors inside the tank. Drain water from the tanks
at least once a week.
NOTICE: Use only CASE CONSTRUCTION approved biocide additives on Tier 4b engines with an exhaust aftertreat-
ment system.
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INTRODUCTION
Capacities
Component 836C 836C AWD 856C 856C AWD
Engine with engine oil filter about about about about
12.5 l 12.5 l 12.5 l 12.5 l
(3.3 US (3.3 US (3.3 US (3.3 US
gal) gal) gal) gal)
Hydraulic system Initial filling about about about about
170 l 185 l 185 l 200 l
(44.9 US (48.9 US (48.9 US (52.8 US
gal) gal) gal) gal)
For oil change about about about about
70 l 70 l 90 l 90 l
(18.5 US (18.5 US (23.8 US (23.8 US
gal) gal) gal) gal)
Powershift transmission Initial filling about about about about
27 l 27 l 27 l 27 l
(7.1 US (7.1 US (7.1 US (7.1 US
gal) gal) gal) gal)
For oil change about about about about
21 l 21 l 21 l 21 l
(5.5 US (5.5 US (5.5 US (5.5 US
gal) gal) gal) gal)
Differential gear about about about about
Side reducer gear 31 l 31 l 36 l 36 l
(8.2 US (8.2 US (9.5 US (9.5 US
gal) gal) about gal) gal) about
31 36
Tandem (chain case) 2 x about 2 x about 2 x about 2 x about
Swing unit 60 l 60 l 64 l 64 l
(15.9 US (15.9 US (16.9 US (16.9 US
gal) gal) gal) gal)
Blade slewing gear about about about about
2 l (0.5 US 2 l (0.5 US 2.5 l 2.5 l
gal) gal) (0.7 US (0.7 US
gal) gal)
Cooling system with heating The coolant is a 50:50 mixture about about about about
(OAT EG2 50-50 Premix) with water 32.0 L 32.0 L 32.0 L 32.0 L
(8.5 US (8.5 US (8.5 US (8.5 US
gal) gal) gal) gal)
Fuel tank about about about about
278.0 L 278.0 L 278.0 L 278.0 L
(73.4 US (73.4 US (73.4 US (73.4 US
gal) gal) gal) gal)
Diesel Exhaust Fluid 54.0 L 54.0 L 54.0 L 54.0 L
(DEF)/AdBlue® tank (11.9 UK (11.9 UK (11.9 UK (11.9 UK
gal) gal) gal) gal)
Windshield washer tank 2.0 L 2.0 L 2.0 L 2.0 L
(0.4 UK (0.4 UK (0.4 UK (0.4 UK
gal) gal) gal) gal)
Refrigerant R134a 1.2 kg 1.2 kg 1.2 kg 1.2 kg
(2.6 lb) (2.6 lb) (2.6 lb) (2.6 lb)
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INTRODUCTION
Consumables
I. Oils for internal combustion engines (change interval 500 OH) Standard
(H) 0W-40 CJ-4 UNITEK to CNH MAT3521

(H) API CJ-4 0W-40*
(H) 5W-30 ACEA E6
(H) 10W-40 CJ-4 UNITEK to CNH MAT3521

(H) API CJ-4 10W-40*
(H) 15W-40 CJ-4 to CNH MAT3522*

(H) API CJ-4 15W-40*
-40 °C -30 °C -20 °C -10 °C 0 °C 10 °C 20 °C 30 °C 40 °C 50 °C

-40 °F -22 °F -4 °F 14 °F 32 °F 50 °F 68 °F 86 °F 104 °F 122 °F
(H) Engine oil pan or coolant block heater recommended in this range
* Requires a 50 % reduction in oil change interval
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INTRODUCTION
II. Oils for hydraulic systems, mineral
SS13K038 1
Specification:
• DIN 51524 HVLP
Oils
(A)
• ISO VG 46 (MS 1230)
e.g.: AKCELA HYDRAULIC EXCAVATOR FLUID
(B)
• ISO VG 68 (MS 1216)
e.g.: AKCELA AW HYDRAULIC FLUID 68 HV
The hydraulic system must be warmed up before commencing work. Warm

up the hydraulic system for approx. 10 min, with the engine at half-speed
and repeated actuation of all control valves.
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INTRODUCTION
II. Oils for hydraulic systems, biodegradable
SS13K040 2
Specification:
• DIN 51524 HVLP
Oils
ISO VG 46 (MS 1230)
e.g.: AKCELA HYDRAULIC EXCAVATOR FLUID BIO
The hydraulic system must be warmed up before commencing work. Warm

up the hydraulic system for approx. 10 min, with the engine at half-speed
and repeated actuation of all control valves.
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INTRODUCTION
III. Oils for powershift transmissions with Ergopower
SS13K039 3
Specification:
• API: CI-4
• ACEA: E7
API: American Petroleum Institute
ACEA: Association des Constructeurs Européen d´Automobiles g.i.e.
Oils
SAE 15W-40 (MS 1121)
e.g.: AKCELA No. 1 ENGINE OIL 15W-40
Automatic powershift transmission-preheating.
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INTRODUCTION
IV.A. Oils for differential gear on rear axle
SS13K061 4
NOTICE: Axles and gearboxes may be damaged by low-grade oils.
Specification:
• API: GL 5 LS additive
LS: Limited slip
Oils
SAE 80W-90
e.g.: AKCELA AXLEPOWER 80W-90
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INTRODUCTION
IV.B. Oils for tandem box on rear axle
SS13K035 5
Specification:
• API: GL 4
Oils
SAE 20W-40 (MS 1317)
e.g.: AKCELA TRANSAXLE FLUID 20W-40
Titan Utto ZF 20W-40
LS-additive: 0 - 0.1 %
S: 0 %
P: 0.15 %
P+S: Phosphor and sulphur alloy corresponding to delivery specification: 2293219
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INTRODUCTION
IV.C. Oils for blade slewing gear
SS13K062 6
Specification:
• API: GL 5
Oils
HYPOIDE SAE 80W-90 (MS 1316)
e.g.: AKCELA GEAR 135 H EP 80W-90
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INTRODUCTION
V. Greases for bearing points and slewing rings
SS13K063 7
Specification:
• NLGI 2
Oils
Multipurpose Grease
e.g.: AKCELA MULTI-PURPOSE GREASE 251H EP
For central lubricating systems and tensioning systems.
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INTRODUCTION
Environment friendly hydraulic fluid

The hydraulic system of this machine can be filled ex factory with environmentally friendly, biodegradable hydraulic
fluid (nonstandard). Stickers with corresponding instructions are then attached to the machine.
For the initial filling, we use only:

ISO VG 46
This synthetic hydraulic fluid has been tested by us and approved for use in our machines. A changeover from mineral
hydraulic fluid to this biodegradable hydraulic fluid can, however, be made at a later date.
Environmentally friendly, biodegradable hydraulic fluid, may also not be simply poured away. They have to be dis-
posed of in the same way that used oil is disposed of.
If hydraulic fluid seeps into the ground, the machine owner and the authorities responsible must be informed.
ISO VG 46 is suitable only for use in hydraulic systems.
As ISO VG 46 is not soluble in water, condensed water may be deposited in the hydraulic fluid tank.
Condensed water must therefore be drained off at regular intervals and after lengthy downtimes, then disposed of in
the same way as used oil.
Use only ISO VG 46 for changing or topping up the hydraulic fluid.
The hydraulic fluid may not be mixed with hydraulic fluids or hydraulic fluids from other manufacturers, as this reduces
its biodegradability.
Operating equipment and attachments operated with mineral hydraulic fluid must not be mounted until thoroughly
emptied, cleaned, and flushed.
Analysis will show whether the hydraulic fluid can be used beyond the standard changing intervals.
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INTRODUCTION
Organic Acid Technology (OAT) coolant

A coolant that relies on inhibitors such as organic acid
salts for corrosion and cavitation protection.
CASE CONSTRUCTION requires the use of a fully for-
mulated Organic Acid Technology (OAT) -based coolant.
CASE AKCELA ACTIFULL™ OT EXTENDED LIFE
COOLANT is preferred. The coolant must meet the
specifications outlined in the CNH material specification
MAT3624. Use of coolant not meeting this specification
is not allowed. Mixing of different coolant brands is not
recommended.
NOTICE: OAT coolant is mandatory for all FPT engines
compliant to Tier 4b emissions using Selective Catalytic
Reduction (SCR). NEVER mix OAT coolant with conven-
tional coolant and with conventional cooling system addi-
tives.
SS14H024 8
NOTICE: Issues as a result of failing to follow the above

guidelines will not be covered under warranty.
In the case that the customer may have topped off an OAT
coolant system with conventional coolant, check the OAT
anti-freeze with conventional anti-freeze test strips to see
if nitriles are present at a level higher than 20 PPM (parts
per million).
If the nitrile level is excessive, follow the procedure below:
1. Empty the engine cooling system and drain the exist-

ing coolant into a suitable container.
2. Fill the system with clean water.
3. Start and run the engine for at least 30 minutes.
NOTE: Ensure to activate the heating system (if
equipped) to circulate fluid through the heater core.
4. Repeat the steps from 1 to 3 twice
5. Fill the system with OAT coolant
The decal shown (CNH part number 47757330) is located

near the fill point of the cooling system whenever CASE
AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT
is filled at the factory. It can also be identified by its yellow
color.
The optimum coolant/water concentration is 50/50. This
concentration will protect the cooling system to -37 °C
(-35 °F).
If a premixed coolant is not available, mix the concentrate
with 50 % of water.
The coolant concentration in the coolant/water mixture
can be determined with a refractometer designed to mea-
sure ethylene glycol content.
Distilled water or deionized water is recommended for the
use in the engine cooling systems.
DO NOT use hard water, sea water and softened sea that
has been conditioned with salt. The minerals and salts
present in potable water can cause corrosion and deposits
resulting in shortened engine life.
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INTRODUCTION
Product identification
Record the machine and part identification numbers. When ordering parts, obtaining information or assistance, always
supply your dealer with the type and serial number of your machine or accessories. Keep a record of these numbers
and your Manufacturer’s Statement of Origin in a safe place. If the machine is stolen, report the numbers to your local
law enforcement agency.
SS14C118 1
Pos. Designation Pos. Designation

1 Model plate of the machine 3 Model plate of the cab
2 Model plate of the engine
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INTRODUCTION
Model plate of the machine

Type/model
PIN
Model year
The machine model plate is affixed to the frame on the right side under the offset cylinder. In addition, the serial
number is stamped onto the front frame.
SS14K156 2

1 Name of the manufacturer 8 Permissible axle 3 load
2 Type / Model & Designation 9 Manufacturer's address
3 Type approval number 10 Designation
4 Product Identification Number (PIN) 11 Year of construction
5 Total Permissible mass 12 Model Year
6 Permissible axle 1 load 13 Unladen mass
7 Permissible axle 2 load 14 Engine Max Net Power (ISO 14396/ECE R120)
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INTRODUCTION
Model plate of the engine

Manufacturer
Engine type number
Engine serial number
The plates are affixed to the cylinder head cover at the top next to the oil filler hole.
SS14J033 3

1 Name of the manufacturer 4 FPT part number
2 Month and year of production 5 Serial number
3 CNH part number
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INTRODUCTION
Pos. Designation
6 Engine type
7 Serial number
8 Engine family
SS14J034 4
County of origin label
SS14J028 5
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INTRODUCTION
Model plate of the cab

Type
Serial number
The cab model plate is affixed to the inside of the cab

centered behind the steering column.
Pos. Designation
1 Machine manufacturer
2 Type
3 Applicable models
4 Serial number
SS14A128 6
5 Total permissible mass
6 Approval standards
CE mark
The CE mark that is located on the machine model plate
(see figure 2) certifies that the machine has been built in
accordance with the CE directives 2006/42/EC.
CE stands for “Communauté Européenne” (European
Community).
SS11K196 7
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INTRODUCTION
Machine number
The model plate with the machine number is attached be-

low the right cab door.
SS14K158 8
The number is moreover marked on the front frame.
SS11H038 9
Powershift transmission number
The model plate with the powershift transmission number

is attached on the transmission housing.
SS11K216 10
Component numbers
Identification plates with the serial number can also be
found on other bigger units. Steel components can have
the parts number or the factory number engraved in the
metal where they are easily visible.
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INTRODUCTION
Product identification - Machine orientation

As used in this manual, the terms “right”, “left”, “front”, and “rear” indicate the sides of the machine as seen from the
operator’s seat.
SS14C119 1

A Front C Left
B Rear D Right
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SERVICE MANUAL
Engine
836C AWD
836C
856C AWD
856C
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Contents
Engine - 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
[10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
[10.501] Exhaust Gas Recirculation (EGR) exhaust treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
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Engine - 10
Engine and crankcase - 001
836C AWD
836C
856C AWD
856C
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10.1 [10.001] / 1
Contents
Engine - 10
TECHNICAL DATA
Engine
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Engine
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine support and mounts
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Engine - Engine and crankcase
Engine - General specification

Type 836C 836C AWD 856C 856C AWD
Manufacturer FPT FPT FPT FPT
Name NEF 6Cyl 115 kW NEF 6Cyl 115 kW NEF 6Cyl 142 kW NEF 6Cyl 142 kW
4Valve TAA 4Valve TAA 4Valve TAA 4Valve TAA
Model/Code F4HFE6133*B003 F4HFE6133*B003 F4HFE613Y*B005 F4HFE613Y*B005
Turbo-charging yes yes yes yes
Cooling Charge air/water Charge air/water Charge air/water Charge air/water
Charge air cooling Turbocharged Turbocharged Turbocharged Turbocharged
Injection Common rail Common rail Common rail Common rail
Cylinder 6 6 6 6
Displacement 6700 cm³ (409 in³) 6700 cm³ (409 in³) 6700 cm³ (409 in³) 6700 cm³ (409 in³)
Power output 115 kW (156 Hp) 115 kW (156 Hp) 142 kW (193 Hp) 142 kW (193 Hp)
Torque 725 N·m (535 lb ft) / 725 N·m (535 lb ft) / 850 N·m (627 lb ft) / 850 N·m (627 lb ft) /
1400 RPM 1400 RPM 1400 RPM 1400 RPM
Nominal speed 2100 RPM 2100 RPM 2100 RPM 2100 RPM
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Engine - Remove
WARNING
Heavy objects!
Lift and handle all heavy components using lifting equipment with adequate capacity. Always support
units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.
Failure to comply could result in death or serious injury.
W0398A
Prior operation:
Rear wheels - Remove (44.520).
Hood - Remove (90.100).
Selective Catalytic Reduction (SCR) muffler and catalyst - Remove (10.500)
Battery - Remove (55.302).
Radiator - Remove (10.400).
Engine support and mounts - Remove (10.001).
Engine hood panel rear support - Remove (90.100).
NOTE: If the optional air conditioning system is installed, drain off the refrigerant if a filling/draining system is available.
If this is not available, the air conditioning compressor should be detached from the engine, the condenser from the
combination cooler and the filter-drier from the bracket without cutting off the refrigerant lines.
NOTE: Emissions sensors mounted in the exhaust stream are sensitive to extreme vibrations. Use of tools that gen-
erate extreme vibrations, such as impact wrenches and hammers, will result in damage to emission sensors. Avoid
using these tools during any service procedure in close proximity of emission sensors. If the use of these tools cannot
be avoided, remove the sensors using extreme caution prior to performing any service procedure.
1. Remove the screws (2).
2. Remove the two rear wheel cover (1) from the rear axle.
SS14J050 1

4. Remove the four wheel cover brackets (1) from the rear
axle.
SS14K001 2
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5. Detach the ground cables for the engine, cab and bat-
tery from the grounding point on the right inside the
frame.
INA 3
6. Remove the hoses from the Organic Acid Technology

(OAT) coolant tank (1).
7. Remove the Organic Acid Technology (OAT) coolant
tank (1).
SS14K002 4
8. Remove the attachments.
SS14K037 5
9. Remove the hoses (3) from the fuel pump (1).

11. Remove the fuel pump (1).
SS14K006 6
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12. Remove the hoses.
SS14K007 7
13. Remove the hose (3).

14. Loosen the clamp (4).
15. Loosen the clamps (2) from the air intake system (1).
16. Remove the air intake system (1).
SS14K008 8
17. Remove the hoses.
SS14K009 9
18. Detach all hydraulic lines from the hydraulic fluid tank.
19. Screw in two M12 eye bolts (1) into the hydraulic fluid
tank and secure with lifting gear.
20. Remove the three mounting bolts (2).
21. Remove the mounting bolt (3) from the underside.
SS14K010 10
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22. Detach all hydraulic lines from the pump unit (1).
24. Remove the pump unit (1) from the transmission.
SS14K011 11
25. Unscrew the 4 cap bolts (2).

26. Remove the power transmission shaft (1) at the trans-
mission side.
SS14K012 12
27. Remove the hydraulic components and hoses.
SS14K013 13
28. Secure the engine-transmission pump unit with lifting

gear.
29. Loosen the assembly mounting bolts (1).
30. Carefully raise the engine out of the grader frame.
SS14K014 14
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31. Set the engine-transmission-pump unit down on a

suitable assembly stand, and secure them.
INA 15
32. Secure the transmission using lifting gear.

33. Remove the cover from the flywheel housing to gain
access to the four bolts (1) that connect the flywheel
to the torque converter.
34. After loosening the first bolt (1), turn the engine by
hand until the second bolt is located at the hole and
can be loosened.
35. Remove the other two bolts in the same way.
SS14K015 16
Next operation:
Powershift transmission - Remove (21.113).
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Engine - Install
WARNING
Heavy objects!
W0398A
Prior operation:
Powershift transmission - Install (21.113).
1. Insert the first of the four bolts (10) into the hole in the
flywheel housing and tighten temporarily.
2. Turn the engine by hand and, in the same way, insert
and temporarily tighten the other three bolts.
SS14K015 1
3. Progressing crosswise, tighten the transmission outer

mounting bolts on the engine.
Tighten the bolts with 44 N·m (32.5 lb ft).
4. Tighten the four inner mounting bolts that fasten the
flywheel to the torque converter.
Tighten the bolts with 44 N·m (32.5 lb ft).
SS12D566 2
5. Check the engine mounts and replace if necessary.

6. Set the engine-transmission unit in the frame, by using
the lifting equipment. When doing so, check that it is
not catching on any hydraulic hoses or electrical lines.
7. Screw in the assembly mounting bolts (1) and tighten
them.
SS14K014 3
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8. Fix the power transmission shaft (1) to the transmission

with the four cap bolts (2).
SS14K012 4
9. Install the pump unit (1) to the transmission.

10. Fix the pump unit (1) with the screws (2).
11. Attach all hydraulic lines on the pump unit (1).
SS14K011 5
12. With the lifting equipment, lift the hydraulic fluid tank
onto the frame and align at the holes.
13. Fix the hydraulic fluid tank to the frame with screws
(2) and (3).
14. Unscrew the two M12 eye bolts (1) and remove them.
15. Connect the appropriate hydraulic lines to the hy-
draulic fluid tank.
SS14K010 6
16. Install the air intake system (1).

17. Lift the Selective Catalytic Reduction muffler (SCR) (1)
into the machine.
18. Fix the clamps (2).
19. Fix the clamp (4).
20. Attach the hose (3).
SS14K008 7
21. Install the DEF/AdBlue tank, refer to Diesel Exhaust

Fluid (DEF)/AdBlue® tank - Install (10.500).
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22. Install the fuel pump (1) with the screws (2).
23. Attach the hoses (3) on the fuel pump (1).
SS14K006 8
24. Install the following attachments.
SS14K037 9
25. Install the Organic Acid Technology (OAT) coolant

tank (1).
26. Attach the hoses to the Organic Acid Technology
(OAT) coolant tank (1).
SS14K017 10
27. Connect the ground cables for the engine, cab, and
battery to the grounding point on the right inside the
frame.
INA 11
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28. Install the four wheel cover brackets (1) on the rear
axle with the screws (2).
SS14K001 12
29. Install the two rear wheel cover (1) on the rear axle
with the screws (2).
SS14J050 13
Next operation:
Engine hood panel rear support - Install (90.100).
Selective Catalytic Reduction (SCR) muffler and catalyst - Install (10.500)

Engine support and mounts - Install (10.001).
Radiator - Install (10.400).
Battery - Install (55.302).
Hood - Install (90.100).
Rear wheels - Install (44.520).
Engine - Complete (10.001).
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Engine - Complete
1. Fill with hydraulic fluid and engine coolant.
2. If draining/filling equipment is available, fill the air con-
ditioning system with refrigerant.
3. Start the engine and carry out a function test.
4. Check all connections for leaks.
5. If necessary, top up the hydraulic fluid and engine
coolant.
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Engine support and mounts - Remove

Removing support bracket together with exhaust muffler and handrail
1. Remove the hoses from the fuel pre-filter (1).
2. Remove the fuel pre-filter (1).
SS14K003 1
3. Loosen the clamp (3) from the dryer (1) of the air con-
ditioning.
4. Loosen the hoses at the screw fitting (2).
5. Remove the dryer (1).
SS14K004 2
6. Secure the bracket (1) using lifting gear.

7. Loosen the mounting bolts from the right side.
8. Loosen the mounting bolts from the left side.
9. Raise the bracket (1), taking care to detach the flexible
exhaust line from the exhaust pipe to the turbocharger.
SS14K022 3
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Engine support and mounts - Install

1. Install the bracket (1) using lifting gear.
2. Fix the mounting bolts from the right side.
3. Fix the mounting bolts from the left side.
4. Attach the flexible exhaust line from the exhaust pipe
to the turbocharger.
SS14K022 1
5. Install the dryer (1) and fix it with the clamp (3).
6. Fix the hoses at the screw fitting (2).
SS14K004 2
7. Install the fuel pre-filter (1).

8. Attach the hoses to the fuel pre filter (1).
SS14K003 3
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Index
Engine - 10

Engine - Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine support and mounts - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Engine support and mounts - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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Engine - 10
Selective Catalytic Reduction (SCR) exhaust treatment - 500
836C AWD
836C
856C AWD
856C
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Contents
Engine - 10
FUNCTIONAL DATA
Selective Catalytic Reduction (SCR) exhaust treatment

Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Selective Catalytic Reduction (SCR) muffler and catalyst

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Diesel Exhaust Fluid (DEF)/AdBlue® tank
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Coolant control valve
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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Engine - Selective Catalytic Reduction (SCR) exhaust treatment
Selective Catalytic Reduction (SCR) exhaust treatment - Dynamic

description
The grader is equipped with the Selective Catalytic Reduction (SCR) engine exhaust emission control system. With
this system, the engines operate as efficiently as possible. During normal operation the diesel engine generates
certain pollutants. Federal law has regulated the levels of these exhaust components that a vehicle is allowed to emit.
Pollutants generated in the normal operation of the engines require after treatment. The SCR system converts the
pollutants to harmless nitrogen and water.
A diesel engine operates most efficiently at higher combustion temperatures. Unfortunately, the higher combustion
temperatures generate increased levels of nitrogen oxides (NOx). A sensor determines the NOx level in the exhaust
stream and reports this information to the Engine Controller. To reduce the NOx level the system adds a urea based
Diesel Exhaust Fluid (DEF) to reduce the pollutant. The NOx sensor monitors the exhaust to assure the system
meets regulations. An alarm sounds and a warning displays on the Advanced Instrument Cluster (AIC) if the system
malfunctions.
Operator Cautions
DEF fluid mishandling causes SCR system problems. It is preferable to dispense DEF directly from factory containers.
If refillable containers are required to handle DEF, make sure that it does not have traces of other contaminating
liquids. Water and oil do not mix. Petroleum contamination causes problems. Make sure that dirty containers are not
used. Replace the tank filler cap after filling. Dirty fluid causes premature filter plugging.
The SCR system requires the exhaust temperature to be above approximately 230 °C (446 °F) for proper function.
Operating units under light load conditions i.e. roading longer distances, idling or light duty cycle applications can
trigger alarms. For example, working for about 10 minutes and then idling for about 20 minutes can trigger an alarm.
Most of the sensors operate in adverse operating conditions and are designed to survive those. Damage can result
when a sensor is exposed to other conditions, For example, rain water can damage the NOx sensor. Operators should
be conscious of parking locations or consider covering the exhaust.
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SCR System Function

To reduce the NOx level the SCR system adds a Diesel Exhaust Fluid (DEF) to the catalyst to reduce the NOx pollu-
tant. DEF fluid is required for the SCR System to function.
Another term for DEF is DEF/AdBlue®. The NOx sensor monitors the exhaust to assure the system is functioning
correctly. A malfunction causes an audible alarm to sound and a warning to display on the AIC screen.
The machine consumes DEF/AdBlue® during operation. The ratio of DEF/AdBlue® to diesel fuel consumed varies
depending on the load on the engine and other factors.
The SCR system is electronically controlled.

The electronic control can be integrated into the Engine Control Unit (ECU) (2). The ECU matches the amount of
DEF/AdBlue® precisely to the relevant engine parameters. In this way it is possible to reduce NOx emissions by up
to 95%.
The supply module (6) provides a fluid pressure to the dosing module (11).
The dosing module (11) injects the required DEF/AdBlue®. The ECU receives inputs from sensors and then the ECU
controls the amount of DEF/AdBlue® injected.
A mixer (12) is located in the Diesel Oxidation Catalyst (DOC) (13) flow at the inlet of the catalyst to assure distribution
of the DEF/AdBlue® to the catalyst.
The ECU (2) monitors the function of the system. The ECU will activate the fault codes when the system malfunctions.
The use of Diesel Oxidation Catalyst (DOC) (13) in combination with Selective Catalytic Reduction (SCR) (17) allows
for better low temperature performance of SCR catalyst, to achieve very low emissions even in low load mission
profiles, through DOC/SCR coupling and improved DEF/AdBlue® hydrolysis.
The Diesel Oxidation Catalyst (DOC) (13) is a key component to increase the SCR performance especially at low
temperatures, in that it creates NO2 from the NO in the exhaust.
Improved dosing system accuracy thanks to closed-loop NH3 ammonia sensing, to avoid reducing agent slip while
achieving NOx conversion higher than 90% in the whole operating speed and load range, both in steady-state and
transient conditions.
Clean Up Catalyst (CUC) (18) after the Selective Catalytic Reduction (SCR) (17) has an important role for minimizing
NH3 slip to the environment.
Thermal management by means of an exhaust flap (3) , to heat up the after-treatment system as quick as possible
and achieve optimal SCR working temperature window.
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LEIL13WHL0189FB 1

1 Engine 12 DEF/AdBlue® mixer
2 Engine Control Unit (ECU) 13 Diesel Oxidation Catalyst (DOC) + mixer
3 Exhaust flap 14 Temperature sensor – DOC upstream
4 Intake air humidity and temperature sensor 15 NOx sensor
5 Air filter 16 Temperature sensor – SCR upstream
6 Supply Module 17 Selective Catalytic Reduction (SCR)
7 DEF/AdBlue® filter 18 Clean Up Catalyst (CUC)
8 DEF/AdBlue® quality sensor 19 Temperature sensor – SCR downstream
9 DEF/AdBlue® level and temperature sensor 20 NH3 sensor
10 DEF/AdBlue® tank 21 NOx sensor
11 DNOx -2.2 Dosing Module
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SCR System Components

The main components of SCR system are:
DEF/AdBlue® solution tank

• A catalyst solution, DEF/AdBlue® is required for the system to operate. The vehicle typically consumes approxi-
mately 5 - 6 % as much DEF/AdBlue® as diesel fuel. This fluid consists of 32.5 % urea mixed into distilled water.
Use of containers with traces of other liquids to handle DEF/AdBlue® causes contamination that fouls the system.
Proper handling procedures are required. Use only American Petroleum Institute (API) certified DEF/AdBlue®.
• Engine coolant circulates through the Tank Heater to thaw the DEF/AdBlue®. An On-Off solenoid valve controls
the coolant flow to prevent DEF/AdBlue® overheating.
• An in-line DEF/AdBlue® filter is installed between the tank and the inlet of the supply module. In extreme dirty
conditions, the vent can allow dirt to enter the tank and plug the filter. Clean this filter initially @ 250 hours and
every 500 hours or yearly thereafter.
Supply Module
The Supply Module (1) contains a pump which withdraws
the DEF/AdBlue® from the DEF/AdBlue® tank (2). The
DEF/AdBlue® is then directed to the dosing module con-
nected to the Diesel Oxidation Catalyst (DOC).
SS14F029 2
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Supply Module external view
SS14K314 3

1 Main Filter 6 Coolant water connector
2 Cover 7 DEF/AdBlue® inlet (from Tank to Supply Module)
3 Fixation points 8 Pressure compensation membrane
4 DEF/AdBlue® outlet (From Supply Module to 9 Electrical connector
Dosing Module)
5 DEF/AdBlue® backflow (From Supply Module to
Tank)
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Supply Module internal view

The Supply Module consists of the following:
• a DEF/AdBlue® membrane pump (5) delivers fluid from the supply tank to the dosing module.
• a reversing valve (4) returns flow from the system back to the DEF/AdBlue® supply tank as the system is shutdown.
The pump may run up to 90 seconds after shutdown.
• the DEF/AdBlue® temperature sensor (3) monitors the temperature.
• the DEF/AdBlue® pressure sensor (2) monitors the fluid pressure to the dosing module.
• a main DEF/AdBlue® filter (1) removes finer contamination. This filter requires service at 4000 hours or 2-yearly.
• There is also a return flow passage within the supply module. This allows for both the DEF/AdBlue® supply and
return connections to the tank to come to one location on the engine.
LEIL13WHL0191FB 4

1 Main Filter 5 DEF/AdBlue® membrane pump
2 Pressure sensor 6 Electrical connector
3 Temperature sensor 7 Lead frame
4 Reversing valve (4/2 Way valve)
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Diesel Oxidation Catalyst (DOC)

The Diesel Oxidation Catalyst (DOC) (1) converts part of
the NO to NO2.
The DOC is required to achieve as close as possible
50 %/ 50 % NO2 /NOx ratio before the SCR.
The presence of NO2 increases the NOx conversion effi-
ciency of the SCR catalyst.
The DEF/AdBlue® is injected in the DOC by the dosing
module (2) connected to the DOC.
SS14E250 5
Dosing Module
The Dosing Module which reduces the nitrogen oxides in the exhaust gas.
The Dosing Module mixes with the exhaust gas the precise amount of the reduction agent DEF/AdBlue® required
for the chemical reaction in the SCR catalytic converter.
LEIL13WHL0192FB 6

1 Gasket (replace the gasket when Dosing Module 4 Valve keeper of the DEF/AdBlue® connector
is removed)
2 Heat shield 5 Electrical connector
3 Coolant connector
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Selective Catalytic Reduction (SCR) + Clean Up Catalyst (CUC)

The Clean Up Catalyst (CUC) is located at the end of the
Selective Catalytic Reduction (SCR). The CUC converts
the ammonia (NH3) slip to N2 and H2.
The CUC ensures that the ammonia slip to ambient is
minimal.
SS14F018 7
SS14F019 8
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Exhaust flap
The exhaust flap is a device located between the turbine
and the exhaust system. The exhaust flap is equipped
with a throttle valve which manages the rate and the “light
off” temperature of the exhaust gas.
The “light off” temperature indicates the temperature at
which the catalytic process is initiated.
SS14K322 9
LEIL13WHL0193FB 10

1 Exhaust air outlet 4 Throttle valve
2 Coolant connections 5 Electrical connector
3 Exhaust air inlet
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Control System Sensors

NOTE: Emissions sensors in the exhaust system and on the vehicle may be damaged by vibrations from use of impact
wrenches or hammers during service work. Avoid using these tools when servicing components close to the sensors.
Remove the sensors with care if use of these tools cannot be avoided.
LEIL13WHL0189FB 11
• Humidity and Ambient Air Temperature sensor at engine intake. Ambient air humidity impacts the amount of NOx
generated. This humidity level is reported directly to the Engine Control Unit (ECU).
• DEF/AdBlue® tank level and temperature sensor (9)
• The temperature of the DEF/AdBlue® is important to the SCR control system. DEF/AdBlue® freezes at -11 °C
(12 °F). It also degrades at elevated temperatures.
• If DEF/AdBlue® is not injected or if it has been contaminated reduced engine power results. A DEF/AdBlue® level
sensor is installed in the tank and the AIC screen displays that level.
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• Fluid Temperature Sensor in Supply Module

• A temperature sensor monitors the fluid temperature at the inlet of the main filter in the supply module.
• Fluid Pressure in Supply Module (6)
• A pressure sensor monitors the fluid pressure delivered to the dosing module.
• Temperature Sensor – DOC upstream (14). A Temperature Sensor is installed upstream of the Diesel Oxidation
Catalyst (DOC) to monitor exhaust temperature. To assure an efficient operating of the Diesel Oxidation Catalyst
(DOC), the exhaust temperature needs to be within a specific range. A too low temperature restricts the Diesel Ox-
idation Catalyst (DOC) function. The Diesel Oxidation Catalyst (DOC) will be damaged if the temperature exceeds
a critical level.
• Temperature Sensor – SCR upstream (16). A Temperature Sensor is installed upstream of the Selective Catalytic
Reduction (SCR) to monitor exhaust temperature after the Diesel Oxidation Catalyst (DOC). To assure an efficient
operating of the Selective Catalytic Reduction (SCR), the exhaust temperature needs to be within a specific range.
A too low temperature restricts the Selective Catalytic Reduction (SCR) function. The Selective Catalytic Reduction
(SCR) will be damaged if the temperature exceeds a critical level.
• Temperature Sensor – SCR downstream (19). A Temperature Sensor is installed downstream of the Selective Cat-
alytic Reduction (SCR) to monitor exhaust temperature. To assure an efficient operating of the Selective Catalytic
Reduction (SCR), the exhaust temperature needs to be within a specific range. A too low temperature restricts
the Selective Catalytic Reduction (SCR) function. The Selective Catalytic Reduction (SCR) will be damaged if the
temperature exceeds a critical level.
• NOx sensor (15) upstream of the Diesel Oxidation Catalyst (DOC)
• A NOx sensor is mounted upstream of the Diesel Oxidation Catalyst (DOC) to monitor the emission level before
the Diesel Oxidation Catalyst (DOC).
• NOx sensor (21) downstream of the Selective Catalytic Reduction (SCR)
• A NOx sensor is mounted downstream of the Selective Catalytic Reduction (SCR) to monitor the emission level
after the SCR process has taken place.
• NH3 sensor (16) downstream of the Clean Up Catalyst (CUC).
• A NH3 sensor is mounted downstream of the Clean Up Catalyst (CUC) to monitor the elimination of the residual
ammonia after the SCR process has taken place.
The elimination of the residual ammonia is electronically controlled by a specific NH3 controller.
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Heaters
• DEF/AdBlue® freezes at -11 °C (12 °F). Many times these units operate in climates colder than this.
• A heating device incorporated within the DEF/AdBlue® tank level sensor thaws the DEF/AdBlue®. Engine
coolant is circulate through this heater to warm the fluid. The flow of coolant to this heater passes through a
solenoid controlled on-off valve. This prevents heating the DEF/AdBlue® fluid once thawed.
• The plumbing between the tank and the supply module can also freeze. The coolant required to thaw the tank is
routed through a plumbing bundle to thaw the hoses.
• There are DEF/AdBlue® passages within the supply module that can freeze. Electric heaters incorporated in
the module thaw this fluid as required.
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Selective Catalytic Reduction (SCR) muffler and catalyst - Remove

NOTICE: Emissions sensors in the exhaust system and on the vehicle may be damaged by vibrations from use of
impact wrenches or hammers during service work. Avoid using these tools when servicing components close to the
sensors. Remove the sensors with care if use of these tools cannot be avoided.
1. Open the hood (1).
SS14K018 1
2. Loosen the hexagonal nut on sensor and remove the

cat upstream temperature sensor (1) of the Selective
Catalytic Reduction (SCR).
SS14K027 2
3. Loosen the hexagonal nut on sensor and remove the

cat downstream temperature sensor (1) of the Selec-
tive Catalytic Reduction (SCR).
SS14K028 3
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4. Loosen the hexagonal nut on NOx sensor (1) and re-

move NOx sensor from Selective Catalytic Reduction
(SCR).
SS14K029 4
5. Loosen the hexagonal nut on NH3 sensor (1) and re-

move the NH3 sensor from the Selective Reduction
(SCR).
SS14K030 5
6. Attach a suitable lifting device and a lift strap to the Se-

lective Catalytic Reduction (SCR) + Clean Up Catalyst
(CUC).
7. Remove the clamp (1), the gasket and the gasket align-
ment sleeve from Diesel Oxidation Catalyst (DOC) and
Selective Catalytic Reduction (SCR) pipe connection.
Discard the clamp and the gasket.
NOTE: Gasket and clamp should be replaced every time
the connection is disassembled.
SS14K035 6
8. Remove the two nuts (1) of the brackets (2). Repeat

the same operation for the opposite side and remove
the brackets (2).
SS14K036 7
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Selective Catalytic Reduction (SCR) muffler and catalyst - Install

1. Attach a suitable lifting device and a lift strap to the Se-
lective Catalytic Reduction (SCR) + Clean Up Catalyst
(CUC). Move the Selective Catalytic Reduction (SCR)
+ Clean Up Catalyst (CUC) into position on the ma-
chine.
Install the brackets (2) and fix the brackets with the nuts
(1).
NOTE: Tighten the nuts (1) to 25.0 N·m (18.4 lb ft) only
when the SCR is aligned with the DOC.
SS14K036 1
2. Install a new gasket and a new clamp (1) at connection

between Diesel Oxidation Catalyst (DOC) and Selec-
tive Catalytic Reduction (SCR) pipe. Tighten the clamp
to 11.0 - 13.0 N·m (8.1 - 9.6 lb ft).
connection is disassembled.
NOTE: It might be necessary to loosen the turbo clamp,
brackets and U-bolts to gain proper alignment of compo-
nents.
SS14K035 2
3. Install the NH3 sensor (1) into the exhaust pipe on the
Selective Catalytic Reduction (SCR).
Torque to 40.0 - 60.0 N·m (29.5 - 44.3 lb ft).
SS14K030 3
47829048B 15/06/2016
10.2 [10.500] / 17
4. Install the NOx sensor (1) into exhaust pipe on the Se-
lective Catalytic Reduction (SCR).
Torque to 40.0 - 60.0 N·m (29.5 - 44.3 lb ft).
SS14K029 4
5. Install the cat downstream temperature sensor (1)

of the Selective Catalytic Reduction (SCR) with the
hexagon nut.
Torque to 40.0 - 50.0 N·m (29.5 - 36.9 lb ft).
SS14K028 5
6. Install the cat upstream temperature sensor (1) of the

Selective Catalytic Reduction (SCR) with the hexagon
nut.
Torque to 40.0 - 50.0 N·m (29.5 - 36.9 lb ft).
SS14K027 6
47829048B 15/06/2016
10.2 [10.500] / 18
Diesel Exhaust Fluid (DEF)/AdBlue® tank - Remove

CAUTION
Flying debris!
Compressed air can propel dirt, rust, etc. into the air. Wear eye and face protection when using com-
pressed air.
C0049A

2. Drain the engine coolant.
SS14K018 1
3. Remove the cover plate (2).

4. Place a suitable container below the DEF/AdBlue®
tank.
Disconnect harness, remove Urea Quality Sensor
(UQS), allow to drain the DEF/AdBlue® through UQS
hole.
Reinstall UQS.
5. Remove the screws that secure the tank to the frame.
SS14K021 2
6. Remove the rubber boot cover from the wires of the

liquid level/temperature sensor sending unit, DEF/Ad-
Blue® and engine coolant supply lines. Mark wire and
hose connection positions.
NOTE: Use compressed air and water to clean debris from
top of DEF/AdBlue® supply tank around the liquid level/
temperature sensor sending unit area.
SS14K024 3
47829048B 15/06/2016
10.2 [10.500] / 19
7. Unplug the wiring harness. Disconnect the engine

coolant lines and the DEF/AdBlue® lines by pushing
coupling together, squeezing tabs and then pulling
connection apart.
8. Pull the wire and the hose harness up and off to the
side out of the way.
NOTE: Plug all lines to prevent debris from entering the
system.
SS14K025 4
9. Remove the hexagonal bolts from the DEF/AdBlue®

tank (1).
10. Remove the DEF/AdBlue® tank (1).
SS14K315 5
47829048B 15/06/2016
10.2 [10.500] / 20
Diesel Exhaust Fluid (DEF)/AdBlue® tank - Install

1. Position the tank.
2. Plug the wiring harness.
Connect the engine coolant lines and the DEF/Ad-
Blue® lines.
SS14K025 1
3. Install the DEF/AdBlue® tank (1) with the hexagonal

bolts.
SS14K315 2
4. Install the rubber boot cover from the wires of the liquid
level/temperature sensor sending unit, DEF/AdBlue®
and engine coolant supply lines.
top of DEF/AdBlue® supply tank around the liquid level/
temperature sensor sending unit area.
SS14K024 3
5. Mount the tank to the frame with the screws.
SS14K022 4
6. Refill the engine coolant.

Refill the tank.
47829048B 15/06/2016
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Coolant control valve - Remove

CAUTION
Flying debris!
pressed air.
C0049A

SS14K018 1
3. Locate the DEF/ADBLUE® Heater Control valve up to

Supply Module on the right–hand side of the engine.
SS14K038 2
4. Disconnect the machine wiring harness (2) from the

DEF/ADBLUE® heater control valve.
Using a small flat blade screw driver, pull up on the
fitting retaining clip and disconnect the coolant inlet (3)
/outlet (5) and by-pass (4) lines from the heater control
valve (1)
5. Remove the hexagonal bolts (6) securing heater con-
trol valve to the mounting support bracket and remove
the heater control valve (1) from machine.
SS14K039 3
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10.2 [10.500] / 22
Coolant control valve - Install

1. Position the DEF/ADBLUE® heater control valve on the
mounting support bracket and secure it with hexagonal
bolts (6).
2. Reconnect the following items to the heater control
valve (1): the coolant inlet line (3), the coolant outlet
line (5), the by-pass line (4).
Reconnect the wiring harness (2).
Refill the engine cooling system.
SS14K039 1
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Index
Engine - 10

Coolant control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Coolant control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Diesel Exhaust Fluid (DEF)/AdBlue® tank - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Diesel Exhaust Fluid (DEF)/AdBlue® tank - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Selective Catalytic Reduction (SCR) exhaust treatment - Dynamic description . . . . . . . . . . . . . . . . . 3
Selective Catalytic Reduction (SCR) muffler and catalyst - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Selective Catalytic Reduction (SCR) muffler and catalyst - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Engine - 10
Exhaust Gas Recirculation (EGR) exhaust treatment - 501
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
10.3 [10.501] / 1
Contents
Engine - 10
SERVICE
Diesel Oxidation Catalyst (DOC)

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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10.3 [10.501] / 2
Engine - Exhaust Gas Recirculation (EGR) exhaust treatment
Diesel Oxidation Catalyst (DOC) - Remove

Prior operation:
Selective Catalytic Reduction (SCR) muffler and catalyst - Remove (10.500)
SS14K018 1
2. Remove the dosing module.

NOTE: Cover the dosing module to protect from contami-
nation.
SS14K042 2
3. Attach a suitable lifting device and a lift strap to the

Diesel Oxidation Catalyst (DOC).
SS14K043 3
47829048B 15/06/2016
10.3 [10.501] / 3
4. Remove the clamp (1).

the connection is disassembled.
SS14K044 4
5. Remove the nuts (1) of the brackets (2) and remove the
brackets (2).
6. Lift the Diesel Oxidation Catalyst (DOC) from machine.
SS14K045 5
47829048B 15/06/2016
10.3 [10.501] / 4
Diesel Oxidation Catalyst (DOC) - Install

NOTICE: emissions sensors in the exhaust system and on the vehicle may be damaged by vibrations from use of
1. Lift the Diesel Oxidation Catalyst (DOC) in the machine.
2. Install the brackets (2) with the nuts (1).
Torque to 10.0 - 12.0 N·m (7.4 - 8.9 lb ft).
SS14K045 1
3. Install the clamp (1).

Torque to 6.0 - 8.0 N·m (4.4 - 5.9 lb ft).
SS14K044 2
4. Install the dosing module and gaskets.

Torque to 6.0 - 10.0 N·m (4.4 - 7.4 lb ft).
NOTE: Install always new dosing module gaskets each
time it is removed and reassembled.
SS14K042 3
Next operation:
Selective Catalytic Reduction (SCR) muffler and catalyst - Install (10.500)
47829048B 15/06/2016
10.3 [10.501] / 5
Index
Engine - 10

Diesel Oxidation Catalyst (DOC) - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Diesel Oxidation Catalyst (DOC) - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47829048B 15/06/2016
10.3 [10.501] / 6
Engine - 10
Engine cooling system - 400
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
10.4 [10.400] / 1
Contents
Engine - 10
SERVICE
Radiator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Engine - Engine cooling system
Radiator - Remove
WARNING
Heavy objects!
W0398A
WARNING
Burn hazard!
Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that
exceed 49 °C (120 °F). Allow fluids to cool before proceeding.
W0330B
Prior operation:
Hood - Remove (90.100)
NOTICE: Hydraulic fluid may flow out when the hydraulic lines are loosened. This fluid should be collected and
properly disposed of.
1. Detach lines (1) to (6) from the combination cooler (7).
• Hydraulic fluid outlet line (1)
• Transmission oil inlet line (2)
• Transmission oil outlet line (3)
• Coolant outlet line (4)
• Charge air cooling inlet line (5)
• Line to coolant expansion reservoir (6)
• Combination cooler (7)
• Disconnect the coolant temperature sensor e-line (8)
SS14E244 1
2. Detach lines (9) to (12) from the combination cooler.

• Hydraulic fluid inlet line (9)
• Coolant inlet line (10)
• Charge air cooling outlet line (11)
• Detach the hydraulic fluid lines from fan hydraulic
(12) motor.
NOTICE: If an air conditioning system is installed and no
filling equipment is available, the condenser (13) should be
disconnected from the combination cooler without detach-
ing the coolant lines.
SS14K323 2
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10.4 [10.400] / 3
3. Secure the combination cooler with lifting gear.

4. Loosen the bolts (14) that fix the combination cooler to
the bracket and to the hydraulic fluid tank.
5. Raise the combination cooler and remove.
6. Close off the inlets and outlets on the combination
cooler.
SS12D535 3
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10.4 [10.400] / 4
Radiator - Install
WARNING
Heavy objects!
W0398A
1. Using the lifting gear, set the combination cooler on the

support bracket or the hydraulic fluid tank.
2. Using the bolts (14), fasten the combination cooler to
the support bracket and to the hydraulic fluid tank.
3. Remove the stop plugs from the inlets and outlets of
the combination cooler.
SS12D535 1
4. Connect lines (9) to (12) to the combination cooler:

• Hydraulic fluid inlet line (9)
• Coolant inlet line (10)
• Charge air cooling outlet line (11)
• Connect the fluid lines to hydraulic motor of the fan
(12).
NOTE: If the condenser of the air conditioning system was
removed without detaching the hoses, the condenser (13)
now needs to be installed at the combination cooler.
SS14K323 2
5. Connect lines (1) to (6) to the combination cooler (7):

• Hydraulic fluid outlet line (1)
• Transmission oil inlet line (2)
• Transmission oil outlet line (3)
• Coolant outlet line (4)
• Charge air cooling inlet line (5)
• Line to coolant expansion reservoir (6)
• Combination cooler (7)
• Connect the coolant temperature sensor e-line (8).
SS14E244 3
Next operation:
Hood - Install (90.100)
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10.4 [10.400] / 5
Index
Engine - 10

Radiator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Radiator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Engine lubrication system - 304
836C AWD
836C
856C AWD
856C
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10.5 [10.304] / 1
Contents
Engine - 10
SERVICE
Crankcase ventilation system

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine - Engine lubrication system
Crankcase ventilation system - Remove

The breather is located on the rear left-hand side on the
engine (in travel direction).
1. Remove the screws on the filter housing. The housing
will contain two filters.
2. Remove the filters from the filter housing and replace
them.
SS13K052 1
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Engine - Engine lubrication system
Crankcase ventilation system - Install

Install the two filters, taking care to fit back into housing
correctly. Install the cover and tighten the screws.
1. Install the screws on the filter housing.
SS13K052 1
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Index
Engine - 10

Crankcase ventilation system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Crankcase ventilation system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47829048B 15/06/2016
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CNH Industrial Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122
SERVICE - Technical Publications & Tools
© 2016 CNH Industrial Italia S.p.A.
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CASE CONSTRUCTION policy is one of continuous improvement and the right to change prices, specification
or equipment at any time without notices is reserved.
All data given in this publication is subject to production variations. Dimensions and weight are approximate only
and the illustrations do not necessarily show products in standard condition. For exact information about any
particular product, please consult your CASE CONSTRUCTION Dealer.
47829048B 15/06/2016
EN
SERVICE MANUAL
Transmission
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
21
Contents
Transmission - 21
[21.113] Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
[21.135] Powershift transmission external controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2
[21.105] Powershift transmission lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3
[21.155] Powershift transmission internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4
[21.700] Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5
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21
Transmission - 21
Powershift transmission - 113
836C AWD
836C
856C AWD
856C
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21.1 [21.113] / 1
Contents
Transmission - 21
TECHNICAL DATA
Powershift transmission
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FUNCTIONAL DATA
Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SERVICE
Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Service instruction - ZF Diagnostic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Disassemble - Inductive sensor, hall sensor, breather, oil fill and drain screw . . . . . . . . . . . . . . . . . . . . . . 46
Assemble - Inductive sensor, hall sensor, breather, oil fill and drain screw . . . . . . . . . . . . . . . . . . . . . . . . . 47
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Transmission/Converter oil pump
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Input shaft coupling
Disassemble - Direct mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Assemble - Direct mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Disassemble - Separate mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Assemble - Separate mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Input shaft
Disassemble - Power take off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Assemble - Power take off with WK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Assemble - Power take off without WK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
47829048B 15/06/2016
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Transmission - Powershift transmission
Powershift transmission - Special tools

NOTICE: Order number is corresponding to ZF-Order number.
Item Figure Designation

No. Order number
Assembly car
1
5870 350 000
SS12H034 1
Bars
2
5870 350 063
SS12H035 2
Support
3
5870 350 090
SS12H036 3
Socket wrench TX 40
4
5873 042 004
SS12H038 4
47829048B 15/06/2016
21.1 [21.113] / 3

No. Order number
Socket wrench TX 27
5
5873 042 002
SS12H038 5
Torx adjusting screws (M6)

6
5870 204 063
SS12H039 6
Lifting device
7
5870 204 002
SS12H040 7
Torx adjusting screws

8
5870 204 036
SS12H041 8
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No. Order number
Locking plate assembling aid

9
5870 345 107
SS12H042 9
HD hand pump
10
5870 287 007
SS12H043 10
Mini measurement coupling (M12x1.5)

11
5870 950 101
SS12H044 11
Ring bolt M20

12
0636 804 003
SS12H045 12
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No. Order number
Ring nut M12

13
0664 462 774
SS12H046 13
Rolling tool (suction tube)

14
5870 600 003
SS12H048 14
Puller insert
15
5870 026 100
SS12H049 15
Grab sleeve
16
5873 001 057
SS12H050 16
47829048B 15/06/2016
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No. Order number
Quick gripper
17
5873 011 011
SS12H051 17
Idler gear separator

18
5870 300 028
SS12H052 18
Idler gear assembling aid

19
5870 345 088
SS12H053 19
Basic set of tools

20
5873 001 000
SS12H054 20
47829048B 15/06/2016
21.1 [21.113] / 7

No. Order number
Grab sleeve, K3
21
5873 001 058
SS12H050 21
Quick gripper
22
5873 011 014
SS12H051 22
Rolling tool (oil pipes)

23
5870 600 005
SS12H055 23
Housing rear section rolling tool

24
5870 600 006
SS12H055 24
47829048B 15/06/2016
21.1 [21.113] / 8

No. Order number
Idler gear installer

25
5870 345 089
SS12H057 25
Hand crank
26
5870 280 007
SS12H058 26
Shaft seal installer

27
5870 048 057
SS12H059 27
Seal installer
28
5870 057 011
SS12H060 28
47829048B 15/06/2016
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No. Order number
Handle - driver
29
5870 260 002
SS12H061 29
Adjusting screws, universal

30
5870 204 011
SS12H062 30
Adjusting screws (M10)

31
5870 204 007
SS12H063 31
Shaft seal installer

32
5870 055 070
SS12H064 32
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No. Order number
Locking plate installer

33
5870 057 010
SS12H065 33
Needle bushing installer

34
5870 048 080
SS12H066 34
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Powershift transmission - General specification

The following transmissions are used in the graders:
• ZF Ergo-Powershift 6WG-115 in 836C/836C AWD
• ZF Ergo-Powershift 6WG-160 in 856C/856C AWD
Full power-shift transmission with 6 forward and 3 reverse

gears selectable under load. One-lever electric gearshift
with reverse lock in gears 3-6.
Model plate
The model plate is located on the converter side of the
transmission housing.
SS14J040 1
Markings on the model plate for ZF power shift transmission

Pos. Designation
1 Transmission type
2 Transmission number (serial number)
3 ZF parts list number
4 Overall transmission ratio
5 Oil specification
6 ZF lubricants list
7 Oil capacity
8 Customer number
SS12H027 2
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Notes on ordering replacement parts

Write down the following details when ordering ZF original replacement parts:
1. Transmission type
2. Assembly number
3. ZF parts list number
4. Brand and type of replacement part
5. Part designation
6. Replacement part number
7. Mode of shipment
Quoting all the above information will prevent shipment errors.
Ratios
836C/836C AWD
Driving Transmission Tandem axle Total
direction Gear Ratio Ring gear Planetary Chain drive Total
and pinion gear drive
Forwards 1 5.202 3.111 3.421 1.421 15.123 78.670
2 3.367 50.919
3 2.191 33.134
4 1.418 21.444
5 0.944 14.276
6 0.611 9.240
Reverse 1 4.933 3.111 3.421 1.421 15.123 74.602
2 2.078 31.426
3 0.895 13.535
856C/856C AWD
Driving Transmission Tandem axle Total
direction Gear Ratio Ring gear Planetary Chain drive Total
and pinion gear drive
Forwards 1 5.202 2.818 6.00 1.167 19.731 102.641
2 3.367 66.434
3 2.191 43.231
4 1.418 27.979
5 0.944 18.626
6 0.611 12.056
Reverse 1 4.939 2.818 6.00 1.167 19.731 97.451
2 2.078 40.001
3 0.895 17.659
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Powershift transmission - Dynamic description

Composition
ZF transmissions consist of a hydrodynamic torque converter upstream of a multiple-gear power shift transmission
with integrated transfer case. The drive shaft is attached directly to an IVECO engine through a diaphragm. Through
the EST-37 electronic control unit, six forward gears and three reverse gears can be selected either manually or
automatically, and there is a reverse gear lock in gears 3 - 6. The front output shaft is connected to the tandem axle
through a propeller shaft. On the rear output shaft, the transmission is equipped with a disk brake, which is used as
the parking brake. Depending on the grader type, hydraulic pumps are attached to the live power take-off. On all
graders, a ZF fine filter is mounted directly on the transmission housing. The transmission is also equipped with an
emergency steering pump, which delivers 16 cm³/rev (1.0 in³/rev).
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SS14J041 1
Exterior views

A Front view 8 Oil filler pipe with dipstick (converter side)
B Rear view 9 Converter
1 Eye bolts 10 Electro-hydraulic control
2 Direct attachment through diaphragm 11 Hydraulically operated parking brake
3 Transmission mounting holes M20 12 Output flange (rear)
4 Emergency steering pump 13 Brake disk
5 Output flange (converter side) 14 Expendable filter (ZF fine filter)
6 Oil drain screw with magnetic insert M38 x 1.5 15 Filter head
7 Model plate 16 Live power takeoff, coaxial
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Structure of 6 WG-160
SS12J204 2
Transmission diagram
SS12J205 3
Gear diagram
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AB Output K3 3rd gear clutch
AN Drive K4 4th gear clutch
K1 1st gear clutch KR Reverse clutch
K2 2nd gear clutch KV Forward clutch
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SS12H031 4
Assembling
SS12H030 5
Clutch
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1 Drive flange - drive through propeller shaft 9 Clutch shaft “K3”
2 Converter 10 Output flange - rear
3 Inductive sensor for engine RPM 11 Output shaft
4 Transmission pump 12 Output flange - converter side
5 Clutch shaft “KR” 13 Clutch shaft “K1”
6 Power take-off; coaxial, live 14 Converter safety valve
7 Clutch shaft “KV” 15 Clutch shaft “K4”
8 Clutch shaft “K2”
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Measurement plan and connections for 6 WG-160
SS14J042 6
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NOTE: The measurements should be taken with the transmission hot (about 80 - 90 °C (176.0 - 194.0 °F)).
Pos. Designation Port Marking

on valve
block
Measuring point for pressure oil and temperature
51 Upstream of converter - 11 bar (159.5 psi) + 2 bar M10 x 1 H
opening pressure (29.0 psi)
52 Downstream of converter - 4.3 bar (62.4 psi) + 3 bar M14 x 1.5
opening pressure (43.5 psi)
53 Forward clutch 16 bar (232.0 psi) + 2 bar KV M10 x 1 B
(29.0 psi)
55 Reverse clutch 16 bar (232.0 psi) + 2 bar KR M10 x 1 E
(29.0 psi)
56 Clutch 16 bar (232.0 psi) + 2 bar K1 M10 x 1 D
(29.0 psi)
57 Clutch 16 bar (232.0 psi) + 2 bar K2 M10 x 1 A
(29.0 psi)
58 Clutch 16 bar (232.0 psi) + 2 bar K3 M10 x 1 C
(29.0 psi)
60 Clutch 16 bar (232.0 psi) + 2 bar K4 M10 x 1 F
(29.0 psi)
63 Downstream of converter M14 x 1.5
- temperature 100.0 °C
(212.0 °F), for brief periods
120.0 °C (248.0 °F)
65 System pressure 16 bar (232.0 psi) + 2.5 bar M10 x 1 K
(36.3 psi)
Measuring point for flow rates
15 Connection to heat 1“ 5/16 - 12 UN-2B
exchanger
16 Connection from heat 1“ 5/16 - 12 UN-2B
exchanger
Inductive pulse speed sensor and switch
21 Inductive sensor “n” turbine M18 x 1.5
34 RPM sensor “n” output and speedometer -
47 Inductive sensor “n” centre wheel chain M18 x 1.5
48 Inductive sensor “n” engine M18 x 1.5
54 Differential pressure switch M14 x 1.5
for pressure filter
Connections
10 Breather M16 x 1.5
37 System pressure M16 x 1.5
39 Return line to sump M26 x 1.5
49 Plug connection on -
electro-hydraulic control
unit
68 System pressure (Option) M16 x 1.5 G
69 Control (Option) M16 x 1.5 J
70 Emergency steering pump Pressure line M22 x 1.5
71 Emergency steering pump Suction line M26 x 1.5
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In the intermediate position, the multiple-gear reversing transmission can be shifted under load using the hydraulically
operated multi-disk clutch.
All gears are continuously engaged and supported on roller bearings.
Gears, bearings, and clutches are oil-cooled and lubricated.
The 6-gear reversing transmission has 6 disk clutches.
When changing gear, the disk pack concerned is compressed by a piston that moves axially when the pressure oil is
applied.
A push spring then moves the piston back and thus releases the pressure on the disk pack.
For transmission structure, and details of the clutches engaged in the individual gears, refer to the following illustra-
tions.
Diagram - clutches
Direction of travel Gear Clutch
Forward 1 KV/K1
2 K4/K1
3 KV/K2
4 K4/K2
5 KV/K3
6 K4/K3
Reverse 1 KR/K1
2 KR/K2
3 KR/K3
Gear diagram
1 Converter AB Front output for tandem axle
2 Pump AN Drive from engine
3 Stator K1 1st gear clutch
4 Turbine K2 2nd gear clutch
5 Converter coupling K3 3rd gear clutch
6 Live power take-off K4 4th gear clutch
7 Rear output for parking brake KR Reverse clutch
8 Emergency steering pump KV Forward clutch
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Power flow
SS12H008 7
Forward gears
____ Gear chain power flow ........ Gears not engaged
A 1st gear D 4th gear

B 2nd gear E 5th gear
C 3rd gear F 6th gear
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SS12J005 8
Reverse gears
____ Gear chain power flow ........ Gears not engaged
G 1st gear I 3rd gear

H 2nd gear
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Torque converter
The torque converter is a wear-free start-up device, which adapts continuously to the particular operating conditions
(torque requirement).
Overall size: W 300, torque multiplication depends on version and converter coupling (WK).
Transmission ratio (mechanical)

Gear Driving direction Ratio
1 Forward 5.202
2 Forward 3.367
3 Forward 2.191
4 Forward 1.418
5 Forward 0.944
6 Forward 0.611
1 Reverse 4.939
2 Reverse 2.078
3 Reverse 0.895
Output
On the power shift transmission, the axis centre distance between drive and output shaft is 500 mm (19.7 in).
The front output shaft is connected to the tandem axle through a propeller shaft.
On the rear output shaft, the transmission is equipped with a disk brake, which is used as the parking brake.
Power take-off
A coaxial live power take-off is provided in order to drive an outboard pressure oil pump.
Depending on the grader type, hydraulic pumps are attached to the live power take-off.
Transmission accessories
If required, the transmission can also be equipped with the following components:
• Emergency steering pump with flow rate 16 cm³/rev (1.0 in³/rev).
• Separate ZF fine filter, mounted directly on the transmission housing.
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Ergopower transmissions have two different oil circuits:

• Main oil circuit in transmission housing
• Control circuit in electro-hydraulic control unit
Main oil circuit

The transmission pump used to supply oil to the converter and transmission control is located on the engine drive
shaft.
Pump delivery rate Q = 85 l/min (22.5 US gpm), where “n” engine = 2000 RPM. The pump draws oil from the sump
through the coarse filter and delivers it to the ZF fine filter.
After passing through the filter, the oil arrives at the main pressure valve (HDV) and each slide valve (NFS) of the
electro-hydraulic control unit. At measuring point (65), system pressure can be measured from 16 - 18 bar (232.0 -
261.0 psi).
The main pressure valve limits the maximum shift pressure to 16 bar (232.0 psi) and releases the main oil flow to the
converter and lubrication circuit. The converter safety valve (WSV) is installed at the converter inlet, to protect the
converter from high internal pressures. Opening pressure 11 bar (159.5 psi).
At measuring point (51), pressure can be measured upstream of the converter.
The pressure oil from the transmission pump flows continuously through the converter and is used for torque trans-
mission; at the same time, the heat generated is dissipated by the oil from the converter.
To prevent cavitation, the converter must be kept constantly filled with oil. This function is performed by a converter
counterpressure valve (WGV) with an opening pressure of 4.3 bar (62.4 psi), which is connected downstream.
At measuring point (63) and (52), the pressure 1.5 bar (21.8 psi)and temperature (T = 100 °C (212.0 °F), and 120 °C
(248.0 °F) for brief periods) can be measured downstream of the converter.
The oil flowing from the converter passes through connection (15) to the combination cooler.
After being cooled, the oil passes through connection (16) to the lubricating oil circuit of the transmission.
Control circuit in electro-hydraulic control unit

The six transmission clutches are actuated by the six pressure controller units (P1) to (P6). Each pressure controller
unit consists of a filter, a 0.8 mm (0.03 in) orifice plate (B), a damping piston (D), a slide valve (NFS), and a propor-
tional valve (Y1).
The 9 bar (130.5 psi) control pressure needed to operate the slide valve is supplied by the pressure reducing valve
(RV9).
Driving switch – neutral position, ignition on

A 100 mA current is applied to all proportional valves. In this position (for example, see (P6)), the control oil reduced
to 9 bar (130.5 psi) max. passes through the pressure regulating units and can be diverted into the sump by the
related proportional valve without doing any work.
Driving switch – position 1. forward gear

The proportional valves ( (Y3) and (Y5)) are actuated by a 500 mA current from the EST-37 electronic control unit.
The proportional valve closes off the free flow to the sump. The pressure oil now creates a pressure between the
proportional valve and the 0.8 mm (0.03 in) orifice plate. The slide valve (NFS) shifts to another position. At this
position, the path is opened for the main 16 - 18 bar (232.0 - 261.0 psi) oil flow to the clutches (KV) and (K1). This
causes the corresponding clutch to be actuated.

B Orifice plate P5 Proportional valve, clutch KV
D Vibration damper P6 Proportional valve, clutch K2
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FDV Differential pressure valve filter (bypass valve) RV-9 Pressure reducing valve ( 9 bar (130.5 psi) ±
Δp = 5.5 bar (79.8 psi) + 3 bar (43.5 psi) 0.5 bar (7.3 psi))
HDV Main pressure valve ( 16 bar (232.0 psi) + TEMP Temperature sensor
2.5 bar (36.3 psi))
NFS Slide valve WGV Converter counter-pressure valve ( 4.3 bar
(62.4 psi) + 3 bar (43.5 psi))
P1 Proportional valve, clutch K4 WSV Converter safety valve ( 11 bar (159.5 psi) +
2 bar (29.0 psi))
P2 Proportional valve, clutch KR WT Heat exchanger
P3 Proportional valve, clutch K1 Y1-Y6 Pressure regulator
P4 Proportional valve, clutch K3
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SS12J006 9
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A Control circuit in electro-hydraulic control unit LU Lubrication
B Main oil circuit MP Main Pressure
BV Bypass valve OS Oil sump
CF Coarse filter, mesh size 0.8 mm (0.031 in) PP Pilot pressure
CV Converter RL Return line to sump
CPI Converter inlet pressure RP Regulated main pressure
CPO Converter outlet pressure TP Transmission pump
p = 16 bar (232.0 psi) + 2 bar (29.0 psi)
QP = 85 l/min (22.5 US gpm)
n = engine 2000 RPM
LB Lubrication ZF ZF fine filter
ISO 4572 filtration ratio
ß30 75 - ß15 25 - ß10 5.0
ISO 4572 dust capacity
17 g (0.6 oz) minimum
Filter surface: 6700 cm² (1038.5 in²)
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ZF fine filter bypass function

The fine filters installed no longer have an integrated bypass function.
The bypass function is now performed by a differential pressure switch (FDV) p = 5.7 bar (82.7 psi), installed in the
transfer plate.
This means that, when the oil is cold or the oil filter is dirty, the oil flow passes directly to the converter, not the
electro-hydraulic control unit.
This has two advantages:

• Protects the electro-hydraulic control unit from soiling
• During the warm-up phase, the oil remains in a shorter circuit, and this accelerates the warm-up process!
At the same time, the differential pressure switch (FDV), through the EST-37 electronic control unit in the digital control
console, can indicate the maintenance condition of the filter as an error code.
1. Bypass open - Filter dirty

2. 24 V voltage interrupted
3. Ground connection interrupted
Pressure regulator Clutches actuated

Direction of travel gear Y1 Y2 Y3 Y4 Y5 Y6
Forward 1 ● ● KV K1
2 ● ● K4 K1
3 ● ● KV K2
4 ● ● K4 K2
5 ● ● KV K3
6 ● ● K4 K3
Reverse 1 ● ● KR K4
2 ● KR K1
3 ● ● KR K2
NEUTRAL KV K3
Clutch actuated K4 KR K1 K3 KV K2
Position on valve block F E D C B A
Lfd. No. of measuring point 60 55 56 58 53 57
● = Pressure regulator active
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SS12J007 10
Electro-hydraulic control unit with proportional valves
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1 Main pressure valve 16 bar (232.0 psi) + 2.5 bar 7 Intermediate plate
(36.3 psi)
2 Pressure reducing valve 9 bar (130.5 psi) 8 Transfer plate
3 Housing 9 Pressure regulator
4 Connector (wiring harness) 10 Vibration damper
5 Cover 11 Slide valve
6 Valve block EC Electro-hydraulic control unit with proportional
valves
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Powershift transmission - Service instruction

Important information
1. Oil level check (See Powershift transmission lubri-
cation system - Change fluid (21.105)):
In the cold start phase, the engine must run for about
2 - 3 min at idle, and the mark on the oil dipstick must
then be above the cold start mark. The oil level in the
transmission must be checked with the engine idling
and with the transmission warm ( 80 - 90 °C (176.0 -
194.0 °F)).
2. Depending on the installation condition, the oil level in
the transmission rises substantially when the engine is
stopped!
3. The ZF fine filter must be replaced at each oil change.
ZF also recommends starting the automatic calibration
of the actuators (AEB).
Automatic calibration must be started after the initial
installation of the transmission and electronics by the
manufacturer, and whenever the transmission or the
electronic system is replaced due to damage.
4. When starting the diesel engine, always put the driving
switch in neutral position.
When the engine is running and the transmission is in
neutral, the parking brake must be engaged or the ser-
vice brake applied to prevent the vehicle from rolling.
5. Before starting off, release the parking brake.
6. A gear can only be engaged from neutral if the trans-
mission is at the programmed initial speed (turbine ro-
tational speed).
7. Neutral position of the driving switch is not allowed at
higher vehicle speeds (above walking speed). In this
case, either engage a suitable gear immediately, or ap-
ply the brakes.
8. Reversing (standard):
Reversing must be selected with the vehicle at a stand-
still or moving at low speed.
Above the programmed reversing speed limit, the
EST-37 electronic control unit places the vehicle in
neutral, and the vehicle continues to move in the
original direction.
9. The gear is only selected in the new direction when the
reversing speed and transmission initial speed (turbine
rotational speed) are below the programmed limits.
The programmed values are specific to the customer
and can therefore vary from the standard values. Refer
to the operating and maintenance instructions for the
correct procedure to be followed!
10. When the engine is switched off, although a gear may
be selected with the driving switch, there is no power
flow between transmission and engine, i.e. the trans-
mission is on idle.
The parking brake must therefore be fully applied! If
leaving the vehicle, secure it by placing chocks at the
wheels!
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11. Towing speed should never be more than 10 km/h

(6.2 mph), and the towing distance not greater than
10 km (6.2 miles). This limit must be applied in all
cases, otherwise the transmission will be damaged as
there is no oil supply!
If the vehicle is faulty and needs to be transported over
a long distance, it is best to load it onto a low-bed
trailer.
12. The permitted operating temperature downstream
of the converter is 65 °C (149.0 °F), and 100 °C
(212.0 °F) in continuous operation with brief increases
to 120 °C (248.0 °F) max.
Sump temperature 60 - 90 °C (140.0 - 194.0 °F). If
there is an anomaly in the transmission, stop the ve-
hicle and call for qualified assistance.
13. Measures to protect the ZF electronics when working
on the vehicle electrical system:
When carrying out any of the following operations, the
ignition must be switched off and the control unit con-
nector disconnected from the ZF electronics:
• Work on the vehicle's electrical system
• Welding operations on the vehicle
• Insulation tests on the electrical system
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Powershift transmission - Service instruction - ZF Diagnostic

system
General
In the Ergopower transmission series, the EST-37 elec-
tronic control unit has a diagnostics package, which
makes it easier for customer service to carry out trou-
bleshooting and repairs. The control unit can monitor
the status of certain inputs and outputs.
If it detects a fault, it stores an error code in the fault
memory (EEPROM), and also sends the error code to
the manufacturer's vehicle controller.
The Laptop versions of the ZF diagnosis and program-
ming systems are required for the following applica-
tions:
AEB
• Separate calibration of actuators
Diagnosis
• Current errors
• Read fault memory
• Clear fault memory
Test inputs and outputs
• Outputs (component actuation)
• Test inputs
• System tests, vehicle stopped
• System test, vehicle moving
Automatic detection of fill parameters

Introduction
The new ERGOCONTROL transmission control con-
sists of an EST-37 electronic control unit and six pro-
portional pressure regulator units, which can be actu-
ated separately. This allows separate pressure buildup
for each of the clutches.
Automatic detection of the "AEB" fill parameter is used
to optimize, for each clutch, the tolerances (disk play
and pressure level) that affect the clutch filling process,
by adapting the "Length of quick-fill time " and "Correct
fill balance pressure" parameters as required.
To optimize these tolerances (disk play and pressure
level) for each clutch, the fill parameters must be de-
termined at startup, at each oil change, and after any
repair to the transmission or its related electronics.
AEB cycle
When
• After each oil change
• 50 h after initial startup of the transmission, then ev-
ery 1000 h (operating hours; recommended by ZF)
• Whenever one of the components of the transmis-
sion or the related electronics is replaced
• Whenever the transmission is replaced
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Duration
• AEB cycle about 3 - 4 min
Execution
• The AEB cycle program is stored in the EST-37 elec-
tronic control unit. When the AEB cycle is complete,
the optimized parameters are stored in the EEPROM
of the EST-37.
Connecting special tools to the XA5 Diagnosis connec-
tion
• AEB Starter or
• Laptop with diagnosis kit and diagnosis software
For detailed information about starting the AEB cycle,
see the operating instructions that come with the AEB
Starter.
Sequence of operations:
1. Warm up the transmission.
2. Turn the starter switch to OFF.
3. Connect the connector (2) to the (XA5) Diagnosis
connector in the driver cab.
The Diagnosis connector (XA5) is located on the
right beside the operator seat, at the front of the
side console.
SS14J039 1
4. Set the gearshift lever to "N" position, apply the

parking brake.
5. Ignition "ON", EST-37 must detect the AEB Starter
for at least 2 seconds
6. Set engine speed.
7. Press the start knob (3) on the AEB Starter to start
the AEB cycle.
8. When the cycle is complete, "OK" must appear on
the display.
9. Ignition "OFF", disconnect the AEB Starter.
NOTE: The display messages from the AEB Starter must SS12H017 2
be shown on the dashboard display.
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Display messages
The AEB status information is read over the CAN bus
and shown graphically at the top right of the dashboard
display.
(AEB) = Automatische Ermittlung Befüllparameter (au-
tomatic fill parameter detection)
(TCU) = Transmission Control Unit (EST-37)
Original transmission information Text information on the display

by CAN
0: AEB mode not selected
1: AEB mode selected, adjusting K1 Clutch 1 being adjusted
5: AEB mode selected, adjusting KV Forward clutch being adjusted
6: AEB mode selected, adjusting KR Reverse clutch being adjusted
7: AEB mode selected, adjustment Changes OK!
complete Ignition key
in 0 position
8: AEB mode selected, adjustement Changes not OK!
aborted, cause: AEB request Process
cancelled unsuccessful
Press ESC
aborted while adjusting K1 Process
unsuccessful
Press ESC
AEB main code: 10: AEB mode selected, adjustement Changes not OK!
unsuccessful
Press ESC
unsuccessful
Press ESC
unsuccessful
Press ESC
13:AEB mode selected, adjustement Changes not OK!
aborted while adjusting KV Process
unsuccessful
Press ESC
14:AEB mode selected, adjustement Changes not OK! Process
aborted while adjusting KR unsuccessful
Press ESC
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Original transmission information Text information on the display

by CAN
1: fault present
2: shift lever not in “N” position Not allowed
Not in neutral
Press ESC
Parking brake not applied Not allowed
Parking brake OFF
Press ESC
4: output speed not 0 Not allowed
when
vehicle moving
Press ESC
5: transmission oil temperature below Not allowed
specified range Oil temp.
too low
AEB sub-code:
Press ESC
Transmission oil temperature above Not allowed
specified range Oil temp.
too high
Press ESC
7: engine RPM below specified range Not allowed
RPM
too low
Press ESC
8: engine RPM above specified range Not allowed
RPM
too high
Press ESC
0: default
SS12H018 3
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Diagnosis – inspection
Requirements for error correction
• Oil level and specifications must be as indicated on
the ZF lubricants list (TE-ML 03) for the new WG
power shift transmissions.
• Transmission temperature 80 - 100 °C (176.0 -
212.0 °F).
• Follow the specified work instructions (for connect-
ing all lines correctly).
• Use only ZF-recommended testing equipment for
the function test on the electrical system!
• Fuses "4F32" and "4F33" ( 7.5 A; see wiring dia-
gram) OK!
• Before working on the vehicle (e.g. welding) or on
the electronics (e.g. connecting a tester), switch off
the ignition, remove the electronics connector and/or
disconnect all battery terminal clamps.
Data sheet 6 WG 160

Data for the 3 inductive sensors of the engine, turbine
and center gear chain:
• Resistance: 1050 Ω (± 10 %) at 20 °C (68.0 °F)
• Temperature range: - 40 °C (-40.0 °F) > + 150 °C
(302.0 °F)
• Tightening torque: Mmax = 30 N·m (22.1 lb ft)
Data for the output Hall sensor:
• Temperature range: - 40 °C (-40.0 °F) > + 150 °C
(302.0 °F)
• Working range: 2 Hz > 5 Hz
• Supply voltage: 24 V
Data for the proportional valves:
• Resistance: 19 Ω (± 10 %) at 20 °C (68.0 °F) ± 0.5 Ω
variation allowed relative to each other
• Current: 100 mA > 500 mA
• Pressure range: 0.8 bar (11.6 psi) > 8.3 bar
(120.4 psi)
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Laptop version
Pentium Laptop min. 100

Specialized trade MHz
WINDOWS 95/98 or NT
SS12H019 4
Basic software Testman

Diagnosis kit 5870 221 179
WIN 95/98 or NT
WIN 95/98 or NT
6008 308 901
SS12H020 5
RS-232 connecting cable

Laptop → DPA-04I
WIN 95/98 or NT
6008 308 601
SS12H021 6
Programming adapter
DPA-04I
WIN 95/98 or NT
6008 308 600
SS12H022 7
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Adapter cable DPA-04I ∅

EST-37
WIN 95/98 or NT
6029 017 005
SS12H023 8
Diagnosis software WG - 115
6008 308 005 GERMAN
SS12H024 9
6008 308 105 ENGLISH
SS12H024 10
6008 308 205 FRENCH
SS12H024 11
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68-pin contact box. For

testing individual control 6008 304 038
signals, open circuits, etc.
SS12H025 12
Read fault memory
SS12H026 13

CH Cable harness LP Laptop
ES EST - 37 TC Transmission control system
GB Gearbox VH Vehicle
1. Connect laptop to the "Diagnosis" connection of the
wiring harness.
2. Under "Diagnosis", select the "Read Fault Storage" op-
tion.
3. Faults and error codes are given in the appendix.
NOTE: At the "Read Fault Storage" step, print the page!
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Clear fault memory
SS12H026 14

CH Cable harness LP Laptop
ES EST - 37 TC Transmission control system
GB Gearbox VH Vehicle
1. Connect laptop to "Diagnosis" connection of wire har-
ness.
2. Under "Diagnosis", select the "Cancel Fault Storage"
option.
3. Select "YES" to confirm.
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Powershift transmission - Remove

WARNING
Avoid injury!
Use Personal Protective Equipment (PPE), including protective goggles, gloves, and safety footwear.
W1036A
WARNING
Heavy objects!
W0398A
Prior operation:
Engine - Remove (10.001)
1. Loosen the transmission outer mounting bolts (11) from

the engine, and remove them.
2. Use lifting gear to lift the transmission away from the
engine.
SS12D564 1
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Powershift transmission - Place on stand

WARNING
Avoid injury!
W1036A
WARNING
Heavy objects!
W0398A
Prior operation:
Powershift transmission - Remove (21.113).
1. Attach the transmission to the assembly car.

Use the special tools 5870 350 000, 5870 350 063 and
the angular support 5870 350 090.
NOTE: Before starting the disassembly work, drain the oil!
SS14J045 1
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Powershift transmission - Disassemble - Inductive sensor, hall

sensor, breather, oil fill and drain screw
Prior operation:
Powershift transmission - Place on stand (21.113)
Transmission oil filter - Remove - ZF fine filter (21.105)
1. Remove parts at the following positions:

• Screw plug (oil drain hole) (1)
• Oil filling tube with dipstick (2)
• Breather (3)
• Inductive sensor for intermediate gear train speed
(4)
• Inductive sensor for turbine speed (5)
• Inductive sensor for engine speed (6)
SS12H105 1
2. Loosen the cap bolt (1) and remove the RPM sensor
(Hall sensor) (2).
NOTE: Remove the O-ring.
SS12H106 2
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Powershift transmission - Assemble - Inductive sensor, hall sensor,

breather, oil fill and drain screw
Prior operation:
Powershift transmission - Place on stand (21.113)
1. Mount the inductive sensor for engine speed (1), the

inductive sensor for intermediate gear train speed (2),
and the inductive sensor for turbine speed (3) with new
15 mm (0.59 in) x 2 mm (0.08 in) O-rings.
2. Tighten the sensor with 30 N·m (22.1 lb ft).
3. Mount the breather (4).
4. Tighten the breather with 12 N·m (8.9 lb ft).
NOTE: On some versions, the inductive sensor (3) must
be mounted along with 3 shims and secured with Loctite
No. 262.
For the relevant parts lists, refer to the replacement parts
SS12J140 1
list for the inductive sensor assembly.
For parts list number, refer to the model plate.
5. Mount the RPM sensor (Hall sensor) (1) with the new
O-ring 15 mm (0.59 in) x 2 mm (0.08 in) and the cap
bolt (2).
6. Tighten the cap bolt (M8/8.8x16) with a torque of
23 N·m (17.0 lb ft).
SS12J141 2
7. Mount the oil drain screw (1) with the new O-ring
35 mm (1.38 in) x 2 mm (0.08 in).
8. Tighten the drain screw (M38x1.5) with 80 N·m (59.0 lb
ft).
9. Bring the oil dipstick tube (2) and its seal into position on
the housing front section and fasten with the hexagon
head bolts (3).
10. Tighten the hexagon head bolts (M8/8.8x50) with a
torque of 34 N·m (25.1 lb ft).
11. Fasten the oil dipstick (4) in the dipstick tube.
12. Attach the model plate (5) to the housing front section. SS12J142 3
NOTE: Stick it on with Loctite No. 5069.
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13. Bring the cover (1) and the gasket into position on the
housing front section and fasten with hexagon head
bolts (2).
14. Tighten the hexagon head bolts (M8/8.8x18) with
23 N·m (17.0 lb ft).
SS12J143 4
Next operation:
Transmission oil filter - Install - ZF fine filter (21.105)
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Powershift transmission - Install

WARNING
Avoid injury!
W1036A
WARNING
Heavy objects!
W0398A
1. With the engine placed on the assembly stand, join the

transmission to the engine using the lifting gear
2. Fasten the transmission temporarily to the engine, by
using the outer mounting bolts.
SS12D565 1
Next operation:
Engine - Install (10.001)
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Transmission/Converter oil pump - Disassemble

WARNING
Avoid injury!
W1036A
Prior operation:
Disassemble the input shaft coupling.
Refer to Input shaft coupling - Disassemble - Direct mounting (21.113) or
Input shaft coupling - Disassemble - Separate mounting (21.113).
1. Loosen the bell housing/oil feed housing union (1) and

remove the bell housing (2).
SS12H116 1
2. Loosen the bolt connection (1) between the oil feed

housing and the transmission housing front section,
and the bolt connection (2) between the pressure oil
pump and the transmission housing front section with
the cap bolts.
NOTE: Separate the oil feed housing and the pressure oil
pump from the transmission housing front section.
SS12H117 2
3. Separate the pressure oil pump (1) from the oil feed
housing (2).
SS12H118 3
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4. Loosen both cap bolts (1) and take out the control disk.
NOTE: If any galling is found in the pump housing or on
the control disk, the complete pressure oil pump must be
replaced.
SS12H119 4
5. Pry off the snap ring (1) and remove the individual com-
ponents:
• Pump housing with rotor (1)
• Snap ring (2)
• Shaft seal (3)
• Support disk (4)
• Needle bearing (5)
• Ring (6)
SS12H120 5
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Transmission/Converter oil pump - Assemble

WARNING
Avoid injury!
W1036A
1. Place the pressure relief valve (1) in position in the

housing bore.
2. Mount the two adjusting screws (S) and place the flat
seal (2).
Use the special tool (S) 5870 204 011.
NOTE: Apply mounting grease!
SS12J088 1
3. Mount the two adjuster screws (S) and fit the stator
shaft (1).
NOTE: Note the radial installation position!
SS12J089 2
4. The following parts should be replaced:

• Pump housing with rotor (1)
• Snap ring (2)
• Shaft seal (3) 75 mm (2.95 in) x 90 mm (3.54 in) x
10 mm (0.39 in))
• Support disk (4) 95 mm (3.74 in) x 76 mm (2.99 in)
x 84 mm (3.31 in) x 3 mm (0.12 in)
• Needle bearing (5) compl. (bearing outer race and
needle bearing)
• Ring (6) 75 mm (2.95 in) x 84 mm (3.31 in) x
4.6 mm (0.18 in)
SS12J090 3
NOTE: If any galling is found in the pump housing or on the

control disk, the pump must be replaced complete.
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5. Mount the following parts in the pump housing (1):

• Ring (6)
• Bearing outer race (5A)
• Needle bearing (5B)
• Support disk (4)
SS12J091 4
6. Insert the shaft seal (3) carefully in position in the pump

housing (1) with the sealing lip facing downward, and
fix with snap ring (2).
Use the special tools 5870 055 070 and 5870 260 002.
NOTE: Wipe the external diameter of the shaft seal with
methylated spirit.
SS12J092 5
7. Mount the external rotor.

The chamfered side faces down.
SS12J093 6
8. Mount the internal rotor.

The toothed side faces up.
SS12J094 7
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9. Place the control disk and fix radially with the two cap
bolts (1).
10. Insert the O-ring 182 mm (7.17 in) x 3 mm (0.12 in)
3 mm (0.12 in) (2) in the radial groove and lubricate
it.
NOTE: Do not tighten the cap bolts - screw them up to the
stop position, then unscrew by about a 1/2 turn! Note the
installation position of the control disk.
SS12J095 8
11. Insert the pre-assembled pump (1) and, for the time
being, bring evenly into position using the cap bolts.
NOTE: Note the radial installation position!
NOTE: Then remove the cap bolts again.
SS12J096 9
12. Fit the new O-rings 9.5 mm (0.37 in) x 1.6 mm

(0.06 in) to the cap bolts.
13. Fasten the transmission pump (2) with the cap bolts
(1).
14. Tighten the cap bolts (M10/8.8x75) with 46 N·m
(33.9 lb ft).
NOTE: Grease the O-rings.
SS12J097 10
15. Fasten the oil feed housing (1) evenly, using the torx
screws (2).
16. Tighten the torx screws with 23 N·m (17.0 lb ft).
17. Fasten the retaining plate (3) with the cap bolts (4).
18. Tighten the cap bolts with 46 N·m (33.9 lb ft).
NOTE: Note the installation position of the retaining plate!
SS12J098 11
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19. Fasten the bell housing (2) with the hexagon head
bolts (1).
20. Tighten the hexagon head bolts with 65 N·m (47.9 lb
ft).
SS12H116 12
Next operation:
Assemble the input shaft coupling.
Refer to Input shaft coupling - Assemble - Direct mounting (21.113) or
Input shaft coupling - Assemble - Separate mounting (21.113).
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Input shaft coupling - Disassemble - Direct mounting

WARNING
Heavy objects!
W0398A
Prior operation:
Powershift transmission - Place on stand (21.113).
1. Loosen the hexagon head bolt (2) and separate the

diaphragm (1) from the converter (3).
SS12H107 1
2. Separate the converter (1) from the transmission using

the hoist.
Use the special tool 5870 204 002.
SS12H108 2
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Input shaft coupling - Assemble - Direct mounting

WARNING
Avoid injury!
W1036A
WARNING
Heavy objects!
W0398A
1. Insert the converter (1) in position using the hoist.

(S) - Lifting Device 5870 204 002
SS12H108 1
2. Fasten the diaphragm (1) using the hexagon head bolt

(2).
115 N·m (84.8 lb ft).
NOTE: Mount washers between converter (3) and di-
aphragm (1) under the hexagon head bolts.
NOTE: Secure the hexagon head bolts with Loctite No.
262!
SS12H107 2
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Input shaft coupling - Disassemble - Separate mounting

WARNING
Heavy objects!
W0398A
Prior operation:
1. Remove the locking plate (1), loosen the hexagon head

bolt and remove the washer.
2. Loosen the cover/bell housing union (2).
NOTE: Mark the radial installation position of the cover/bell
housing with a center punch mark.
SS12J139 1
3. Separate the cover from the bell housing, by using a

hoist.
SS12H110 2
4. Detach the output flange.
SS12H111 3
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5. Press the drive shaft and/or converter out of the cover

(ball bearing).
SS12H112 4
6. Pry off the circlip (1) and the ball bearing (2).
SS12H113 5
7. Remove the hexagon head bolts (1) and the diaphragm

(2) from the converter.
SS12H114 6
8. Loosen the hexagon head bolt (1) and separate the

diaphragm (2) from the drive shaft (3).
SS12H115 7
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Input shaft coupling - Assemble - Separate mounting

WARNING
Avoid injury!
W1036A
WARNING
Heavy objects!
W0398A
1. Screw in the drive shaft (3) and the diaphragm (2) with
the hexagon head bolts (1).
115 N·m (84.8 lb ft).
SS12H115 1
3. Fasten the diaphragm (1) to the converter (3) using the

hexagon head bolts (2).
115 N·m (84.8 lb ft).
NOTE: Smear the threads of the hexagon head bolts with
Loctite No. 262!
SS12J099 2
5. Mount the ball bearing (1) and fix it with V-Ring JV 100
(2).
SS12H113 3
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6. Place the cover (1) on the converter and push into po-
sition.
NOTE: Support thrust piece (S) on the bearing inner race!
SS12J100 4
7. Press the shield (1) onto the driver flange (2).
SS12J126 5
8. Heat up the inside diameter of the drive flange to about

120 °C (248 °F).
SS12J127 6
9. Push the drive flange (1) into position.
SS12J128 7
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10. Fix the drive flange (3) with the disk (1) and the
34 N·m (25.1 lb ft).
SS12J129 8
12. Fix the locking plate with the mounting tool (S).
Use special tools (S) 5870 057 010 and 5870 260 002.
SS12J130 9
13. Using the hoist, mount the converter until the cover (1)
and the bell housing (2) are in position.
Use special tool (S) 5870 204 002.
SS12J131 10
14. Screw the bell housing (1) and the cover (2) together
with the cap bolts and the hexagon nuts.
15. Tighten the hexagon nuts (M10/8.8) with 46 N·m
(33.9 lb ft).
NOTE: Note the radial installation position - refer to the
markings made when disassembling.
SS12J132 11
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Input shaft - Disassemble - Power take off

Prior operation:
Disassemble the converter oil pressure adjustment valve.
Refer to Converter oil pressure adjustment valve - Disassemble - Temperature sensor (Measuring point “63”
downstream of converter) (21.135).
1. Loosen the hexagon head bolts (1).

2. Remove the cover (2).
SS12H150 1
3. Take the O-ring (1) out of the cover and loosen the cap
bolts (2).
SS12H151 2
4. Remove the flange (1) and the O-ring (2).

5. Loosen the hexagon nuts and remove the two covers
(3) with the O-rings.
6. Pry off the circlip (4) and remove it.
SS12H152 3
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7. Pull the pump shaft (1) out of the housing bore.

8. Pry off the plain compression ring (2).
SS12H153 4
9. Press the ball bearing (1) away from the pump shaft.
SS12H154 5
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Input shaft - Assemble - Power take off with WK

1. Mount the four-point bearing (1) on the pump shaft (3):
• Press the lower bearing inner race up to the stop.
• Place the ball bearing.
• Press the upper bearing inner race into position.
NOTE:
Thickness:
2.2 - 2.5 mm (0.09 - 0.10 in) (in 0.05 mm (0.002 in)).
Axial play:
0.0 - 0.05 mm (0.0 - 0.002 in)
SS12J047 1
2. Mount the plain compression ring (2)

60 mm (2.36 in) x 3 mm (0.12 in).
3. Grease the plain compression ring and align centrally.
4. Push the pump shaft (1) into position.
SS12H153 2
5. Secure the pump shaft with the circlip (1)

85 mm (3.35 in) x 3 mm (0.12 in).
6. Mount the O-ring (2)
104 mm (4.09 in) x 3 mm (0.12 in) on the flange (3),
grease it, then bring into position on the housing rear
section.
SS12J048 3
7. Fasten the flange with the cap bolts (2).

Insert the O-ring (1)
130 mm (5.12 in) x 3 mm (0.12 in)
in the hole in the flange, and grease it.
8. Tighten the cap bolts (M16/8.8-30) with 195 N·m
(143.8 lb ft).
SS12H151 4
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9. Place the cover panel (2) on the flange and fasten with
46 N·m (33.9 lb ft).
SS12H150 5
11. Mount the power takeoff lubricating line:

• Power takeoff lubricating line (1)
• Banjo bolt (6 - DIN 7643) Seal ring (A - 10 Cu) (2)
• Screw-in fitting (SDS-L6 10x1) O-ring (10x1) (3)
SS12J049 6
Next operation:
Assemble the converter counterpressure valve.
Refer to Converter oil pressure adjustment valve - Assemble - Temperature sensor (Measuring point “63”
47829048B 15/06/2016
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Input shaft - Assemble - Power take off without WK

1. Press the ball bearing (1) into position on the pump
shaft (2).
SS12J046 1
2. Mount the plain compression ring (2)

50 mm (1.97 in) x 2.5 mm (0.10 in).
3. Grease the plain compression ring and align centrally.
4. Push the pump shaft (1) into position.
NOTE: 50 mm (1.97 in) x 2.5 mm (0.10 in)
SS12H153 2
5. Secure the pump shaft with circlip (1)

85 mm (3.35 in) x 3 mm (0.12 in).
6. Mount the O-ring (2)
104 mm (4.09 in) x 3 mm (0.12 in) on the flange (3),
grease it, then bring into position on the housing rear
section.
SS12J048 3
7. Fasten the flange with the cap bolts (2).

8. Insert the O-ring (1)
130 mm (5.12 in) x 3 mm (0.12 in)
in the hole in the flange and grease it.
9. Tighten the cap bolts (M16/8.8-30) with 195 N·m
(143.8 lb ft).
SS12H151 4
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10. Place the cover panel (2) on the flange and fasten with
46 N·m (33.9 lb ft).
SS12H150 5
Next operation:
Assemble the converter counterpressure valve.
Refer to Converter oil pressure adjustment valve - Assemble - Temperature sensor (Measuring point “63”
47829048B 15/06/2016
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Index
Transmission - 21

Input shaft - Assemble - Power take off with WK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Input shaft - Assemble - Power take off without WK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Input shaft - Disassemble - Power take off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Input shaft coupling - Assemble - Direct mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Input shaft coupling - Assemble - Separate mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Input shaft coupling - Disassemble - Direct mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Input shaft coupling - Disassemble - Separate mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Powershift transmission - Assemble - Inductive sensor, hall sensor, breather, oil fill and drain screw 47
Powershift transmission - Disassemble - Inductive sensor, hall sensor, breather, oil fill and drain
screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Powershift transmission - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Powershift transmission - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Powershift transmission - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Powershift transmission - Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Powershift transmission - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Powershift transmission - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Powershift transmission - Service instruction - ZF Diagnostic system . . . . . . . . . . . . . . . . . . . . . . . . . 35
Powershift transmission - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Transmission/Converter oil pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Transmission/Converter oil pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
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Transmission - 21
Powershift transmission external controls - 135
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
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Contents
Transmission - 21
FUNCTIONAL DATA
Transmission hand lever

SERVICE
Converter oil pressure adjustment valve

Disassemble - Temperature sensor (Measuring point “63” downstream of converter) . . . . . . . . . . . . . . . . 5
Assemble - Temperature sensor (Measuring point “63” downstream of converter) . . . . . . . . . . . . . . . . . . . 7
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Transmission - Powershift transmission external controls
Transmission hand lever - Dynamic description

Driving switch
The console switch VTS-3 (preselection switch) is used to preselect the direction of travel when the driving switch
lever is moved horizontally.
Gears can be preselected by pushing the driving switch lever to the right (+) or left (-).
The driving switch is equipped with a function knob, which, depending on the driving conditions, can be used as a
kick-down or release knob for starting off, and for automatic or manual driving mode.
VTS-3 Gear assignments
General
The function knob must be pressed to engage a gear.
Automatic mode is always selected when a gear is engaged from neutral.
Automatic forwards gears 1 to 6.

Automatic reverse gear 1.
There are two ways to change to manual mode:

• Press the function knob (while remaining in the current gear).
• Select a lower or higher gear by tipping the lever to the left (-) or right (+).
It is then only possible to engage a gear from neutral when the turbine rotational speed is below 1200 RPM.
47829048B 15/06/2016
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SS12H013 1
Driving switch code Location

F R N T+ T- KD/E
AD1 T+ ●
AD2 T- ●
Function ●
AD4 F
switch
AD5 R ●
AD6 AS/N ●
AD8 KD/E ●
47829048B 15/06/2016
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Converter oil pressure adjustment valve - Disassemble -

Temperature sensor (Measuring point “63” downstream of
converter)
Prior operation:
Transmission/Converter oil pump - Disassemble (21.113)
1. Pre-tension the converter safety valve (1) using a

screwdriver or the assembling aid (S) and remove the
locking plate (2).
SS12H121 1
2. Remove the exposed components from the converter

safety valve:
• Pressure plate (1)
• Push spring (2)
• Piston (3)
SS12H122 2
3. Remove the temperature sensor (1).
SS12H123 3
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4. Remove the stator shaft (1).

5. Pull the pressure relief valve (2) out of the housing bore.
SS12H124 4
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Converter oil pressure adjustment valve - Assemble - Temperature

sensor (Measuring point “63” downstream of converter)
1. Parts of the converter counterpressure valve:
• Oil feed housing (1)
• Piston (2)
• Push spring (3)
• Pressure plate (4)
• Locking plate (5)
NOTE: Mount the pressure plate (4) with dog (∅ 6 mm
(0.2 in)) toward the locking plate (5).
SS12J086 1
2. Mount the individual parts, preload with the assembling

aid (S) and fasten with the locking plate (1).
SS12J087 2
3. Mount the temperature sensor (1) with the new O-ring

11 mm (0.43 in) x 2 mm (0.08 in).
4. Tighten the temperature sensor with 25 N·m (18.44 lb
ft).
NOTE: On the version without temperature sensor, a screw
plug (1) must be mounted with a new 11 mm (0.43 in) x
2 mm (0.08 in) O-ring.
Tighten the screw plug (M14x1.5) with 25 N·m (18.44 lb ft).
SS12H123 3
Next operation:
Transmission/Converter oil pump - Assemble (21.113).
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Index
Transmission - 21

Converter oil pressure adjustment valve - Assemble - Temperature sensor (Measuring point “63”
downstream of converter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Converter oil pressure adjustment valve - Disassemble - Temperature sensor (Measuring point “63”
downstream of converter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Transmission hand lever - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Transmission - 21
Powershift transmission lubrication system - 105
836C AWD
836C
856C AWD
856C
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Contents
Transmission - 21
SERVICE
Powershift transmission lubrication system

Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Change fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Transmission oil filter
Service instruction - ZF fine filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Remove - ZF fine filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install - ZF fine filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Transmission - Powershift transmission lubrication system
Powershift transmission lubrication system - Service instruction

Notes on the oil quality required
NOTE: Approved oils for power shift transmission 6 WG
-160 are indicated on ZF lubricants list TE-ML 03.
NOTE: The lubricants list is continuously updated and can
be obtained or viewed as follows:
- at any ZF factory
- at any ZF customer service
- on the internet at http//www.zf.com Informationen/Tech.
Information
NOTE: For details relating to description, operation, and
maintenance, refer to the corresponding operating instruc-
tions (ZF Order No: 5872 153 001).
Front PTO
NOTE: When checking the oil level, the safety instructions
in § 6 of the German accident prevention regulations for
engine power units must be applied in all cases in Ger-
many, and the corresponding national regulations in any
other country.
For example, the vehicle must be chocked to prevent
rolling, and articulated vehicles must also be secured to
prevent accidental jack-knifing.
An oil level check must be performed as follows:
• Oil level check interval: weekly
• Vehicle parked on a horizontal surface
• Transmission in neutral position ("N")
• In the cold start phase, the engine must run for about
2 - 3 min at idle, and the mark on the oil dipstick must
then be above the cold start mark (“COLD MIN”).
• With transmission at operating temperature (about
80 - 90 °C (176.0 - 194.0 °F))
• With engine idling
• Release the oil dipstick by turning counterclockwise,
then remove and clean it
• Insert the dipstick slowly as far as the stop in the
dipstick tube, then take it out.
• The oil level must be in the "HOT" range on the dip-
stick.
• Insert the dipstick again and turn clockwise to lock it.
NOTICE: If the oil level has fallen below the "HOT" range
when the engine is warm, the oil must be topped up using
one of the oils on the ZF lubricants list TE-ML 03.
An oil level above the "HOT" mark will cause the oil to over-
heat.
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SS14J046 1

1 Oil-filling tube with dipstick 3 Expendable filter (ZF fine filter)
2 Oil drain screw M38x1.5
Oil dipstick
SS12H015 2

A Range “HOT” B Cold min
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Powershift transmission lubrication system - Change fluid

Oil and filter replacement interval
NOTE: Oil changes every 1000 operating h.
The ZF fine filter (pressure filter) must be replaced at each oil change.
Oil change and fill quantity
An oil level check must be performed as follows:

1. With the transmission warm and the vehicle parked on
a horizontal surface, open the oil drain screw and drain
off the old oil.
2. Clean the oil drain screw with its magnetic insert and
the sealing surface on the housing, fit a new O-ring,
and insert the screw again.
3. Add oil (about 21 l (5.5 US gal)), as indicated in the ZF
lubricants list TE-ML 03.
NOTE: (Sump quantity, external oil quantities, e.g. in the
cooler, pipes etc., depend on the vehicle).
The value indicated is given as a guideline only.
NOTE: In all cases, ensure that the oil and filter are com-
pletely clean!
Always check the mark on the oil dipstick!
4. Start the engine and leave it to idle.
5. Transmission in neutral position ("N").
6. Add oil up to the "COLD - MIN" mark.
7. Apply the parking brake and allow the transmission to
warm up.
8. Shift the driving switch through all positions.
9. Check the oil level again, and add more oil if necessary.
10. The oil level must be in the "HOT" range on the dip-
stick.
11. Insert the dipstick again and turn clockwise to lock it.
NOTE: At the initial filling of the transmission, remember that the oil cooler and pipes must also be filled with oil.
The oil fill quantity is larger than the quantity added at the later oil changes during normal maintenance.
NOTE: At each oil change, ZF recommends starting the AEB. Refer to Powershift transmission - Service instruc-
tion - ZF Diagnostic system (21.113).
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Transmission oil filter - Service instruction - ZF fine filter

WARNING
Avoid injury!
W1036A
When replacing the ZF fine filter:

• Check that no dirt or oil sludge is allowed to pene-
trate into the circuit.
• Cover the parking brake to prevent oil fouling.
• Never use force.
• Handle the filter carefully.
• Never use damaged filters.
NOTE: The pressure differential valve filter (bypass valve)
is equipped with a filter soiling switch, which tells the driver
when the ZF fine filter is dirty.
When the symbol lights up, the ZF fine filter must be re-
placed.
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Transmission oil filter - Remove - ZF fine filter

WARNING
Avoid injury!
W1036A
Prior operation:
1. Disconnect the ZF fine filter (1) from the filter head us-
ing a strap wrench.
SS12H087 1
2. Loosen the torx screws (2) and separate the filter head
(1) from the transmission housing.
NOTE: Remove the O-rings!
SS12H088 2
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Transmission oil filter - Install - ZF fine filter

WARNING
Avoid injury!
W1036A
Filter head
1. Fasten the filter head (1) with the new O-rings
34 mm (1.34 in) x 3 mm (0.12 in)
to the housing rear section using the torx screws (2).
2. Tighten the torx screws (M8/10.9x60) with
34 N·m (25.1 lb ft) x 3 mm (0.12 in).
SS12H088 1
Filter
1. Oil the seal lightly.
2. Screw the filter in until it touches the sealing surface.
3. Then hand-tighten with about a 1/3 or 1/2 turn.
NOTICE: Before starting up the transmission, fill it with oil
as described in the operating instructions.
SS12J174 2
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Index
Transmission - 21

Powershift transmission lubrication system - Change fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Powershift transmission lubrication system - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Transmission oil filter - Install - ZF fine filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Transmission oil filter - Remove - ZF fine filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Transmission oil filter - Service instruction - ZF fine filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Transmission - 21
Powershift transmission internal components - 155
836C AWD
836C
856C AWD
856C
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Contents
Transmission - 21
FUNCTIONAL DATA
Internal components
Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Clutch
Dynamic description - Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Output shaft
Disassemble - Output flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assemble - Output flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Internal components
Service instruction - Disassemble powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Remove - Drive shaft, output shaft and clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Disassemble - Clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Disassemble - Clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Disassemble - Clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Disassemble - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Disassemble - Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Service instruction - Clutches KV, KR, K1, K2, K3, K4, drive shaft, and output shaft . . . . . . . . . . . . . . . . 55
Assemble - Clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Assemble - Clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Assemble - Clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Assemble - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Assemble - Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Install - Drive shaft, output shaft, and clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Service instruction - Assemble powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
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Transmission - Powershift transmission internal components
Internal components - Component identification

Clutches KV, K1, K2 K3, K4 and drive shaft
SS12K373 1

AN Drive shaft K4 Clutch
K1 Clutch KR Clutch
K2 Clutch KV Clutch
K3 Clutch
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Clutch - Dynamic description - Transmission Clutch Calibration

The clutches gradually wear in the transmission therefore the calibration procedure should first be performed after the
first 250 hours of operation and then every 1500 hours thereafter.
NOTE: this calibration can also be executed using the CNH Service Tool (EST).
Multifunction Navigation Key Pad

Pos. Designation
A Interrupt key/Escape: With this key, the driver
can exit a submenu screen and go back to
the travel information screen, discard changes
made, and recall active fault codes.
B Entry key/Enter: This key confirms the selection
of a specific function and stores the entry.
C Up key: This key is used for scrolling up through
the screen selection.
D Down key: This key is used for scrolling down
through the screen selection.
NOTE: The scrolling direction (up or down) from the cur- SS11H004 1
rent position is indicated by arrows on the screen.
Accessing Clutch Calibration Feature

1. Check that the parking brake is applied.
2. Place the transmission control lever in neutral.
3. Start the engine.
4. With the engine running at idle, enter the service screen menu and scroll to calibration screen.
SS14H031 2
5. Press the confirm key.

6. Use the down arrow button to scroll to clutch calibration. Highlight clutch calibration and press the confirm key.
Always follow the prompts on the screen.
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SS14C105 3
NOTE: You can use the escape key to leave the calibration procedure at any time.
7. If the transmission oil temperature is too low, the message “Please wait for Sump Temp” appears on the screen
and the machine must be warm-up before the calibration can be executed. The message is active as long as the
oil temperature has reached the necessary temperature.
NOTE: To execute the calibration procedure the transmission oil temperature must be 70.0 - 95.0 °C (158.0 -
203.0 °F).
8. Warm-up procedure:
– Press and hold the travel brake.
– Engage the 3rd gear in manual mode.
– Set up the engine to high idle and change from 3rd gear into neutral from time to time to speed up the process.
9. If the oil temperature is in range to start the calibration process, follow the prompts on the screen to finish the
process.
The screen will show a confirm prompt. If you doubt your ability to perform this operation, press the escape key
and call your dealer.
SS14C106 4
If machine conditions are incorrect, an error message will appear. The calibration procedure will not complete. Follow
the prompts to aid in correcting any machine conditions.
The screen may display the following prompts to guide the user to correct machine conditions:
• Not in neutral
• Parking brake OFF
• Machine moving
• Oil temp too low
• Oil temp too high
• Engine RPM low
• Engine RPM high
If conditions are correct, the user will see six calibration screens displayed. They will appear in the following order:
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• Adjust K1
• Adjust K2
• Adjust K3
• Adjust K4
• Adjust KV
• Adjust KR
• Adjust KW (5-speed only)
Once the calibration process is complete, the user will be prompted to turn the engine Off and restart the machine.
If the process is not completed, the screen will prompt the user to escape.
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Output shaft - Disassemble - Output flange

Prior operation:
Output flange on output side without parking brake

bolts, and remove the washer and the O-ring.
SS12H128 1
2. Pull off the output flange (1) and remove the shaft seal
(2).
SS12H129 2
Output flange on output side with parking brake

1. Connect the HD pump at the connection (1) and apply
a pressure of about 80 bar (1160.0 psi) to the hydrauli-
cally operated parking brake (2) until the brake disk (3)
can be turned freely with the hand.
SS12H130 3
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2. Loosen the hexagon head bolts (1) on the parking

brake/console union.
SS12H131 4
3. Remove the parking brake (1).

4. Remove the locking plate (2).
5. Loose the hexagon head bolts.
6. Remove the washer and O-ring.
NOTE: Types:
M-90 - mechanically operated
FSG-75 - hydraulically operated
FSG-90/110 - hydraulically operated
NOTE: For further parking brake information, refer to
Parking brake caliper - Dynamic description - FSG 88
(spring loaded) (33.110). SS12H132 5
(2).
8. Loosen the cap bolts (3) on the console/transmission
housing (rear section) union and remove the console.
SS12H133 6
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Output flange converter side (without axle shutoff)

bolts, remove the washer and O-ring.
SS12H134 7
(2).
SS12H135 8
Output flange converter side (with axle shutoff)

1. Loosen the cap bolts (1) and separate the axle shutoff
(2) from the housing using the two assembly levers.
SS12H136 9
2. Pry off the circlip (1).
SS12H137 10
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3. Remove the adjusting shim (1) and the driver (2).
SS12H138 11
4. Pull off the output flange (1), loosen the cap bolts (2)
and disk (3), intermediate disk and bushing (4).
SS12H139 12
5. Remove the shaft seal (1).
SS12H140 13
SS12H141 14
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7. Drive out the output shaft (1) using a plastic mallet.
SS12H142 15
8. Press the ball bearing (1) out of drive shaft (2).
SS12H143 16
9. Remove the sliding sleeve (1).
SS12H144 17
10. Remove the slide blocks (1) and loosen the hexagon
head bolts (2).
SS12H145 18
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11. Take out the bolt (1) and remove the shift fork (2).
SS12H146 19
12. Remove the switch (1) and the locking pin (2).
SS12H147 20
13. Loosen the cap bolts (1), take out the cylinder (2) and
the seal.
SS12H148 21
14. Remove the exposed components:

• Piston (1)
• Push spring (2)
• Spring retainer (3)
SS12H149 22
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Output shaft - Assemble - Output flange

Output flange on output side without parking brake
1. Mount the shaft seal using the mounting tool (S), with
the sealing lip facing towards the oil gallery.
SS12J050 1
2. Push the output flange (1) into position.

NOTE: Fill the space between sealing lip and dust lip
with grease. Wipe the external diameter (rubberized) with
methylated spirit.
SS12J051 2
3. Insert the O-ring 38 mm (1.50 in) x 4 mm (0.16 in) into

the space between the output flange and the shaft.
4. Fasten the output flange with the disk (1) and the
5. Tighten the bolts with 34 N·m (25.1 lb ft).
SS12J052 3
6. Fasten the locking plate.

Use the special tools (S) 5870 057 011 and 5870 260
002.
SS12J053 4
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Output flange on output side with parking brake

1. Mount the shaft seal with the sealing lip facing towards
the oil gallery.
methylated spirit.
SS12J050 5
Version with fording capacity:

Mount the shaft seal 1 with the sealing lip facing towards
the oil gallery and the shaft seal 2 facing away from the
oil gallery.
NOTE: To obtain the exact installation position, use the
specified mounting tool (S).
(Mounting tool with circlip for 1st shaft seal ring).
(Mounting tool without circlip for 2nd shaft seal ring).
methylated spirit.
SS12J050 6
2. Fasten the brake disk (1) to the output flange (2) with
the hexagon head bolts (3) and the washers.
3. Tighten the head bolts with 68 N·m (50.2 lb ft).
4. Bring the console (4) into position on the transmission
housing rear section and fasten with the cap bolts (5).
6. Push the output flange (1) into position.
SS12J054 7

the space between the output flange and the shaft.
9. Tighten the hexagon head bolts with 34 N·m (25.1 lb
ft).
SS12J055 8
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SS12J056 9
11. Connect the HD pump at the connection (1), apply a

pressure of about 80 bar (1160.0 psi) to the parking
brake (2), and bring it into position at the console.
Use the special tools 5870 287 007, 5870 950 101,
and the mini measurement coupling 0501 207 939
(M10x1).
NOTE: Inspect the threaded stud (1).
SS12J057 10
12. Fasten the parking brake type FSG-75 (1) to the con-
sole with the hexagon head bolts.
NOTE: For all information on installation, assembly, func-
tion, and maintenance and for setting instructions for the
parking brake (1), refer to the original documentation pro-
vided by KNOTT.
SS12J058 11
NOTE: Types:
M-90 - mechanically operated
FSG-75 - hydraulically operated
FSG-90/110 - hydraulically operated
NOTE: FSG-75/90
Air gap 0.5 - 1.5 mm (0.02 - 0.06 in)
Nominal air gap 1 mm (0.039 in)
NOTE: FSG-110
Air gap 1.5 - 2 mm (0.059 - 0.079 in)
Nominal air gap 1.7 mm (0.067 in)
SS12J059 12
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Output flange converter side (without axle shutoff)

1. Mount the shaft seal with the sealing lip facing towards
the oil gallery.
methylated spirit.
SS12J060 13
2. Push the drive flange (1) into position.
SS12H135 14

the space between output flange and shaft.
hexagon head bolt (2).
5. Tighten the bolt with 34 N·m (25.1 lb ft).
SS12J061 15

002.
SS12J062 16
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Output flange converter side (with axle shutoff)

1. Mount the spring retainer (1) with the push spring (2).
SS12J063 17
2. Insert the plain compression ring (Viton) 40 mm

(1.57 in) x 47 mm (1.85 in) x 2 mm (0.08 in) (1) into
the radial groove and grease it.
NOTE: Ensure the radial position of the piston! The contact
surface of the locking pin must face towards the hole.
3. Insert the piston (2).
SS12J064 18
4. Mount the two adjusting screws (S) and place the flat
seal (1).
Mount the cylinder (2)
SS12J065 19
5. Using the torx screws (1), bring the cylinder (2) evenly
into position.
6. Tighten the screws with 23 N·m (17.0 lb ft).
SS12H148 20
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7. Mount the grub screw M6x8-10.9 (1).

NOTE: Smear the thread with Loctite No. 262.
SS12J066 21
8. Bring the shift fork (1) into position.

NOTE: Note the installation position!
SS12J067 22
9. Insert the O-rings 8 mm (0.31 in) x 2 mm (0.08 in) (1)

in the radial grooves in the bolts (2) and grease them.
10. Fix the shift fork (4) using the bolt (2) and fasten with
the hexagon head bolts.
11. Tighten the bolts with 9.5 N·m (7.0 lb ft)
SS12J068 23
12. Mount the two slide blocks (1) and insert the sliding
sleeve (2).
SS12J069 24
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13. Mount the O-ring 15 mm (0.59 in) x 2 mm (0.08 in)

(1) on the switch (3) and grease it. Mount the locking
pin (2) and the switch.
14. Tighten the switch with 30 N·m (22.1 lb ft).
SS12J070 25
15. With the tube (S), press the ball bearing (1) into posi-
tion on the drive shaft (2).
Use the special tool (S).
SS12J071 26
16. Insert the output shaft (1) (while mounting the sliding
sleeve) and press into position.
SS12J072 27
17. Fix the output shaft (1) with the circlip 120 mm
(4.72 in) x 4 mm (0.16 in) (2).
NOTE: Ensure that the circlip is placed radially, so that the
oil groove remains unobstructed.
SS12J073 28
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18. Standard version:

Mount the shaft seal (1) with the sealing lip facing
towards the oil gallery.
methylated spirit.
SS12J074 29
Version with fording capacity:

Mount the shaft seal (1) with the sealing lip facing to-
wards the oil gallery.
(Mounting tool without circlip)
SS12J075 30
Mount the shaft seal (1) with the sealing lip facing away
from the oil gallery.
Use special tool (S) 5870 048 300.
(Mounting tool with circlip)
methylated spirit.
SS12J074 31
19. Press the shield (1) flush onto the output flange (2)
using the jack (S).
SS12J076 32
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20. Version with the sliding output flange:

Press the bushing (1) onto the output shaft.
Insert the intermediate disk and disk (2) in the bushing
and secure with the cap screws (3).
Tighten the cap screws (M10/8.8x25) with 46 N·m
(33.9 lb ft).
NOTE: Smear the thread with Loctite No. 262.
SS12J077 33
21. Mount the output flange (1) on the output shaft (2).
SS12J078 34
22. Version with bolt-on the connecting flange:

Mount the output flange (1) on the output shaft (2).
SS12J079 35
23. Insert the O-ring 48 mm (1.89 in) x 4 mm (0.16 in)

and the disk (1) in the space between the drive flange
and shaft and fasten with the hexagon head bolts (2).
NOTE: Smear the thread with LOCTITE® 262™.
SS12J080 36
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25. Check that the switch is functioning correctly by doing

a resistance test:
If the switch is undamaged and the axle shutoff is ac-
tuated with compressed air, there should be a change
in the resistance!
Use the special tool measuring instrument (multi-me-
ter) 5870 221 196.
SS12J081 37
26. Insert the stop disk (perforated plate) in the hole (1).
Lubricate the O-ring 146 mm (5.75 in) x 2.65 mm
(0.10 in) (2) with mounting grease and insert it in the
radial groove.
SS12J082 38
27. Insert the needle bushing (1) carefully into position in

the hole in the output shaft (2), with the reinforced
casing facing toward the special tool.
28. Grease the needle rollers.
132.
SS12J083 39
29. Mount the driver (1) and the adjusting shim (2) on the
drive shaft (3).
SS12J084 40
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30. Fix the driver (1) using the adjusting shim (empirical
value s = 2.4 mm (0.1 in)) and V-ring (2).
NOTE: Check that the axial play of the driver is max.
0.2 mm (0.008 in)!
SS12J085 41
31. Insert the pre-assembled axle shutoff (2) and fasten

with the cap bolts (1).
SS12H136 42
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Internal components - Service instruction - Disassemble powershift

transmission
NOTE: For disassemble the powershift transmission and replacing internal parts e.g. clutches follow these instruc-
tions:
1. Remove the powershift transmission from the grader.
Refer to Powershift transmission - Remove (21.113).
2. Place the powershift transmission on a stand.
Refer to Powershift transmission - Place on stand
(21.113).
3. Remove the transmission oil filter.
Refer to Transmission oil filter - Remove - ZF fine
filter (21.105).
4. Remove the converter coupling valve.
5. Remove the electrohydraulic control valve.
Refer to Electro-hydraulic control valve - Disassem-
ble - Control unit (35.204).
6. Remove the inductive sensor, hall sensor, breather, oil
fill and drain screw.
Refer to Powershift transmission - Disassemble -
Inductive sensor, hall sensor, breather, oil fill and
drain screw (21.113).
7. Remove the input coupling.
Refer to Input shaft coupling - Disassemble - Direct
mounting (21.113) or Input shaft coupling - Disas-
semble - Separate mounting (21.113).
8. Remove the transmission converter oil pump.
Refer to Transmission/Converter oil pump - Disas-
semble (21.113).
9. Remove the temperature sensor.
Refer to Converter oil pressure adjustment valve
- Disassemble - Temperature sensor (Measuring
point “63” downstream of converter) (21.135).
10. Remove the emergency steering pump.
Refer to Emergency steering pump - Disassemble
(41.206).
11. Remove the output shaft.
Refer to Output shaft - Disassemble - Output flange
(21.155).
12. Remove the input shaft.
Refer to Input shaft - Disassemble - Power take off
(21.113).
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Internal components - Remove - Drive shaft, output shaft and

clutches
WARNING
Heavy objects!
W0398A
1. Drive out both cylinder pins (1).

2. Loosen the union (2) (housing front section to housing
rear section) and separate the housing rear section us-
ing a hoist.
SS12H155 1
3. Loosen the union (1) of oil screen plates.
SS12H156 2
4. Remove the output shaft (1) and the lower oil screen
plate (2) from the housing.
SS12H157 3
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5. Remove all plain compression rings (1) from the

clutches and the O-rings (2) from the oil pipes.
SS12H158 4
6. Using the hoist, bring the housing rear section (1) back
into position against the housing front section (2).
SS12H159 5
7. Secure all clutches using the handle (1).

NOTE: Due to installation conditions, it is not possible to
remove individual clutches without using the special tool.
SS12H160 6
8. Using the hoist, separate the housing rear section to-

gether with the clutches from the housing front section
and fasten to the maintenance unit.
SS12H161 7
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9. Loosen the cap bolts on the oil tubes (1) in the housing
front section, and remove them.
Use the special tool 0501 210 712 and 5870 600 003.
NOTE: Intake pipe (2) and lubricant lines (3) are rolled in
(3), and cannot be removed.
If damage has occurred, assembly and/or replacement can
be carried out only with the related ZF special tool.
SS12H162 8
10. Remove the bearing outer races from the housing

front section.
NOTE: If the tapered roller bearings for the clutches, drive
and output shafts are not to be replaced (not recommended
by ZF), the existing pair (bearing outer race/bearing inner
race) must be retained.
NOTE: The bearing outer race and inner race must be
marked!
SS12H163 9
11. Lift the clutches out of the housing in numerical order,

as indicated in the legend.
• Clutch K1 (1)
• Clutch K2 (2)
• Clutch K3 (3)
• Clutch K4 (4)
• Clutch KR (5)
• Clutch KV (6)
• Drive shaft (7)
SS12H164 10
12. Remove the bearing outer races from the housing rear
section.
by ZF), the existing pair (bearing outer race/bearing inner
race) must be retained.
NOTE: The bearing outer race and inner race must be
marked!
SS12H165 11
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NOTE: The lubricant lines are rolled in (1) and (2), and
cannot be removed.
NOTE: If damage has occurred, assembly and/or replace-
ment can be carried out only with the related ZF special
tool.
SS12H166 12
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Internal components - Disassemble - Clutch KV

Prior operation:
Remove the clutches.
Refer to Internal components - Remove - Drive shaft, output shaft and clutches (21.155).
1. Remove the stud bolt (1) and pry off the piston ring (2).
SS12H168 1
2. Pull the tapered roller bearing (inner race) away from

the shaft.
Use the special tools 5870 026 100, 5873 001 057, and
5873 011 011.
SS12K411 2
3. Pull the clutch (1) away from the shaft.

NOTE: For disassembly of the clutch (1), refer to 11 to 15.
SS12H170 3
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SS12H171 4
5. Fix the idler gear (1) using the separator (S) and re-
move it from the clutch shaft (2).
SS12H172 5
6. Pry the circlip (2) out of the idler gear (1) and the ball
bearing (3).
SS12H173 6
7. Remove the needle cage (1) from the shaft (2).
SS12H174 7
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8. Turn the shaft (2) through 180 ° and pry off the piston
ring (1).
SS12H175 8

the shaft.
5873 011 011.
SS12K412 9
10. Pry off the snap ring (1).
SS12H177 10
11. Remove the end plate (1) and the disk pack (2) from
the plate support (3).
SS12H178 11
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12. Pre-tension the push spring and pry off the snap ring
(1).
SS12H179 12
13. Remove the guide ring (1), push the spring (2) and the
washer (3).
SS12H180 13
14. Raise the piston (1) out of the bore in the plate support
using compressed air, and remove it.
SS12H181 14
15. Remove both O-rings (1) and (2).
SS12H182 15
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Internal components - Disassemble - Clutch KR

Prior operation:
SS12H168 1

the shaft.
5873 011 011.
SS12K411 2

NOTE: For disassembly of the clutch (1), refer to Steps 10
to 15.
SS12H170 3
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SS12H171 4
5. Fix the idler gear (1) using the separator (S) and re-
move it from the clutch shaft (2).
SS12H172 5
6. Pry the circlip (2) out of idler gear (1) and the ball bear-
ing (3).
SS12H173 6
7. Remove the needle cage (1) from the shaft (2).
SS12H174 7
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ring (1).
SS12H175 8

the shaft.
5873 011 011.
SS12K412 9
SS12H177 10
SS13J042 11
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(1).
SS12H179 12
13. Remove the guide ring (1), push the spring (2) and the
washer (3).
SS12H180 13
using the compressed air, and remove it.
SS12H181 14
15. Remove the O-rings (1) and (2).
SS12H182 15
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Internal components - Disassemble - Clutch K1

Prior operation:
SS12H183 1

the shaft.
5873 011 011.
SS12K413 2
SS12H185 3
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4. Thrust the bearing (1) with the support ring.
SS12H186 4
5. Take off the idler gear (1), the needle cage (2) and
remove the thrust bearing (3).
SS12H187 5

NOTE: For disassembly of clutch (1), refer to Steps 9 to
14.
SS12H188 6
ring (1).
SS12H189 7
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the shaft.
5873 011 011.
SS12K414 8
SS12H177 9
SS12H178 10
(1).
SS12H179 11
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12. Remove the guide ring (1), the push spring (2), and
the washer (3).
SS12H180 12
SS12H181 13
SS12H182 14
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Prior operation:
SS12H183 1

the shaft.
5873 011 011.
SS12K413 2
SS12H185 3
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4. Remove the thrust bearing (1) with the support ring.
SS12H186 4
5. Take off the idler gear (1), needle cage (2) and remove
the thrust bearing (3).
SS12H187 5

NOTE: For the disassembly of the clutch (1), refer to Steps
9 to 14.
SS12H188 6
ring (1).
SS12H189 7
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the shaft.
5873 011 011.
SS12K414 8
SS12H177 9
10. Remove the end plate (1) and disk pack (2) from the
plate support (3).
SS12H178 10
(1).
SS12H179 11
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the washer (3).
SS12H180 12
SS12H181 13
SS12H182 14
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Prior operation:
SS12H191 1

the shaft.
5873 011 011.
SS12K527 2
3. Remove the thrust bearing (1) completely.
SS12H193 3
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4. Take off the idler gear (1), the needle cage (2), and
remove the thrust bearing (3).
SS12H194 4

8 to 13.
SS12H195 5
ring (1).
SS12H196 6

the shaft.
5873 011 011.
SS12K415 7
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SS12H177 8
plate support (3).
SS12H178 9
(1).
SS12H179 10
the washer (3).
SS12H180 11
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SS12H181 12
SS12H182 13
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Prior operation:
SS12H198 1

the shaft.
5873 011 011.
SS12K416 2
SS12H200 3
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9 to 14.
SS12H201 4
5. Remove the thrust bearing (1) with the idler gear (2).
SS12H202 5
6. Remove the needle cage (1) and the thrust bearing (2)
with the support ring.
NOTE: The gear wheel (3) cannot be removed (shrink fit)!
SS12H203 6
ring (1).
SS12H204 7
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the shaft.
5873 011 011.
SS12K417 8
SS12H177 9
plate support (3).
SS12H178 10
(1).
SS12H179 11
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the washer (3).
SS12H180 12
SS12H181 13
SS12H182 14
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Internal components - Disassemble - Input shaft

Prior operation:
Remove the input shaft.
1. Pry off the piston ring (1).

The turbine wheel shaft (2) and the drive gear (3) are
fixed by a snap ring.
NOTE: If separated, these components are irreparably
damaged.
SS12H206 1

the drive gear.
5873 011 014.
SS12K418 2

the drive gear.
5873 011 014.
SS13N026 3
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Internal components - Disassemble - Drive shaft

Prior operation:
Remove the drive shaft.

the output shaft and remove the oil screen plate (1).
5873 011 014.
SS12K521 1
2. Turn the output shaft through 180 ° and remove the

tapered roller bearing (inner race).
5873 011 014.
SS12K420 2
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Internal components - Service instruction - Clutches KV, KR, K1,

K2, K3, K4, drive shaft, and output shaft
General notes on clutches
NOTE: Due to further design developments, the clutch (FLOW clutch), which could previously only be replaced in full,
now allows the individual components to be replaced separately.
“Old” clutch (FLOW clutch)

NOTE: This clutch can only be supplied/replaced com-
plete.
SS12H211 1
“New” clutch
If damaged, this clutch also allows individual compo-
nents to be replaced separately.
NOTE: However, this clutch can also be supplied or re-
placed complete.
NOTE: The part numbers required can be found on the
corresponding replacement parts list.
SS12H212 2
Assembly instructions in the event of repairs

NOTE: The change to the ‘NEW’ clutch was introduced
starting from transmission No. 842654
NOTE: In case of damage, please note the following. The
'old' clutch (FLOW clutch) and 'new' clutch are identical in
design. If repairs are required, the ‘old’ clutch must be
replaced with the ‘new’ one.
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Information about the changeover and clutches concerned.

Designation Old New
Clutch KV and KR 0501 212 261 4656 275 001
Clutch KV and KR 0501 212 263 4656 275 002
Clutch K1 0501 212 261 4656 271 262
Clutches K2 and K3 0501 212 261 4656 272 259
Clutch K4 0501 212 261 4656 274 260
NOTE: These part numbers are for information only. The required part numbers are found on the replacement parts
list. The parts number for the complete clutch is indicated on both versions.
“Old” clutch (FLOW clutch)

NOTE: The parts number (1) for the complete clutch (2) is
located on the rear of the plate support (3).
SS12H213 3
“New” clutch
NOTE: The parts number (1) for the complete clutch (2) is
located on the front of the end plate (3).
SS12H214 4
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Internal components - Assemble - Clutch KV

1. Press the tapered roller bearing inner race (1) up to the
stop on the shaft (2).
SS12H215 1
2. Mount the piston ring (1).
SS12H216 2
3. Mount the needle bearing (1) on the shaft.
SS12H217 3
4. Insert the ball bearing (2) in the position in the idler gear
(1) and fasten it with the circlip (3).
SS12H218 4
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5. Press the pre-assembled idler gear (1) into position.
SS12H219 5
6. Fix the idler gear (1) with the circlip (2).
SS12H220 6
7. Insert the O-rings (1) and (2) in the recesses in the

piston, and lubricate them.
(1) = 75 mm (2.953 in) x 3 mm (0.118 in)
(2) = 142 mm (5.591 in) x 3 mm (0.118 in)
NOTE: Check the function of the drain valve (3) – the ball
should not stick!
SS12H221 7
8. Insert the piston (1) in the plate support.

SS12H181 8
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9. Using the assembling aid, insert the piston into the

plate support with a hand-press.
SS12H222 9
10. Mount the washer (1), the push spring (2), and the
guide ring (3).
SS12H223 10
11. Pre-tension the push spring with the assembling aid

and push the snap ring 64 mm (2.520 in) x 3.2 mm
(0.126 in) (1) into the radial groove.
NOTE: Depending on the parts list version, different
clutches (different disk coatings with the corresponding
disk play) can be installed.
NOTE: The particular clutch or disk coating required can
be found on the corresponding replacement parts list.
NOTE: Steps 12 and 13 show the different disk coatings.
NOTE: Refer to the replacement parts list for the part re-
SS12H179 11
quired.
12. Fit the external and internal plates alternately in the
plate support (4):
• 2 pcs. Friction plates – coated on one side (1)
• 6 pcs. Externally toothed plates (2)
• 10 pcs. Internal plates (3)
NOTE: The friction plate (1) must be mounted with the un-
coated (bare) side facing towards the piston or end plate!
There are 20 friction surfaces!
SS12H224 12
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13. Fit the external and internal plates alternately in plate

support (4):
• 2 pcs. Friction plates – coated on one side (1)
• 6 pcs. Externally toothed plates (2)
• 7 pcs. Internal plates (3)
coated (bare) side facing towards the piston or end plate!
SS12H225 13
14. Fit the end plate (1) and fix the disk pack with the snap
ring (2) (for example s = 2.65 mm (0.104 in)/empirical
value).
SS12H226 14
15. Press on the end disk with force (F) (about 100 N
(22.5 lb)) and set the gauge to “ZERO”.
SS12H227 15
16. Then press the end disk against the snap ring (up-
ward) and read off the disk play.
NOTE: Disk play 2.45 - 2.75 mm (0.10 - 0.11 in) (refer to
12).
NOTE: Disk play 1.7 - 2 mm (0.07 - 0.08 in) (refer to 13).
NOTE: If the value is different, adjust the disk play using
the corresponding snap ring (optionally, s = 2.1 - 4.2 mm
(0.08 - 0.17 in).
SS12H228 16
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17. Heat up the inside diameter of the clutch (to about

120 °C (248.0 °F)).
SS12H229 17
18. Mount the clutch in position. With short turns to the left
and the right, mount the internal plates on the inner
plate support.
SS12H181 18
19. Press the tapered roller bearing inner race (1) into
position.
SS12H230 19
20. Mount the stud bolt (1).

21. Tighten the stud bolt with 17 N·m (12.5 lb ft).
NOTE: Test the opening and/or closing of the clutch by
applying compressed air at the hole (2).
The opening/closing of the clutch must be clearly heard!
SS12H231 20
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Internal components - Assemble - Clutch KR

SS12H215 1
SS12H216 2
3. Mount the needle bearing (1) on the shaft.
SS12H217 3
4. Insert the ball bearing (2) in position in the idler gear (1)
and fasten it with the circlip (3).
SS12H218 4
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5. Press pre-assembled idler gear (1) into position.
SS12H219 5
6. Fix the idler gear (1) with the circlip (2).
SS12H220 6

(1) = 75 mm (2.953 in) x 3 mm (0.118 in)
(2) = 142 mm (5.591 in) x 3 mm (0.118 in)
NOTE: Check the function of drain valve (3) – the ball
should not stick!
SS12H221 7

SS12H181 8
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SS12H222 9
guide ring (3).
SS12H223 10

NOTE: Depending on the parts list version, different
clutches (different disk coatings with the corresponding
disk play) can be installed.
NOTE: The particular clutch or disk coating required can
be found on the corresponding replacement parts list.
NOTE: The different disk coatings are shown in Steps 12
and 13.
SS12H179 11
NOTE: Refer to the replacement parts list for the part re-
quired.
plate support (4):
• 2 pcs. friction plates - coated on one side (1)
• 6 pcs. externally toothed plates (2)
• 10 pcs. internal plates (3)
coated (bare) side facing towards the piston or the end
plate!
SS12H224 12
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plate support (4):
plate!
SS12H225 13
14. Mount the end plate (1) and fix the disk pack with
the snap ring (2) (for example s = 2.65 mm (0.1 in)/
empirical value).
SS12H226 14
SS12H227 15
12).
NOTE: Disk play 1.7 - 2 mm (0.07 - 0.08 in) (refer to 13).
(0.08 - 0.17 in)).
SS12H228 16
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120 °C (248.0 °F)).
SS12H229 17
18. Mount the clutch in position.

19. With short turns to the left and the right, mount the
internal plates on the inner plate support.
SS12H232 18
position.
SS12H230 19

22. Tighten the stud bolt (M10/8.8x15) with 17 N·m
(12.5 lb ft).
SS12H231 20
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Internal components - Assemble - Clutch K1

stop on the shaft.
SS12H233 1
SS12H234 2

(1) = 75 mm (2.953 in) x 3 mm (0.118 in)
(2) = 142 mm (5.591 in) x 3 mm (0.118 in)
NOTE: Check the function of the drain valve (3) - the ball
should not stick!
SS12H221 3

SS12H181 4
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SS12H222 5
guide ring (3).
SS12H223 6

SS12H179 7
8. Mount the external and internal plates alternately in the

plate support (4):
plate!
SS12H224 8
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9. Fit the plate (1) and fasten the disk pack with snap
the ring (2) (for example s = 2.65 mm (0.1 in)/empirical
value).
SS12H226 9
SS12H227 10
NOTE: Disk play 2.5 - 2.8 mm (0.10 - 0.11 in)
13).
(0.08 - 0.17 in).
SS12H228 11

120 °C (248.0 °F).
SS12H229 12
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SS12H235 13
14. Mount the washer disk (1), the thrust collar (2), and
the axial disk (3).
NOTE: Mount the washer disk (1) with the chamfered side
(A) toward the thrust collar!
SS12H236 14
15. Mount the needle cage (1).
SS12H237 15
16. Mount the idler gear (1).

SS12H238 16
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18. Mount the axial disk (1), the thrust collar (2), and the
washer disk (3).
(A) facing toward the thrust collar.
SS12H239 17
19. Fasten the idler gear (1) and individual parts using the
circlip (2).
SS12H240 18
position.
SS12H241 19

(12.5 lb ft).
SS12H242 20
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stop on the shaft.
SS12H233 1
SS12H234 2
3. Insert the O-rings (1) 75 mm (2.953 in) x 3 mm

(0.118 in) and (2) 142 mm (5.591 in) x 3 mm (0.118 in)
in the recesses in the piston, and lubricate them.
NOTE: Check the function of drain valve (3) – the ball
should not stick!
SS12H221 3

SS12H181 4
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SS12H222 5
guide ring (3).
SS12H223 6

SS12H179 7
8. Mount the external and internal plates alternately in the

plate support (4):
plate!
SS12H224 8
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9. Fit the end plate (1) and fasten the disk pack with the
snap ring (2) (for example s = 2.65 mm (0.1 in)/empir-
ical value).
SS12H226 9
10. Press on the end disk with force (F) (about 100 N·m
(73.8 lb ft)) and set the gauge to “ZERO”.
SS12H227 10
figure 13).
(0.08 - 0.17 in)).
SS12H228 11

120 °C (248.0 °F).
SS12H229 12
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SS12H235 13
the axial disk (3).
SS12H236 14
SS12H237 15

SS12H238 16
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18. Mount the axial disk (1), the thrust collar (2), and the
washer disk (3).
(A) facing toward the thrust collar.
SS12H239 17
19. Fasten the idler gear (1) and individual parts using the
circlip (2).
SS12H240 18
position.
SS12H241 19

(12.5 lb ft).
SS12H242 20
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stop on the shaft.
SS12H243 1
SS12H244 2

4. Tighten the stud bolt (M10/8.8x15) with 17 N·m (12.5 lb
ft).
SS12H245 3

(1) = 75 mm (2.953 in) x 3 mm (0.118 in)
(2) = 142 mm (5.591 in) x 3 mm (0.118 in)
should not stick!
SS12H221 4
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SS12H181 5

SS12H222 6
guide ring (3).
SS12H223 7

SS12H179 8
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10. Mount the externally and internal plates alternately in

the plate support (4):
plate!
SS12H224 9
11. Fit the end plate (1) and fasten the disk pack with
the snap ring (2) (for example s = 2.65 mm (0.1 in)/
empirical value).
SS12H226 10
SS12H227 11
NOTE: Disk play 1.7 - 2.0 mm (0.07 - 0.08 in) (refer to 13).
(0.08 - 0.17 in)).
SS12H228 12
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120 °C (248.0 °F).
SS12H229 13
SS12H246 14
the axial disk (3).
SS12H247 15
SS12H248 16
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SS12H249 17
20. Mount the axial disk (1), the thrust collar (2) and the
washer disk (3).
NOTE: Mount the washer disk (1) with chamfered side (A)
facing toward the thrust collar.
SS12H250 18
position.
SS12H251 19

SS12H252 20
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SS12H253 1
SS12H254 2
3. Supercool the shaft (1) (to about -80 °C (-112.0 °F)),

heat up the gear (2) (to about 120 °C (248.0 °F)) and
mount it up to the stop.
SS12H255 3
NOTE: Secure the gear wheel with the circlip ( 80 mm

(3.150 in) x 2.5 mm (0.098 in) (1)).
SS12H256 4
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4. Mount the lower axial disk (1), the thrust collar (2), and
the upper axial disk (1).
NOTE: The upper and lower axial disks are identical (
50 mm (1.969 in) x 70 mm (2.756 in) x 1 mm (0.039 in)).
SS12H257 5
5. Mount the two needle bearings.
SS12H258 6
SS12H259 7
7. Mount the axial disk (1), the needle cage (2), and the
washer disk (3).
(A) towards the needle cage!
SS12H260 8
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8. Insert the O-rings (1) 75 mm (2.953 in) x 3 mm

(0.118 in) and (2) 142 mm (5.591 in) x 3 mm (0.118 in)
in the recesses in the piston, and lubricate them.
should not stick!
SS12H221 9

SS12H181 10
SS12H222 11
guide ring (3).
SS12H223 12
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SS12H179 13
13. Mount the externally and internal plates alternately in

the plate support (4):
plate!
SS12H224 14
14. Mount the end plate (1) and fix the disk pack with the
snap ring (2) (for example s = 2.65 mm (0.104 in)/
empirical value).
SS12H226 15
SS12H227 16
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NOTE: Disk play 1.7 - 2.0 mm (0.07 - 0.08 in) (refer to 13).
(0.08 - 0.17 in).
SS12H228 17

120 °C (248.0 °F)).
SS12H229 18
18. Mount the clutch (1) in position and fasten with the
circlip ( 50 mm (1.969 in) x 2 mm (0.079 in) (2)).
internal plates on the plate support.
SS12H261 19
position.
SS12H262 20
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(12.5 lb ft).
SS12H263 21
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Internal components - Assemble - Input shaft

1. Supercool the drive shaft (1) (to about -80 °C
(-112.0 °F)), heat up the drive gear (2) (to about 120 °C
(248.0 °F)) and mount it up to the stop.
SS12H264 1
2. Secure the drive gear with a 90 mm (3.54 in) x 3 mm

(0.12 in) circlip (1).
SS12H265 2
3. Press the tapered roller bearing inner race (1) into po-
sition on the drive shaft.
SS12H266 3
SS12H267 4
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Version with converter coupling

5. Insert the O-ring 35 mm (1.38 in) x 2 mm (0.08 in) (1)
in the lower radial groove in the drive shaft and grease
it.
SS12H268 5
6. Insert the snap ring SB 38 (1) in the radial groove (2) in

the turbine shaft.
SS12H269 6
7. Insert the turbine shaft (1) until the snap ring snaps into
the recess in the drive shaft. The turbine shaft is fixed
axially.
Insert 60 mm (2.36 in) x 3 mm (0.12 in) plain compres-
sion ring (2) and block it.
SS12H270 7
Version with converter coupling

8. Insert the turbine shaft (1) until the snap ring snaps into
the recess in the drive shaft. The turbine shaft is fixed
axially.
Insert the plain compression ring and block it.
(2) = 60 mm (2.36 in) x 3 mm (0.12 in)
(3) = 36 mm (1.42 in) x 2.5 mm (0.10 in)
SS12H271 8
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Internal components - Assemble - Drive shaft

SS12H272 1
2. Mount the shield (2) and press the tapered roller bear-
ing inner race (1) into position on the drive shaft.
SS12H273 2
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Internal components - Install - Drive shaft, output shaft, and

clutches
WARNING
Avoid injury!
W1036A
WARNING
Heavy objects!
W0398A
Prior operation:
Internal components - Assemble - Clutch KV (21.155)
Internal components - Assemble - Clutch KR (21.155)
Internal components - Assemble - Clutch K1 (21.155)
Internal components - Assemble - Input shaft (21.155)
Internal components - Assemble - Drive shaft (21.155)
1. If the intake pipe (1) in the housing front section has

to be replaced, it must be mounted with the ZF special
tool (rolling tool).
2. Fasten with the cap bolt (2) (M8/8.8x12) with 23 N·m
(17.0 lb ft).
SS12J024 1
3. Mount the O-rings 22 mm (0.87 in) x 3 mm (0.12 in)

in the radial groove in the oil pipes (1) and (2) and
lubricate them.
4. Insert the housing front section and fasten it with the
cap bolts (3) (M8/8.8x12) with 23 N·m (17.0 lb ft).
SS12J025 2
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5. Mount the screw plug M38 x 1.5 (1) with new O-ring
35 mm (1.38 in) x 2 mm (0.08 in).
6. Tighten the screw plug with 140 N·m (103.3 lb ft).
SS12J026 3
7. Use the special tool 5870 600 006.

NOTE: The spare parts service only supplies lubricating
oil pipes (1) and (2) complete with the housing rear sec-
tion. Available individually only on request! Can only be
mounted using the ZF special tool (see also figure 1)!
SS12H166 4
8. Insert all bearing outer races in the bearing bores in

both housing sections.
Housing front section:
• Drive (AN)
• Output (AB)
• Forward clutch (KV)
• Reverse clutch (KR)
• 1st gear clutch (K1)
• 2nd gear clutch (K2)
• 3rd gear clutch (K3)
SS12J027 5
• 4th gear clutch (K4)
9. Housing rear section:
See legend at Step 8.
NOTE: Insert all bearing outer races with mounting grease
in the bearing bores.
by ZF), the existing pairing (bearing outer race/bearing in-
ner race) must be retained.
SS12J028 6
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10. Install the clutches using the housing rear sections

(see steps 9 to 18).
11. Insert the clutch (KR), the drive shaft (AN) and the
clutch (KV) together in the housing rear section.
NOTE: The housing rear section is lifted off again later.
SS12J029 7
12. Lift the drive gear slightly and the bring clutch (K4) into
position.
SS12J030 8
13. Mount the clutch (K3).
SS12J031 9
14. Bring the clutch (K2) into position.
SS12J032 10
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15. Lift the clutch (K4) slightly and bring the clutch (K1)
into position.
SS12J033 11
The illustration opposite shows the installation position

of the individual clutches in the housing rear section.
16. Inspect the plain compression rings, grease them and
align centrally.
17. Secure all clutches using handles (S).
SS12J034 12
18. Swivel the housing rear section through 180 °C

(356.0 °F).
19. Mount the ring bolts and the ring nuts.
003.
SS12J366 13
20. Using the hoist, bring the housing rear section into
position against the housing front section; while doing
so, carefully insert the clutches.
21. Remove the handles.
SS12J036 14
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22. Lift off the housing rear section again.
SS12J037 15
23. Place the shield (2).

24. Insert the pre-assembled output shaft (1).
SS12H157 16
25. Fasten the shields with cap bolts (1).

26. Tighten the cap bolts (M8/8.8-12) with
23 N·m (17.0 lb ft).
27. Mount the O-rings 22 mm (0.87 in) x 3 mm (0.12 in)
(2) in the radial groove in the oil pipes and lubricate
them.
28. Mount the plain compression rings, grease them and
align them centrally.
29. Smear the flange-on surface (3) with Loctite sealant
No. 574.
SS12J039 17
30. Using the hoist, bring the housing cover carefully into
position on the transmission housing.
Use the special tools (S) 0664 462 774, 0636 804 003.
NOTE: Check that the two oil pipes are aligned with the
holes in the housing rear section.
SS12K374 18
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31. Mount the two cylinder pins (1) at the center of the
flange-on surface.
SS12J041 19
32. Mount the driver (S) and rotate the clutch shaft KV.
SS12J042 20
33. Fasten the housing front section and the housing rear
section using the cap bolts (1).
34. Tighten the cap bolts (M10/8.8x65) and
(M10/8.8x40) with 46 N·m (33.9 lb ft)
Mount the stud bolts (2).
35. Tighten the stud bolts (M8/10.9x25) with
15 N·m (11.1 lb ft).
NOTE: Smear the screw-in thread with Loctite No. 243.
SS12J043 21
36. Insert the O-ring 76 mm (2.99 in) x 3 mm (0.12 in) (1)

in the radial groove in the cover (2).
SS12J044 22
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37. Fasten the cover (1) with the hexagon nuts (2).
38. Tighten the hexagon nuts (M8/10) with
25 N·m (18.4 lb ft).
SS12J045 23
Next operation:
See the assemble service instructions.
Refer to Internal components - Service instruction - Assemble powershift transmission (21.155).
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Internal components - Service instruction - Assemble powershift

transmission
Prior operation:
Install the internal components.
Refer to Internal components - Install - Drive shaft, output shaft, and clutches (21.155).
NOTE: For assemble the powershift transmission follow this instructions:

1. Place the powershift transmission on a stand.
Refer to Powershift transmission - Place on stand
(21.113).
2. Install the input shaft.
Refer to Input shaft - Assemble - Power take off with
WK (21.113) or Input shaft - Assemble - Power take
off without WK (21.113).
3. Install the output shafts.
Refer to Output shaft - Assemble - Output flange
(21.155).
4. Install the converter counterpressure valve and the
temperature sensor.
Refer to Converter oil pressure adjustment valve -
Assemble - Temperature sensor (Measuring point
“63” downstream of converter) (21.135).
5. Install the transmission converter oil pump.
Refer to Transmission/Converter oil pump - Assem-
ble (21.113).
6. Install the input coupling.
Refer to Input shaft coupling - Assemble - Direct
mounting (21.113) or Input shaft coupling - Assem-
ble - Separate mounting (21.113).
7. Install the emergency steering pump.
Refer to Emergency steering pump - Assemble
(41.206).
8. Install the inductive sensor, hall sensor, breather, oil fill
and drain screw.
Refer to Powershift transmission - Assemble - In-
ductive sensor, hall sensor, breather, oil fill and
drain screw (21.113).
9. Install the electrohydraulic control valve.
Refer to Electro-hydraulic control valve - Assemble
- Control unit (35.204).
10. Install the converter coupling valve.
Refer to Electro-hydraulic control valve - Assem-
ble - Converter coupling valve (35.204).
11. Install the transmission oil filter.
Refer to Transmission oil filter - Install - ZF fine
filter (21.105).
12. Install the powershift transmission.
Refer to Powershift transmission - Install (21.113).
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Index
Transmission - 21

Clutch - Dynamic description - Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Internal components - Assemble - Clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Internal components - Assemble - Clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Internal components - Assemble - Clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Internal components - Assemble - Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Internal components - Assemble - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Internal components - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Internal components - Disassemble - Clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Internal components - Disassemble - Clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Internal components - Disassemble - Clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Internal components - Disassemble - Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Internal components - Disassemble - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Internal components - Install - Drive shaft, output shaft, and clutches . . . . . . . . . . . . . . . . . . . . . . . . . 91
Internal components - Remove - Drive shaft, output shaft and clutches . . . . . . . . . . . . . . . . . . . . . . . . 25
Internal components - Service instruction - Assemble powershift transmission . . . . . . . . . . . . . . . . . 98
Internal components - Service instruction - Clutches KV, KR, K1, K2, K3, K4, drive shaft, and output
shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Internal components - Service instruction - Disassemble powershift transmission . . . . . . . . . . . . . . . 24
Output shaft - Assemble - Output flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Output shaft - Disassemble - Output flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Transmission - 21
Torque converter - 700
836C AWD
836C
856C AWD
856C
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Contents
Transmission - 21
TECHNICAL DATA
Torque converter
FUNCTIONAL DATA
Torque converter
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Transmission - Torque converter
Torque converter - General specification

Single-stage torque converter integrated in manual transmission.
Automatic torque adjustment to variations in air drag and rolling resistance.
Designation 836C/836C AWD 856C/856C AWD

Converter ratio 1.87 : 1 1.91 : 1
Cooling Heat exchanger Heat exchanger
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Torque converter - Dynamic description
SS12J001 1
Mode of operation of the hydrodynamic torque converter (illustration of principle).

A Engine F Intermediate status
B Transmission G Status at draw-bar hitch point
C Impeller TP Impeller torque
D Turbine wheel TR Torque at reaction member wheel (stator)
E Torque status at startup TT Turbine wheel torque
The converter works like a Trilok converter, i.e. at high turbine rotational speeds, it takes on the characteristics and
efficiency advantages of a fluid coupling.
This depends on the engine power output, so that the most favorable operating conditions are produced in each
installation case.
The torque converter is made up of three main components:

• Impeller
• Turbine wheel
• Stator (reaction member)
These three wheels are in a ring, so that the fluid flows through the different parts of the circuit in the required order.
Pressure oil from the transmission pump flows continuously through the converter. This allows it to perform its function
of multiplying the engine torque, while at the same time dissipating the heat from the converter through the flowing oil.
The oil driven by the impeller enters the turbine wheel, where it is turned to the direction of flow. Depending on the
degree of deflection, a greater or lesser reaction torque is applied to the turbine wheel (and therefore the output shaft).
The function of the stator (reaction member) placed after the turbine wheel is to divert the oil from the turbine back to
a flow direction suitable for delivery to the impeller.
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Deflection of the flow causes a reaction torque to be applied to the stator.

The ratio of turbine torque to impeller torque is defined as torque conversion. This becomes greater in proportion to
the difference between the impeller and turbine wheel rotational speeds.
Maximum conversion therefore occurs when the turbine wheel is stopped.

As the output speed increases, the torque conversion rate decreases. The torque converter adapts the working speed
continuously and automatically to the specific torque output requirement.
If the turbine speed reaches about 80 % of the pump speed, the conversion rate is 1.0, i.e. the turbine torque is equal
to the pump torque.
From this point onwards, the converter behaves like a fluid coupling.
A stator freewheel is used to improve efficiency in the higher range; in the conversion range, it allows the torque to
be supported on the housing, and it is released in the coupling range.
The stator wheel can then turn freely.
Converter coupling
When the coupling is closed, the slip between impeller and turbine wheel is 'zero', and so therefore is the hydraulic
loss in the converter.
The converter coupling is actuated automatically according to turbine wheel RPM.
The pressure oil ( 15.0 - 16 bar (217.5 - 232 psi)) needed to close the coupling is delivered through a solenoid switch
valve to the piston, which compresses the disk pack.
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Torque converter - Component identification
SS12H004 1

A Coupling open 1 Disk spring
B Coupling closed 2 Disk pack
C Pressure oil from converter coupling valve 3 Stator
4 Circuit cover/impeller
5 Turbine wheel
6 Piston
SS12J002 2
Converter coupling

A Transfer plate D Coupling solenoid
B Connection to coupling E Ventilation bore
C Coupling measuring point F System pressure from control unit
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Index
Transmission - 21

Torque converter - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Torque converter - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Torque converter - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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47829048B 15/06/2016
EN
SERVICE MANUAL
Front axle system
836C AWD
836C
856C AWD
856C
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25
Contents
Front axle system - 25
[25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1
[25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2
47829048B 15/06/2016
25
Powered front axle - 100
836C AWD
836C
856C AWD
856C
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Contents
TECHNICAL DATA
Powered front axle

Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUNCTIONAL DATA
Powered front axle

Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE
Powered front axle

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DIAGNOSTIC
Powered front axle

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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Front axle system - Powered front axle
Powered front axle - Dimension

NOTE: Axle 856C is shown.
SS14H016 1
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A 20.5 ° O 1556.0 mm (61.3 in)
B 20.5 ° P 1405.0 mm (55.3 in)
C 1305.0 mm (51.4 in) Q 35.5 °
D 290.0 mm (11.4 in) R 11 °
E 395.0 mm (15.6 in) S 42.5 °
F 262.0 mm (10.3 in) T 42 °
G 149.0 mm (5.9 in) U 118.0 mm (4.6 in)
H 250.0 mm (9.8 in) V 304.5 mm (12.0 in)
I 1263.0 mm (49.7 in) W 365.5 mm (14.4 in)
J 1763.0 mm (69.4 in) X 192.0 mm (7.6 in)
K 21.0 mm (0.8 in) Y 12.0 mm (0.5 in)
L 44.0 mm (1.7 in) Z 462.5 mm (18.2 in)
M 2059.0 mm (81.1 in) A.a 192.0 mm (7.6 in)
N 1602.0 mm (63.1 in)
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Powered front axle - Sealing
SS14H017 1
NOTE: B2 = LOCTITE® 242®

Apply to the threads on screw bolts.
Powered front axle - Special tools

We recommend using spinner handles to protect the hands.
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Order Designation Picture

number
2897043 Hub removal
SS12E336 1
2897044 Steering cylinder joint
SS12E337 2
2897045 Articulated joint bearing
SS12E338 3
Powered front axle - General specification

All-wheel drive
The hydraulic system for the all-wheel drive consists of an adjustable axial piston pump and two radial piston motors.
These main components operate in a closed circuit and form the hydrostatic drive for the front wheels.
Technical data
Swing axle with double-pivot steering and hydraulic wheel camber adjustment.
836C/836C AWD 856C/856C AWD

Oscillation +/- 15 ° +/- 15 °
Effective wheel lean +/- 14 ° 24 ' +/- 12 °
Ground clearance 485 mm (19.1 in) 554 mm (21.8 in)
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836C/836C AWD 856C/856C AWD

Variable displacement pump A4VG 56EP2 A4VG 71EP2
Flow volume 0 - 56 cm³/rev (0.0 - 3.4 in³/rev) 0 - 71 cm³/rev (0.0 - 4.3 in³/rev)
Volume flow 115 l/min (30.4 US gpm) 160 l/min (42.3 US gpm)
Wheel motor MS 8 MS 11
Cubic capacity 857 cm³ (52.3 in³) / 1239 cm³ (75.6 in³) /
428 cm³ (26.1 in³) 629 cm³ (38.4 in³)
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Powered front axle - Static description

Intended use
This axle has been developed and produced for installing on industrial machines. The axles is the part of the machine
that transmits power from the engine to the wheels.
It has been produced to the customer's specifications, and is used to:

• Increase the tractive force while at the same time reducing rotational speed.
• Balance the speeds of inner and outer wheels while steering.
NOTICE: Never install this axle in machines other than those specified.
The manufacturer will not be liable for any damage to property or injuries to personnel if the axle is not used according
to the specified conditions. In such cases, the customer alone will be liable.
Even when used correctly, the manufacturer's maintenance and repair instructions must be followed in all cases.
General Description
The axle described in this section is made up of the axle casing and the wheel hub assemblies at both ends of the
axle.
SS14H018 1

A Wheel lean cylinder C Axle casing
B Steering cylinders D Drive train
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Powered front axle - Component identification

NOTE: The vehicle is shown without equipment.
SS12E346 1

3 Screws 14 Shaft seal
4 Front cover 15 Adjusting shims
5 Screws 16 Grub screw
6 Rear cover 17 Lock washer
7 Counter-nut 18 Lube nibble
8 Connecting pin 19 Bushings
13 Washer
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Powered front axle - Service instruction

Maintenance
Read through the whole manual to enable you to carry
out ordinary and extraordinary maintenance correctly.
Failure to follow the instructions can shorten the service
life and impair the performance of the axle, and can
result in damage and injuries to personnel. If faults or
anomalies occur, a prompt intervention by specialized
personnel will ensure long service life of the assembly
and prevent greater damage over the long term.
Repairs
The axle disassembly/assembly instructions can be
used to carry out a complete overhaul of the assembly.
The procedure is described in steps, and illustrated by
figures to ensure a safe working method.
A thorough knowledge of the assembly will allow any
problems to be assessed correctly. Consequently, this
will allow a more targeted intervention without having to
dismantle the entire assembly.
Conventions and terms used

The illustrations in this manual are NOT true to scale,
i.e. NO conclusions can be drawn about the real dimen-
sions of the components represented.
The figures are intended only to illustrate the working
procedure on the axle, and the illustration in your man-
ual may therefore not represent your particular axle as-
sembly. It may simply represent a similar axle.
Location references
L.H. (left hand) or left side means the left side of the
axle looking in the direction of travel of the machine.
R.H. (right side) or right side means the left right of the
General disassembly/assembly
The axle should be inspected and/or repaired only by
specialized personnel who have a thorough knowledge
of the product, and who follow the corresponding safety
instructions (accident prevention).
Before starting work, the axle should be thoroughly
cleaned to remove any deposits, grease, and/or accu-
mulated dirt.
To prevent possible damage, all components removed
from the axle must be cleaned with a suitable cleaning
agent. Check the parts for wear. If there is any damage,
cracking, corrosion or other defects that could impair
axle function, replace them.
In particular, all parts that are in constant movement
(bearings, gears, shafts) and their seals (O-rings, gas-
kets) must be inspected for wear, as these are subject
to greater stress.
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It is recommended to change the seals at each mainte-

nance or repair operation.
Note that the components of bevel gear pairs must al-
ways be replaced in pairs.
As described in the disassembly instructions, certain
operations are final for some of the axle components,
i.e. these components must be replaced each time,
as they are destroyed by the removal process. The
individual steps must be followed exactly as described,
in order to avoid impairing the correct function of the
entire assembly.
Before starting disassembly and assembly work, read
through the following instructions carefully.
Shaft sealing rings

When assembling the shaft seals, do the following:
1. Clean the shaft thoroughly, and inspect the areas
of the seal rings that come into contact with the
shaft for any signs of deformation or damage.
2. Insert the seal ring such so that the lip is facing in
the direction of the oil flow.
3. Lubricate the lip (preferably with grease), and 3/4
fill the recesses in the rings with grease.
4. When mounting the rings, use a suitable press-on
tool. Do not strike the rings directly with a hammer.
5. Do not damage the rings when mounting on the
shaft.
O-rings
Grease the O-rings before pressing into position. Avoid
rolling them.
Shim washers
For adjustments, use appropriate shim washers. These
must be measured individually. The measured dimen-
sions of the whole set or the values printed on the wash-
ers do not necessarily correspond to the real values –
these must be checked.
Bearing
For correct mounting on the shaft, it is recommended
beforehand to heat the bearing to 80 - 90 °C (176.0 -
194.0 °F) in an oven. It should then be mounted in the
bearing seat, where it should be allowed to cool. Al-
ways use a suitable extracting tool to remove bearings.
Before mounting, clean, inspect, and lubricate the bear-
ing.
Sprung dowel pins

Before mounting grooved pins, check that the grooves
are pointing in the direction of force. There is no special
mounting direction for spiral roll pins.
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Sealant
Only use suitable sealants. Check that the surfaces are
clean, dry, and free of grease.
Draining oil
Before any work is performed on the assembly, drain
off the oil.
NOTICE: Dispose of used oil as required by regulations.
Clean
Clean all moving parts (gears, bearings, etc.) thor-
oughly using gas, oil, or paraffin.
Avoid using gasoline or alkaline solvents.
Do not use water or steam, which would leave the sur-
faces damp.
Dry off all parts with compressed air or a cleaning cloth,
to remove any residues that might scratch the surface.
To prevent oxidation, lightly grease all surfaces.
Inspection
Inspect all bearings, all outer rings that may still be in
place, and all bolts over which rollers move. Parts that
show signs of wear or damage should be replaced.
Inspect all gear teeth for wear or damage. No wear
should be visible on the tooth surfaces. Check that the
grooves are not damaged, and that they do not show
excessive wear. Replace worn parts with original re-
placement parts only. It is recommended to replace the
shaft seals after each disassembly operation.
Flange and tool end pieces

When fitting flange and tool end pieces, take care to
prevent any deformation that might impair their func-
tional efficiency.
Mounting methods
Use a suitable workbench for working on the assembly.
Use lifting gear when raising the assembly, when dis-
assembling/assembling gear pairs, and for supporting
the gear housing.
For an illustration of the disassembly/assembly pro-
cesses, refer to a drawing of the entire assembly.
Using lubricants
For correct lubrication, and to be able to reach the exact
operating temperature of the axles, it is important to use
only the recommended lubricants and to keep the oil
constantly at the levels described in this manual.
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Powered front axle - Remove

WARNING
Heavy objects!
W0398A
1. Hold the front axle with suitable lifting gear.

2. Remove the front wheels.
3. Loosen the bolts (1) and take off the mudguard (2).
SS12E347 1
4. Detach all hydraulic lines from the two steering cylin-

ders and the wheel lean cylinder, and close them off.
SS12E348 2
5. Detach and close off the hydraulic lines to the flow di-
vider.
NOTE: Applies only to all-wheel models 836C AWD and
856C AWD.
SS12E349 3
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6. Loosen the four screws (3) and take off the cover (4).
SS12E350 4
7. Loosen the screws (5) and take off the cover (6).
SS12F011 5
8. Loosen the counter-nut (7) and remove the grub screw

(16) that secures the front axle connecting pin (8) to the
frame.
SS12F012 6
9. At the rear, drive out the connecting pin (8) using a

suitable drift punch.
SS12F013 7
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10. Remove the front axle, raising it onto the adjusting

shim(s) (15), washers (13), and shaft seals (14) lo-
cated between the front axle and the frame.
SS12F014 8
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Powered front axle - Install

WARNING
Heavy objects!
W0398A
1. Check the bushings (19) in the front frame and con-

necting pin (8) for damage, and replace if necessary.
2. Position the front axle so that the holes in the front
frame are aligned with those in the front axle.
3. From the front, push in the bolt (8) a short way.
SS12F013 1
4. Insert the special tool (10) and fasten to the front frame
with bolts (11).
5. Using the bolts of the special tool (12), push the front
axle forward as far forward as possible, to make as
much room as possible between front frame and front
axle.
SS12F015 2
6. Measure the internal dimension (X).

If the internal dimension (X) is greater than 474 mm
(18.7 in), mount the adjusting shims (15).
SS12F016 3
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7. Check the shaft seal (14) and washer (13) for damage,
and replace if necessary.
8. Push in the adjusting shims (15) to obtain the specified
gap between front frame and front axle.
SS12F017 4
9. Remove the tool and drive the connecting pin (8) fully
in.
10. Screw the grub screw (16) into the connecting pin and
tighten the counter-nut (7).
SS12F012 5
11. Place the rear cover (8) and tighten the screws (5).
SS12F011 6
12. Place the front cover (4) and tighten the screws (3).
SS12E350 7
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13. Connect all hydraulic lines to the two steering cylin-

ders and wheel lean cylinders.
SS12E348 8
14. Connect the hydraulic lines to the flow divider.

NOTE: Applies only to all-wheel models 836C AWD and
856C AWD.
SS12E349 9
15. Installation of the front wheels.

16. Mount the mudguards (2) and tighten the screws (1).
SS12E347 10
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Powered front axle - Troubleshooting

Problem Possible Cause Correction
No tractive force at front No power supply to FWD control Check the fuse,
wheels test the power supply
Faulty On/Off switch Check the signal from the switch;
repair or replace it
Faulty FWD control Check the FWD switch-on function,
replace the control if necessary.
Pressure cut-off valve faulty Check pressure cut-off
Replace valve if faulty
A high-pressure limiting valve is faulty. Check whether high pressure builds up on
one side
Replace valve if faulty
Faulty purge valve Repair or replace it
Feed pressure too low or absent Check feed pressure at measuring point
(MS), set the feed pressure limiting valve,
or replace it.
On/Off solenoid valve faulty Check FWD shift pressure at measuring
point (1), replace valve
6/2 way valve faulty Repair or replace it
Wheel motor faulty Repair or replace it
Pump drive faulty The pump should be replaced by a new
(If the pump drive is faulty, i.e. the axial one.
piston pump is no longer operated when
the diesel engine is running, then the ve-
hicle should not be driven, even with the
all-wheel drive switched off.)
Tractive force too low at Value settings IXV, IKV, IXR, and IKR Check the value settings, and correct if
front wheels necessary.
8-stage rotary feed switch faulty Check the signal from the switch; repair or
replace it
Pressure cut-off valve faulty Check pressure cut-off
Replace valve if faulty.
A high-pressure limiting valve is faulty. Check whether high pressure builds up on
one side.
Replace valve if faulty.
Feed pressure too low or absent Check feed pressure at measuring point
(MS), set the feed pressure limiting valve,
or replace it
Tractive force too high at Refer to "tractive force too low”
front wheels
Other possible cause: wheel motor control Check chamber pressure at measuring
faulty point (2), replace 4/2 way valve.
Front wheels lock in Inductive sensor signal for signal transmis- Check the inductive sensors using the re-
normal straight-ahead sion input/output speed faulty lated cable connection.
running
incorrect IXV, IKV, IXR and IKR values pro- Correct the value settings IXV, IKV, IXR,
grammed and IKR.
Gear detection incorrect Test the gear detection on the EDS tester,
gearshift unit, and FWD control
Front wheels block when Air in the control line of the chamber switch- Bleed the control line
shifting from 3rd – 4th over valve to the wheel motor
forward gear or shifting
from 2nd – 3rd reverse
gear
Chamber switch-over valve or electric con- Check and replace if necessary.
nection faulty
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Feed pressure too low or absent Check that nozzle ∅ 1.8 836C AWD and
nozzle ∅ 2.0 856C AWD are correctly in-
stalled
Check feed pressure valve setting and cor-
rect if necessary.
Reservoir preload pressure in feed pump Check the reservoir 16 bar (232.0 psi)
circuit too high or too low preload pressure and correct if necessary
Chamber parameter t Reduce the parameter value on the EDS
tester.
Front wheels braking in Wheel motor control faulty Check chamber pressure at measuring
gears 4 and 5 point (2) replace 4/2 way valve.
Wheel motor switch-over faulty Check the switch-over Replace or repair
wheel motors.
Front wheels braking Pump and wheel motor housing pressure Check pressure at pressure limiting valve.
when FWD Off and vehicle too low (rattling noise at wheel motors) Set the feed pressure limiting valve or re-
speed increasing place it.
Pump shaft seal faulty Housing pressure too high Check pressure at pump housing (connec-
tion T1).
Check tank return line filter.
Uncontrolled spinning of Differential lock fault Repair or replace it
a front wheel in forward
travel
A wheel motor switch-over is faulty Check the switch-over.
Replace or repair faulty wheel motor.
Engine stalls when Current reduction fault when braking Check the function of the brake lamp or
braking i-Brems parameter brake lamp switch.
Increase the parameter value using the
EDS tester.
Oil temperature too high Faulty purge valve Repair or replace it.
(purge oil temperature >
90 °C (194.0 °F), at pump
housing connection T1)
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Index

Powered front axle - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Powered front axle - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Powered front axle - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Powered front axle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Powered front axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Powered front axle - Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Powered front axle - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Powered front axle - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Powered front axle - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Powered front axle - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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Final drive hub, steering knuckles, and shafts - 108
836C AWD
836C
856C AWD
856C
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Contents
FUNCTIONAL DATA
Final drive hub, steering knuckles, and shafts

Wheel hub
SERVICE
Final drive hub, steering knuckles, and shafts

Disassemble - Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assemble - Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Wheel hub
Disassemble - Hub and transmission (836C AWD and 856C AWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Assemble - Hub and transmission (836C AWD and 856C AWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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Front axle system - Final drive hub, steering knuckles, and shafts
Final drive hub, steering knuckles, and shafts - Component

identification
SS12F041 1

1 Cotter pin 16 Nut
2 Castle nut 17 Cotter pin
3 Cylinder rod 18 Castle nut
4 Cotter pin 19 Thrust plate
5 Castle nut 20 Bolt
6 Ball head 21 Seals
7 Steering cylinder 22 Bearing outer race
8 Bolt 23 Bolt
9 Thrust plate cover 24 Bolt
10 Thrust plate cover 25 Nut
11 Axle casing 26 Bolt
12 Hub carrier 27 Bolt
13 Cylinder rod 28 Nut
14 Bolt 29 Wheel lean cylinder
15 Bolt
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Wheel hub - Component identification
SS12F018 1

1 Bolt 11 Carrier
2 Washer 12 Plug
3 Transmission 13
4 Bolt 14 Hub
5 Cover 15 Ring
6 Bolt 16 Bolt
7 Ring 17 Lower ring
8 Upper hub 18 Spring
9 Ring 19 Bolts
10 Plug
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Final drive hub, steering knuckles, and shafts - Disassemble -

Casing
NOTE: Some of the illustrations may show a different axle. Nevertheless, the procedures are the same.
1. Remove the cotter pin (1).
SS12F042 1
SS12F043 2
3. Unscrew and remove the castle nut (2).
SS12F044 3
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4. Unscrew and remove the castle nuts (5).
SS12F045 4
5. Knock the cylinder rod (3) out of the tapered seat.
SS12F046 5
6. Knock the steering cylinder (7) to loosen it from the

tapered seat along with its connection.
SS12F047 6
7. Remove the retainer from the thrust plate cover (9).
SS12F048 7
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8. Loosen the bolts (8) and remove them.

9. Remove the thrust plate cover (9) and the thrust plate
cover (10).
SS12F049 8
10. Loosen the bolt on the ball head (6).
SS12F050 9
11. Unscrew the ball head (6) from the steering cylinder
piston rod (7).
SS12F051 10
12. Remove the steering cylinder (7) from the axle casing.
SS12F052 11
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13. Remove the bolt (14) and the nut (16).
SS12F053 12
14. Knock out the bolt (15).
SS12F054 13
SS12F055 14
16. Remove the castle nut (18) and the thrust plate (19).
SS12F056 15
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17. Knock out the bolt (20) and remove it.
SS12F057 16
18. Remove the bolt (20).
SS12F058 17
19. Remove the hub carrier (12).

20. Remove the seals (21) on both sides of the hub carrier.
SS12F059 18
21. Using an extractor tool, remove the bearing outer race

(22) on both sides of the hub carrier (12).
SS12F060 19
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22. Loosen the bolt (23) and remove it along with the nut
(25)
SS12F061 20
23. Knock out the bolt (24) and remove it.
SS12F062 21
24. Remove the bolt (26) and the nut (28).
SS12F063 22
25. Knock out the bolt (27).

26. Remove the bolt (27) and the wheel lean cylinder (29).
SS12F064 23
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Final drive hub, steering knuckles, and shafts - Assemble - Casing

CAUTION
Pinch hazard!
Always use suitable tools to align mating parts. DO NOT use your hand or fingers.
C0044A
1. Mount the hub carrier (on camber cylinder side).
2. Place the cylinder rod (13).
3. Place the wheel lean cylinder (stem inside the hub car-
rier).
4. Knock in the bolt (27) until flush.
SS12F065 1
5. Tighten the bolt with the screw (26) and the nut (28).
SS12F063 2
6. Place the wheel lean cylinder (cylinder liner between

axle casing plates).
SS12F066 3
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8. Tighten the bolt with the screw (23) and the nut (25).
SS12F061 4
9. Mount the bearing (22) on both sides of the hub carrier

(12).
SS12F067 5
10. Insert the seals (21) on both sides of the hub carrier
(12) and mount the hub carrier.
SS12F059 6
SS12F068 7
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12. Mount the thrust plate (19).

13. Tighten the castle nut (18).
SS12F056 8
14. Mount the cotter pin (17).
SS12F069 9
15. Position the cylinder rod (13) and knock in the bolt
(15).
SS12F070 10
16. Secure the bolt (15) with the screw (14) and the nut
(16).
SS12F053 11
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17. Set the steering cylinder (7) on the bolt in the axle
casing (11).
SS12F071 12
18. Screw the ball head (6) into the steering cylinder pis-
ton rod (7).
SS12F051 13
19. Mount the ball head (6) on the wheel carrier.
SS12F072 14
20. Mount the thrust plate (10) and the shim washer cover
(9).
21. Tighten the bolts (8) to the specified torque.
SS12F049 15
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22. Insert the retainer in the thrust plate cover (9).
SS12F073 16
23. Mount the cylinder rod (3).
SS12F074 17
24. Screw on the castle nut (2) and tighten to the specified
torque.
SS12F075 18
25. Screw on the castle nut (5) and tighten to the specified
torque.
SS12F076 19
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SS12F043 20
SS12F042 21
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Wheel hub - Disassemble - Hub and transmission (836C AWD and

856C AWD)
1. Loosen the bolt (1) and remove it.
SS12F019 1
2. Remove the transmission (3).
SS12F020 2
3. Remove the cotter pin and the nut and knock out the
link rod.
SS12F021 3
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4. Remove the cotter pin and the nut and knock out the
steering cylinder.
SS12F022 4
SS12F023 5
6. Remove the cover (5).
SS12F024 6
SS12F025 7
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8. Remove the plug (10).

Use the special tool 2897043.
SS12F026 8
9. To loosen the upper hub (8), knock from underneath.
SS12F027 9

11. Remove the spring (18).
SS12F028 10
12. Remove the lower ring (17).
SS12F029 11
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SS12F030 12
14. Remove the plug (12).

SS12F031 13
15. Remove the lower hub (14) and the carrier (11).
SS12F032 14
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Wheel hub - Assemble - Hub and transmission (836C AWD and

856C AWD)
1. Mount the carrier (11).
SS12F032 1
2. Insert the lower hub (14) together with the plug.

3. Insert the bolt (16) and tighten it.
SS12F033 2
4. Mount the lower ring (17).
SS12F029 3
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5. Mount the spring (18).

6. Insert the bolts (19) and tighten them.
SS12F028 4
7. Insert the upper hub (8).
SS12F034 5
8. Knock in the hub (8).
SS12F035 6
9. Mount the plug (10).

10. Tighten the bolts (6).
SS12F036 7
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11. Mount the cover (5).
SS12F024 8
12. Insert the bolts (4) and tighten them to the specified
torque.
SS12F037 9
13. Insert the steering cylinder bolt and secure it with the
castle nut and the cotter pin.
SS12F038 10
14. Insert the cylinder rod and secure it with the castle nut
and the cotter pin.
SS12F039 11
47829048B 15/06/2016
25.2 [25.108] / 23
15. Mount the transmission (3).
SS12F020 12
16. Apply LOCTITE® 242® to the bolts (1).
SS12F040 13
17. Insert the bolts (1) and tighten to the specified torque.
SS12F019 14
47829048B 15/06/2016
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Index

Final drive hub, steering knuckles, and shafts - Assemble - Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Final drive hub, steering knuckles, and shafts - Component identification . . . . . . . . . . . . . . . . . . . . . . 3
Final drive hub, steering knuckles, and shafts - Disassemble - Casing . . . . . . . . . . . . . . . . . . . . . . . . 5
Wheel hub - Assemble - Hub and transmission (836C AWD and 856C AWD) . . . . . . . . . . . . . . . . . . 21
Wheel hub - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Wheel hub - Disassemble - Hub and transmission (836C AWD and 856C AWD) . . . . . . . . . . . . . . . . 17
47829048B 15/06/2016
25.2 [25.108] / 25
47829048B 15/06/2016
EN
SERVICE MANUAL
Rear axle system
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
27
Contents
Rear axle system - 27
[27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1
[27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2
[27.600] Tandem axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3
[27.650] Chain drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.4
47829048B 15/06/2016
27
Rear bevel gear set and differential - 106
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
27.1 [27.106] / 1
Contents
SERVICE
Differential
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
47829048B 15/06/2016
27.1 [27.106] / 2
Rear axle system - Rear bevel gear set and differential
Differential - Disassemble
WARNING
Avoid injury!
W1036A
WARNING
Heavy objects!
W0398A
Prior operation:
Planetary final drive - Remove - Half-axle (27.120).
1. Loosen and remove the screws (1).

2. Using lifting gear, lift the differential assembly out of the
center housing.
SS12J389 1
3. Place the differential on a suitable holder and lock it.

4. Mark the position of the bearing shell.
5. Loosen the screws.
SS12J390 2
47829048B 15/06/2016
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SS12J391 3
6. Turn the headstock round by 90 °, so that it is positioned as shown in the illustration.

7. Remove the roll pins (3).
8. Loosen and remove the screws (4).
9. Remove the bearing shells (5).
10. Unscrew the slotted nuts (6) and (10).
11. Take out the outer races of the tapered roller bearings (7) and (9).
12. Remove the differential lock (8) using lifting gear with sufficient load capacity.
13. Remove the 4 screws (11).

14. Remove the support frame (12) for the pinion shaft
lug, using the prying holes.
15. Remove the cotter (13) and the bolt (15).
16. Remove the cylindrical roller bearing (16) out of the
support frame (12).
NOTE: Applies to 836C/836C AWD only.
SS12J392 4
47829048B 15/06/2016
27.1 [27.106] / 4
SS12J393 5
17. Straighten any notches in the pinion nut (17).

18. Attach a counter-holding tool to the drive flange and loosen the pinion nut.
19. Remove the pinion nut (17) and the washer (18).
20. Remove the drive flange (19) from the pinion shaft.
21. Carefully knock out the pinion shaft (26) from the differential housing.
22. Remove the shaft seal (20) from the drive flange.
23. Remove the tapered roller bearing (21) and the spacer (23).
24. Remove the outer races of the tapered roller bearings (22) and (25).
25. Remove the spacer (24) for the pinion shaft axial play.
26. Pull out the tapered roller bearing (27) from the pinion
shaft (26).
27. Pull out the bearing inner race (28).
NOTE: Applies to 836C/836C AWD.
SS12J394 6
47829048B 15/06/2016
27.1 [27.106] / 5
28. Pull out the tapered roller bearing (27) from the pinion
shaft (26).
SS12J395 7
Replacing the differential lock and ring gear

NOTE: Do not open the differential lock, as the internal components are not available as replacement parts.
NOTE: Ring gear and pinion shaft are always supplied as one item and must always be replaced together.
1. If a ring gear/pinion set needs to be replaced, unscrew
the bolts (29) and remove the ring gear (30) from the
differential lock housing (8).
2. Fix the new ring gear (30) to the differential lock housing
(8) with the screws (29).
NOTE: After replacing the ring gear & pinion and the differ-
ential lock, check and adjust the gear backlash and bearing
preload.
SS12J396 8
3. Replace the tapered roller bearings (31) and (32), if

necessary.
Remove them with a suitable extractor tool.
Before mounting the bearing, heat it up to about 120 °C
(248.0 °F).
4. Remove them with a suitable extractor tool.
5. Before mounting the bearing, heat it up to about 120 °C
(248.0 °F).
SS12J397 9
Maintenance and overhaul of the differential

1. Thoroughly clean all parts of the differential.
2. Lubricate the bearing so that the rollers and roller
cages turn freely. It must rotate evenly, without
obstructions.
3. Check all mating surfaces of the ring gear, bearing
supports, bearing shells, etc. Damage can lead to
vibrations.
4. Clean all threads so as to ensure correct adjust-
ment and allow the required tightening torques.
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Differential - Assemble
WARNING
Avoid injury!
W1036A
WARNING
Heavy objects!
W0398A
1. Before the pinion shaft is installed in the differential

housing, the thickness of the adjusting shim inserted
between the main bearing and the housing has to be
determined.
2. Measure the gap between the pinion center line and the
main bearing shoulder, designated as dimension (A),
by placing a cylinder on the ring gear bearing. Add the
radius of the bearing to the measured gap dimension.
e.g.:
(A) = Measured gap + 62.5 mm (2.5 in)
In this case:
(A) = 162.6 mm (6.40 in) + 62.5 mm (2.46 in) =
225.1 mm (8.86 in)
SS12J398 1
3. A number is stamped into the front side of the pinion

shaft head, and marked with a “±".
This number is in tenths of millimetres, and indicates
the deviation from the nominal dimension ( 184 mm
(7.2 in)) between the center of the ring gear and pinion
shaft head.
e.g.:
-1 = 0.1 mm (0.004 in)
In this case:
(B) = nominal 184 mm (7.244 in) - 0.1 mm (0.004 in)
= 183.9 mm (7.240 in)
SS12J399 2
4. Pinion head height (H) between the bearing seat sur-

face and the pinion shaft end.
e.g.:
(H) = 62 mm (2.44 in)
SS12J400 3
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27.1 [27.106] / 7
5. Pinion head height (H) between the bearing seat sur-

face and the pinion shaft end.
e.g.:
H = 82 mm (3.23 in)
NOTE: Applies to 836C/836C AWD only.
SS12K001 4
6. Measure the height of the tapered roller bearing – di-

mension (D).
D = 37 mm (1.46 in)
SS12K002 5
7. For correct adjustment of the differential, dimension (S)

(adjusting thim thickness) has to be determined.
e.g.: (S) = (A) - ( (B) + (D))
In this case:
(S) = 225.1 mm (8.86 in) - ( 183.9 mm (7.24 in) +
37 mm (1.46 in)) = 4.2 mm (0.17 in)
To compensate for the difference after the bearing is
assembled, the calculated nominal dimension must be
reduced by 0.05 mm (0.002 in).
Round off the calculated thickness to the nearest tenth
of a millimeter.
SS12K003 6
8. Mount the tapered roller bearing (28) on the pinion lug.

9. Heat up the tapered roller bearing (27) to 80 - 90 °C
(176.0 - 194.0 °F), and push it into position on the pinion
shaft (26).
SS12J394 7
47829048B 15/06/2016
27.1 [27.106] / 8
10. Heat up the tapered roller bearing (27) to 80 - 90 °C

(176.0 - 194.0 °F), and push it into position on the
pinion shaft (26).
SS12J395 8
11. Insert the adjusting shim for the pinion shaft axial po-
sition. The thickness has been previously calculated.
12. Mount the outer races of the tapered roller bearings
(25) and (22).
SS12K004 9
13. To ensure the correct assembly of the differential, po-

sition the pinion shaft in its seat, place the cylinder on
the ring gear bearing, and measure the dimension (E).
E = B - ( 62.5 mm (2.46 in) + (H))
In this case:
(E) = 183.9 mm (7.24 in) - ( 62.5 mm (2.46 in) +
82 mm (3.23 in)) = 39.4 mm (1.55 in)
At this stage, the resulting dimension (E) must be
around 0 - 0.05 mm (0.0 - 0.002 in) of the calculated
nominal dimension.
SS12K005 10
14. To ensure correct assembly of the differential, position

the pinion shaft in its seat, place the cylinder on the
ring gear bearing, and measure the dimension (E).
(E) = (B) - ( 72.5 mm (2.85 in) + (H))
In this case:
(E) = 207.9 mm (8.19 in) - ( 72.5 mm (2.85 in) +
62 mm (2.44 in)) = 73.4 mm (2.89 in)
At this stage, the resulting dimension (E) must be at
around 0 - 0.05 mm (0.0 - 0.002 in) of the calculated
nominal dimension.
SS12K006 11
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27.1 [27.106] / 9
15. Push the bearing preload spacer (23) onto the pinion
shaft (26).
To make it easier to determine the bearing preload, we
recommend inserting as many spacers as necessary
to ensure the axial play, not the pre-loading of the
bearing.
16. Insert the pinion shaft (26) in the housing (2).
17. Insert the tapered roller bearing (21) as the outer pin-
ion bearing.
18. Mount the drive flange (19) on the pinion shaft.
19. Mount a suitable counter-holding tool.
SS12K007 12
20. Mount the washer (18) and tighten the nut (17).
21. Tighten the nut with 570 - 630 N·m (420.41 - 464.66 lb
ft).
22. Check the axial play on the pinion shaft using a dial
gauge.
23. Disassemble again and replace the spacer (23) in or-
der to obtain an axial play close to the bearing preload.
24. Reassemble again, then check the bearing preload.
For new bearings without the shaft seal mounted, this
should correspond to a torque of 2 - 4 N·m (1.48 -
2.95 lb ft).
SS12K008 13
25. After calculating the bearing preload, remove the drive

flange.
26. Lubricate the inner race of the shaft seal ring (20) and
mount it.
27. Mount the flange (19), the washer (18), and the nut
(17) again.
28. Tighten the nut with 570 - 630 mm (22.44 - 24.80 in).
SS12K009 14
29. Mount the support frame (12).

30. Tighten the 4 screws (4).
31. Tighten the screws with
315 - 345 N·m (232.33 - 254.46 lb ft).
SS12K010 15
47829048B 15/06/2016
27.1 [27.106] / 10
32. Install the differential unit (8):

33. Install the bearing shells (5), checking that they are
not interchanged (see marks).
34. Tighten the screws on the bearing shells.
35. Tighten the screws with 315 - 345 N·m (232.33 -
254.46 lb ft).
36. Using a dial gauge, check the axial play of the differ-
ential unit.
37. Turn the slotted nut (6) so that one of the notches is
aligned with the hole (a) for the roll pin (3).
38. Turn the opposite slotted nut (10) until no axial play
remains.
SS12K011 16
39. Adjust the bearing preload by turning the slotted nut

again to align with the next notch.
40. Install the differential unit (8).
41. Install the bearing shells (5), checking that they are
not interchanged (see marks).
42. Tighten the screws on the bearing shells with
315 - 345 N·m (232.33 - 254.46 lb ft).
43. Using a dial gauge, check the axial play of the differ-
ential unit.
44. Turn the slotted nut (6) so that one of the notches is
aligned with the hole (a) for the roll pin (3).
45. Turn the opposite slotted nut (10) until no axial play
remains.
46. Adjust the bearing preload by turning the slotted nut
again to align with the next notch.
SS12K012 17
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27.1 [27.106] / 11
47. Set the dial gauge vertically at one of the teeth in

the ring gear, and measure the tooth flank play – this
should be 0.18 - 0.23 mm (0.007 - 0.009 in).
If this is not obtained, adjust the slotted nuts (6) and
(10) to move by one notch one way or the other, in
order to move ring gear and pinion shaft either closer
to or further away from each other.
SS12K013 18
48. A good way of checking the tooth flank play is to ex-

amine the contact pattern.
Apply a marker material to the crest and turn the ring
gear and pinion shaft through a few rotations.
Check the contact pattern. The marker impression
should be located centrally both on the driven side of
the tooth and on the opposite side.
If this is not the case, change the adjusting shim thick-
ness in order to obtain the optimal setting of the ring
gear and pinion shaft, as well as the specified tooth
flank play and bearing preload.
(A) = Power output
(B) = Power input
SS12K014 19
SS12K015 20
47829048B 15/06/2016
27.1 [27.106] / 12
49. Lock the setting of the two slotted nuts with the roll
pins (3).
50. Secure the setting of the slotted nut (17) using a notch
on the nut.
SS12K016 21
51. Apply sealant, mount the differential housing (2), and

fasten it with the bolts (1).
SS12J389 22
52. Tighten the bolts with

105 - 115 N·m (77.44 - 84.82 lb ft).
Next operation:
Planetary final drive - Install - Half axle (27.120).
47829048B 15/06/2016
27.1 [27.106] / 13
Index

Differential - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Differential - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47829048B 15/06/2016
27.1 [27.106] / 14
Planetary and final drives - 120
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
27.2 [27.120] / 1
Contents
SERVICE
Planetary and final drives

Remove - Wheel drive and brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install - Wheel drive and brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Remove - Swivel mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install - Swivel mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Planetary final drive
Remove - Half-axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disassemble - Planetary gear set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Assemble - Planetary gear set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Install - Half axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
47829048B 15/06/2016
27.2 [27.120] / 2
Rear axle system - Planetary and final drives
Planetary and final drives - Remove - Wheel drive and brake

WARNING
Heavy objects!
W0398A
Prior operation:
Drain the oil.
Refer to Tandem axle - Change fluid (27.600).
Raise the vehicle and support it.
1. Remove the screws (1), take off the chain inspection

cover (2) and the seal (3).
2. Remove the screws (4), take off the cover (5) and the
seal (6).
seal (9).
SS14H019 1
4. Bring the chain master link into position at the side ac-
cess opening.
5. Remove the two pins (a).
6. Remove the master link (b).
SS12J221 2
47829048B 15/06/2016
27.2 [27.120] / 3
7. Support the chain on the tandem housing and pull it out.
SS12J222 3
8. Attach the special tool (S) 4A94740 to the wheel drive

and secure it with the lifting gear.
10. Remove the wheel drive and brake.
SS12J226 4
11. Flatten the locking plate (13).

13. Remove the washer (14) and adjusting shim (15).
14. Remove the sprocket (16).
SS12J227 5
15. Remove the brake carrier plate (17) together with the
tapered roller bearing (18) and the O-ring (19) from
the brake housing.
16. Check the outer race of the tapered roller bearing (18)
for wear, and remove it with a suitable extractor tool if
necessary.
17. Use a suitable fitting tool for mounting.
SS12J228 6
47829048B 15/06/2016
27.2 [27.120] / 4
18. Remove the retaining ring (20).

19. Remove the brake disk carrier (21).
20. Remove the brake disks (22) and steel disks (23) from
the brake disk carrier (21).
SS12J229 7
21. Mount the special tool (4A95444).

22. Remove the locking pin (27).
23. Place the special tool (4A95444) and fasten the tool
nuts so that the retaining rings (24) can be removed.
24. Remove the special tool (4A95444).
25. Remove the spring retainer (25) and the springs (26),
and set them aside.
26. Remove the brake piston (28).
SS12J230 8
27. Press the output shaft (29) out of the brake housing
(30).
SS12J231 9
28. Using a suitable press, force out the outer race of the
tapered roller bearing (31).
29. Remove the sealing rings (Quadrings) (32) and (33).
SS12J232 10
47829048B 15/06/2016
27.2 [27.120] / 5
30. Using a suitable extractor tool, pull out the tapered

roller bearing (inner race) (35).
31. Remove the shaft seal (34) and the cap (36).
SS12J233 11
32. Check the wheel fastening bolts (37) for damage or

deformation of the threads.
33. Press out any damaged wheel fastening bolts using a
suitable press.
34. When mounting the new wheel fastening bolts, ensure
that the threads are not damaged.
SS12J234 12
Wheel drive maintenance and overhaul:

NOTE: To allow visual inspection of the disassembled
parts, we recommend cleaning all metal parts thoroughly
with a solvent (biodegradable if possible). After washing,
the parts should be dried off (blown out) with compressed
air.
NOTE: Particular attention should be given to the internal
lubrication ducts – these should be made perfectly clean.
NOTE: Check carriers and covers for damage (notching,
dents, etc.) and that their seatings are sound and free of
scoring and wear. If this is not the case, these parts should
be replaced immediately.
NOTE: Check that shaft threads and grooves are in good
condition.
47829048B 15/06/2016
27.2 [27.120] / 6
Planetary and final drives - Install - Wheel drive and brake

WARNING
Avoid injury!
W1036A
WARNING
Heavy objects!
W0398A
1. Apply LOCTITE® 601 sealant to the cap (36) and push

it onto the output shaft.
SS12J235 1
2. Mount the outer race (31) of the tapered roller bearing

in the brake housing (30).
3. Lubricate the new sealing rings (Quadrings) (32) and
(33) with TUTELA MR2 or similar, and install them in
the brake housing (30).
4. Insert the tapered roller bearing (35).
5. Using the special tool 4A95443, mount the shaft seal
in the brake housing.
SS12J236 2
6. Push the output shaft (29) into the brake housing (30).
SS12J231 3
47829048B 15/06/2016
27.2 [27.120] / 7
7. To mount the brake piston:

Place the springs (26) and spring retainers (25) on the
pins.
8. Place the special tool (A4A95444) and tighten the tool
nuts, so that the springs are compressed when you
mount the clamping rings.
SS12J237 4
9. Place the clamping ring on the tapered tool (4904506/

00).
10. Place the tool vertically with the clamping ring (24) and
press it in.
11. Repeat the procedure for the other two
12. Remove the special tool (S) 4904506.
SS12J238 5
13. Apply LOCTITE® 270 to the thread and install the lock-
ing pin (27).
SS12J247 6
14. Push the brake disk carrier (21) onto the output shaft
and secure it with the retaining ring (20).
SS12J239 7
47829048B 15/06/2016
27.2 [27.120] / 8
15. Place a counter-disk (22) first, then a brake disk (23).

Continue in this way until all disks are in place.
NOTE: Mounting in the reverse order will cause the brake
to be irreparably damaged.
SS12J240 8
16. Apply sealing paste to the contact surface of the brake

body (30).
17. Set a new O-ring (19) on the brake holder (17).
18. Mount the tapered roller bearing (18).
NOTE: Mount the brake holder (17) as shown in the illus-
tration. The slots (a) must be on the left of the oil inlet for
front-right and rear-left, and on the right of the oil inlet for
front-left and rear-right.
SS12J241 9
SS12J242 10
19. Mounting the front left and right sprockets:

Push the sprocket (16) onto the output shaft.
NOTE: Pay attention to the installation direction of the
sprocket.
SS12J243 11
47829048B 15/06/2016
27.2 [27.120] / 9
Mounting the rear left and right sprockets:

Push the sprocket (16) onto the output shaft.
NOTE: Pay attention to the installation direction of the
sprocket.
SS12J244 12
20. Measure the distance between the sprocket surface

and the shaft output (s).
21. Subtract 0.05 mm (0.002 in) from the measured value
in order to determine the adjusting shim required (15).
SS12J245 13
22. Insert the adjusting shim (15).

23. Mount the sprocket shim (14) and the locking plate
(13), and tighten the screws (12).
24. Tighten the screws with 120 - 130 N·m (88.5 - 95.9 lb
ft).
25. Check the axial play: The torque should be between
15 N·m (11.1 lb ft) and 30 N·m (22.1 lb ft).
26. Bend up the locking plate (13).
SS12J246 14
27. Mount the special tool 4A94740 on the wheel (11).

28. Clean the contact surfaces between the tandem hous-
ing and the wheel.
29. Apply an even layer of LOCTITE® 510™ around the
holes on the inside of the tandem housing.
30. Mount the wheel drive (11).
31. Apply the sealant to the screw thread (10) and tighten
it to the specified torque.
32. Tighten the screw with 190 N·m (140.1 lb ft) +/- 5 %.
33. Remove the tool 4A94740. SS12J226 15
47829048B 15/06/2016
27.2 [27.120] / 10
(a) Slots
SS12J248 16
34. Guide the chain over the drive gear.
SS12J223 17
35. Join the two ends of the chain using the master link.
Attach the master link using the special tool 4A95322.
NOTE: Align the chain link inward.
SS12J224 18
36. Remove the special tool 4A95322 and insert the pins
(c).
NOTE: Check that the chain is aligned with the sprockets.
SS12J225 19
47829048B 15/06/2016
27.2 [27.120] / 11
37. Mount the seal (9) and the cover (8).

38. Apply the sealant to the threads of the screws (7) and
tighten the screws.
tighten the screws.
42. Apply the sealant to the threads of screws (1) and
tighten the screws.
43. Tighten the screws with 68.25 N·m (50.34 lb ft).
SS14H019 20
Next operation:
Pour oil into the tandem axles and axle housing.
Raise the rear end, remove the supports, and lower the rear of the grader.
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Planetary and final drives - Remove - Swivel mechanism

WARNING
Heavy objects!
W0398A
Prior operation:
Remove the cover and chains.
Refer to Chain drive - Remove (27.650).
1. Secure the tandem axle and the axle housing with suit-
able lifting gear.
2. Remove the screws (1), lift out the tandem axle (2), and
remove the seal (3).
SS14H020 1
3. Flatten the locking plates (5) and remove the screws

(4).
4. Remove the washer (6) and the adjusting shim (7).
5. Remove the drive chain sprockets from the driver shaft.
SS12J250 2
6. Remove the inner thrust washer (9).

7. Flatten the locking plate (11) and remove the screws
(10).
8. Remove the flange (12) and the outer thrust washer
(13).
SS12J356 3
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9. Remove the pendulum carrier (14).

10. Remove the bushing (16).
11. Remove the sealing rings (15) and (17).
SS12J357 4
Swivel mechanism maintenance and overhaul:

NOTE: To allow visual inspection of the disassembled
parts, we recommend cleaning all metal parts thoroughly
with a solvent (biodegradable if possible). After washing,
the parts should be dried off (blown out) with compressed
air.
NOTE: Particular attention should be given to the internal
lubrication ducts – these should be made perfectly clean.
NOTE: Check carriers and covers for damage (notching,
dents, etc.) and that their seatings are sound, and free of
scoring and wear. If this is not the case, these parts should
be replaced immediately.
NOTE: Check that shaft threads and grooves are in good
condition.
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Planetary and final drives - Install - Swivel mechanism

WARNING
Heavy objects!
W0398A
Determining the adjusting shim thickness

1. With the pendulum carrier (14) in vertical position, place
the outer thrust washer (13), the flange (12), and the
inner thrust washer (9).
SS12J358 1
Measure the gap (X) at 6 equidistant points.

Maximum value measured = (X)
Calculate the adjusting-shim thickness:
(P) = (X) + ( 0.15 - 0.2 mm (0.006 - 0.008 in))
SS12J359 2
2. Lubricate the new sealing ring (17) and mount it.

NOTE: Pay attention to the mounting direction.
SS12J360 3
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3. Lubricate the bushing (16) and push it on.

4. Mount the pendulum carrier (14).
5. Lubricate the new sealing ring (15) and mount it.
NOTE: Pay attention to the mounting direction.
SS12J361 4
6. Insert the outer thrust washer (13), the flange (12), and
the inner thrust washer..
7. Fasten the flange with the 8 locking plates (11) and 16
screws (10).
9. Secure the screws with the locking plates.
SS12J356 5
10. Push the sprockets (8) onto the output shaft.

11. Insert the adjusting shim (7).
12. Mount the washer (6), the locking plates (5), and the
screws (4).
SS12J250 6
14. Fasten the tandem axle (2) to the axle housing with
the screws (1) and the adjusting shim (3).
SS14H020 7
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16. When turning on its axis, the tandem axle should apply
a force (P) of 150 - 300 kg (330.7 - 661.4 lb), applied
at the centre point of a wheel.
SS12J367 8
Next operation:
Mount the chains and covers.
Refer to Chain drive - Install (27.650).
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Planetary final drive - Remove - Half-axle

WARNING
Heavy objects!
W0398A
Prior operation:
Tandem axle - Remove (27.600).
Planetary and final drives - Remove - Swivel mechanism (27.120).
1. Using a suitable holder to prevent accidents, bring the

axle into vertical position.
SS12J368 1
2. Unscrew the 18 hexagon nuts (1) and lift the axle hous-
ing (2) using lifting gear.
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Planetary final drive - Disassemble - Planetary gear set

WARNING
Heavy objects!
W0398A
Prior operation:
Planetary final drive - Remove - Half-axle (27.120).
1. Press the planetary gear set (3) out of the axle housing.
2. Pull the tapered roller bearing (4) out of the hub.
SS12J369 1
3. Take out the internal gear (5).

4. If necessary, pull out the tapered roller bearing and
mount a new tapered roller bearing (6) after heating it
up to 80 - 90 °C (176.0 - 194.0 °F).
SS12J370 2
5. Remove the roll pin (7).

6. Remove the bolt (8) and the planetary gear (9).
7. Repeat the procedure for the other two planetary gears.
SS12J371 3
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8. Check the needle bearing (10), the spacer (12), the

thrust washers (13), the bolt (8), and the planetary
gears (9) for wear. Replace the parts if necessary.
NOTE: The needles in the needle bearing (10) may fall out
while being removed.
SS12J372 4
9. If it is necessary to separate the hub from the carrier,

unscrew the 6 screws.
SS12J373 5
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Planetary final drive - Assemble - Planetary gear set

WARNING
Avoid injury!
W1036A
WARNING
Heavy objects!
W0398A
NOTE: If replacing, use a bearing of the same class.

1. Assemble:
1. Lubricate the needle bearing (10).
2. Place the bolt (8) on a level surface.
3. Mount the thrust washer (13) and lubricate the bolt
(8).
4. Push on the first needle bearing (10).
5. Mount the spacer (12).
6. Push on the second needle bearing (10).
7. Bring the planetary gear (9) and the second thrust
washer (11) into position.
SS12J374 1
2. Hold the two thrust washers and remove the bolt (8).
SS12J375 2
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3. Push the planetary gear into the planet carrier.
SS12J376 3
4. Align the bolt (8) so that the holes in the bolt are in line
with the holes in the planet carrier.
SS12J377 4
5. Knock the roll pin (7) into the hole.

The planetary gear must be able to turn freely.
(A) = 40 mm (1.57 in)
(B) = Roll pin
NOTE: Always use a new roll pin.
NOTE: Repeat the procedure for the other two planetary
gears.
SS12J378 5
6. Mount the internal gear (5).

NOTE: The gear might fall while being removed.
SS12J379 6
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7. Check the tapered roller bearing and replace it if nec-

essary.
SS12J380 7
8. Using a suitable fitting tool, mount a new shaft seal (15)

with a gap (A) of 6 mm (0.2 in) from the bearing seat.
9. Mount the outer races of the tapered roller bearings
(14) and (16).
SS12J381 8
10. Place the planetary gear set on a support pad (a) with
about 150 mm (5.9 in) height.
The stud bolts should not touch the ground.
SS12J382 9
11. Heat up the tapered roller bearing (4) to about 90 -

100 °C (194.0 - 212.0 °F) and mount it.
SS12J383 10
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12. Check the individual components of the half-axle for

wear or damage.
13. Replace the parts if necessary.
SS12J384 11
Next operation:
Planetary final drive - Install - Half axle (27.120).
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Planetary final drive - Install - Half axle

WARNING
Avoid injury!
W1036A
WARNING
Heavy objects!
W0398A
1. Remove the thrust washer (18) from the half-axle and

take off the adjusting shims (19).
SS12J385 1
2. Fabricate a plate with the same dimensions as the

thrust washer (18), but with a thickness of 13 mm
(0.512 in).
Install the plate – this ‘stop plate’ has the dimension “E”.
3. Mount the half-axle and measure the gap at 3 points
using a feeler gauge.
4. Calculate the average value – this is taken as dimen-
sion “F”.
E - F = G (e.g. 13 mm (0.512 in) – 0.5 mm (0.020 in)
= 12.5 mm (0.492 in))
To obtain the dimension “G”, subtract the gap dimen-
sion “F” from the stop plate dimension “E”.
SS12J386 2
5. The shim thickness “X” is calculated by subtracting
11 mm (0.4 in) (thickness of the original thrust washer
10.5 mm (0.413 in) + 0.5 mm (0.020 in) play of the
axle end) from the calculated dimension “G”.
X = 12.5 mm (0.492 in) – 11 mm (0.433 in) = 1.5 mm
(0.059 in)
This is the thickness of the adjusting shim that is now
required between the thrust washer and the half-axle.
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6. Install the adjusting shim with the dimension (X).

Apply LOCTITE® 270 to the original thrust washer (18)
and insert the thrust washer in the half-axle housing.
SS12J387 3
7. Clean the contact surfaces thoroughly.

8. Apply the sealing paste to the mating surface in the
center housing.
SS12J388 4
9. Mount the axle housing (2), paying attention to the

alignment of the input shaft.
10. Apply LOCTITE® 242® to hexagon nuts (1) and tighten
them.
11. Tighten the hexagon nuts with 240 N·m (177.0 lb ft)
NOTE: Ensure correct alignment of the reduction gear.
SS12J368 5
Next operation:
Planetary and final drives - Install - Swivel mechanism (27.120).
Tandem axle - Install (27.600).
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Index

Planetary and final drives - Install - Swivel mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Planetary and final drives - Install - Wheel drive and brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Planetary and final drives - Remove - Swivel mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Planetary and final drives - Remove - Wheel drive and brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Planetary final drive - Assemble - Planetary gear set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Planetary final drive - Disassemble - Planetary gear set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Planetary final drive - Install - Half axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Planetary final drive - Remove - Half-axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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Tandem axle - 600
836C AWD
836C
856C AWD
856C
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Contents
Tandem axle - 600
TECHNICAL DATA
Tandem axle
Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUNCTIONAL DATA
Tandem axle
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SERVICE
Tandem axle
Change fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Check - Chain elongation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DIAGNOSTIC
Tandem axle
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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Rear axle system - Tandem axle
Tandem axle - Dimension
SS12J201 1
Main dimensions of tandem axle 836C/836C AWD
Pos. Value Pos. Value

A 599 mm (23.58 in) D 958 mm (37.72 in)
B 2040 mm (80.31 in) E 1241 mm (48.86 in)
C 1360 mm (53.54 in) F 1784 mm (70.24 in)
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SS12J202 2
Main dimensions of tandem axle 856C/856C AWD
Pos. Value Pos. Value

A 592 mm (23.3 in) D 1119 mm (44.06 in)
B 2070 mm (81.50 in) E 1572.4 - 1572.8 mm (61.9 - 61.9 in)
C 1517 mm (59.72 in) F 2146 mm (84.5 in)
Tandem axle - General specification

Grader rear axle with automatic no-spin differential.
Tandem axles in swing arrangement with power transmission through high-performance roller chains.
47829048B 15/06/2016
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Specifications, fill quantities and operating fluid specifications

836C/836C AWD 856C/856C AWD
Mass without/with oil 2109 kg (4649.5 lb)/ 2398 kg (5286.7 lb)/
2260 kg (4982.4 lb) 2560 kg (5643.8 lb)
Max. brake torque per brake
Oil filling quantity - differential 31 l (8.2 US gal) 36 l (9.5 US gal)
Oil filling quantity - tandem axle 2 x 60 l (15.9 US gal) 2 x 64 l (16.9 US gal)
Center housing MIL-L-2105-C and API GL5, viscosity SAE 80W90
Tandem axle / brake MIL-L-2104-C and API GL4, viscosity SAE 20W40
Grease Lithium-based lubricating grease with molybdenum disulfide – NLGI-2
(Tutela MRM-2 NLGI-2)
Tandem axle - Special tools

Tool No.: Designation
4904506 Mounting tool for spring plate retaining ring
4904506/00
4A94740 Retaining bracket for disassembly / assembly of wheel drive
4A95321/00 Pliers for chain assembly
4A95322 Mounting tool for chain master link
4A95443 Fitting tool for shaft seal
4A95444 Mounting tool for spring plate
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Tandem axle - Identification

The model plate is located on the center housing of the
tandem axle.
SS12J195 1
The axle is identified by the axle type identification number

and the manufacturer’s serial number.
SS14J047 2
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Tandem axle - Component identification

Wheel drive and brake
SS12K018 1
47829048B 15/06/2016
27.3 [27.600] / 7

1 Cover 15 Adjusting shim
2 Spring plate 16 Tapered roller bearing
3 Spring 17 Tapered roller bearing
4 Bolt 18 Shaft seal ring
5 Sprocket 19 Hexagon head bolt
6 Locking plate 20 Retaining ring
7 Output shaft 21 Sealing ring (Quadring)
8 Mounting plate 22 Sealing ring (Quadring)
9 Brake piston 23 Retaining ring
10 Brake disks 24 Retaining ring
11 Steel disk 25 O-ring
12 Brake disk carrier 26 Bolt
13 Brake carrier plate 27 Chain
14 Brake housing
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Differential and half-axle 836C/836C AWD
SS12K019 2
47829048B 15/06/2016
27.3 [27.600] / 9

1 Sprocket 21 Nut
2 Adjusting shim 22 Washer
3 Mounting plate 23 Drive flange
4 Locking plate 24 Shaft seal ring
5 Flange 25 Spacer
6 Inner thrust washer 26 Adjusting shim
7 Adjusting shim 29 No-Spin differential
8 Pendulum carrier 30 Tapered roller bearing
9 Outer thrust washer 31 Slotted nut
10 Sealing ring 32 Axle
11 Bushing 33 Retaining ring
12 Thrust washer 34 Gear
13 Planetary gear 35 Reduction gear
14 Spacer 36 Reduction gear carrier
15 Needle bearing 37 Tapered roller bearing
16 Bolt 38 Thrust washer
17 Differential housing 39 Adjusting shim
18 Ring gear & pinion set 40 Shaft seal ring
19 Tapered roller bearing 41 Tapered roller bearing
20 Tapered roller bearing 42 Reduction gear hub
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Differential and half-axle 856C/856C AWD
SS12K021 3
47829048B 15/06/2016
27.3 [27.600] / 11

1 Sprocket 22 Washer
2 Adjusting shim 23 Drive flange
3 Mounting plate 24 Shaft seal ring
4 Locking plate 25 Spacer
5 Flange 26 Adjusting shim
6 Inner thrust washer 27 Cylindrical roller bearing
7 Adjusting shim 28 Adapter frame
8 Pendulum carrier 29 No-Spin differential
9 Outer thrust washer 30 Tapered roller bearing
10 Sealing ring 31 Slotted nut
11 Bushing 32 Axle
12 Thrust washer 33 Retaining ring
13 Planetary gear 34 Gear
14 Spacer 35 Reduction gear
15 Needle bearing 36 Reduction gear carrier
16 Bolt 37 Tapered roller bearing
17 Differential housing 38 Thrust washer
18 Ring gear & pinion set 39 Adjusting shim
19 Tapered roller bearing 40 Shaft seal ring
20 Tapered roller bearing 41 Tapered roller bearing
21 Nut 42 Reduction gear hub
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Tandem axle - Static description

Intended use
The axle is the part of the machine whose purpose is:
• Transmitting the power from the engine to the wheels.
• Increasing the tractive force while at the same time reducing rotational speed.
• Balancing the speeds of inner and outer wheels while steering.
Never install this axle in machines other than those specified.
The manufacturer will not be liable for any damage to property or injuries to personnel if the axle is not used according
to the specified conditions.
In such cases, the customer alone will be liable. Even when used correctly, the manufacturer's maintenance and
repair instructions must be followed in all cases.
General Description
The axle described in this manual, developed and produced to the customer's requirements, consists of the axle
housing, with the differential assembly at the center, and the wheel hub assemblies at both ends of the axle.
The differential assembly is the self-locking limited-slip type, and is supported on two bearings, which are mounted
using a special structure. This structure allows easy access for adjustment operations on the bevel gear pair. The
position of the bevel gear pair can be changed by turning the two slotted nuts located opposite. The bevel gear
(supported on two bearings) is adjusted by inserting intermediate shim washers.
The wheel hubs, which contain the epicycloidal gear ratios, are supported on two tapered roller bearings and con-
trolled by the hydraulically operated steering assembly.
The axle also has its own brake system, and is equipped with a mechanical control for the service brake.
This structure is completed by a drive/reduction gear housing, which is used to control all input movements to the
bevel gear pair.
Drive diagram
SS12J197 1
All-wheel only on for 836C AWD and 856C AWD

A Level E Engine
B Parking brake F Differential
C Transmission G Spatial working angle of steering shaft
• 836C and 836C AWD = 4.43 °
• 856C and 856C AWD = 6.7 °
D Converter
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Tandem axle 836C/836C AWD
SS14H022 2

A Differential L Left
B Wheel hubs R Right
C Attachment point
47829048B 15/06/2016
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Tandem axle 856C/856C AWD
SS14H025 3

A Differential L Left
B Wheel hubs R Right
C Attachment point
47829048B 15/06/2016
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Tandem axle - Service instruction

Overview of maintenance work
Maintenance work Maintenance intervals in operating
hours
Check oil levels every 250
1st oil change once after 250
Tandem box every 1000
Differential / side reducer gear every 2000
Lubricate half-axle every 100
Check chain elongation every 500
Maintenance
Read through the whole manual to enable you to carry
out ordinary and extraordinary maintenance correctly.
Failure to follow the instructions can shorten the service
life and impair the performance of the axle, and can
result in damage and injuries to personnel. If faults or
anomalies occur, a prompt intervention by specialized
personnel will ensure long service life of the assembly
and prevent greater damage over the long term.
Conventions and terms used

The figures are intended only to illustrate the working
procedure on the axle, and the illustration in your man-
ual may therefore not represent your particular axle as-
sembly. It may simply represent a similar axle.
Location references
LH (left hand) or left side means the left side of the axle
looking in the direction of travel of the machine.
RH (right hand) or right side means the left right of the
Repairs
The axle disassembly/assembly instructions can be
used to carry out a complete overhaul of the assembly.
The procedure is described in steps and explained by
illustrations, in order to ensure a safe and secure work-
ing method. A thorough knowledge of the assembly
will allow any problems to be assessed correctly. Con-
sequently, this will allow a more targeted intervention
without having to dismantle the entire assembly.
General disassembly/assembly instructions

The axle should be inspected and/or repaired only by
specialized personnel who have a thorough knowledge
of the product, and who follow the corresponding safety
instructions (accident prevention).
Before starting work, the axle should be thoroughly
cleaned to remove any deposits, grease, and/or accu-
mulated dirt.
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To prevent possible damage, all components removed

from the axle must be cleaned with a suitable cleaning
agent. Check the parts for wear. If there is any damage,
cracking, corrosion or other defects that could impair
axle function, replace them.
In particular, all parts that are in constant movement
(bearings, gears, shafts) and their seals (O-rings, gas-
kets) must be inspected for wear, as these are subject to
greater stress. It is recommended to change the seals
at each maintenance or repair operation.
Note that the components of bevel gear pairs must al-
ways be replaced in pairs.
Always use the specified replacement parts and
screws. Use metric tools for metric screws and UK
tools for UK screws.
As described in the disassembly instructions, certain
operations are final for some of the axle components,
i.e. these components must be replaced each time,
as they are destroyed by the removal process. The
individual steps must be followed exactly as described,
in order to avoid impairing the correct function of the
entire assembly.
Before starting disassembly and assembly work, read
through the following instructions carefully.
Shaft sealing rings

1. When assembling the shaft seals, do the following:
1. Clean the shaft thoroughly, and inspect the areas
of the seal rings that come into contact with the
shaft for any signs of deformation or damage.
2. Insert the seal ring such so that the lip is facing in
the direction of the oil flow.
3. Lubricate the lip (preferably with grease), and 3/4
fill the recesses in the rings with grease.
4. When mounting the rings, use a suitable press-on
tool. Do not strike the rings directly with a hammer.
5. Do not damage the rings when mounting on the
shaft.
O-rings
Grease the O-rings before pressing into position. Avoid
rolling them.
Shim washers
For adjustments, use appropriate shim washers. These
must be measured individually. Measuring the entire
pack, or taking the dimension stamped on the disks,
will not always give the actual value: it must therefore
be checked.
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Bearing
For correct mounting on the shaft, it is recommended
beforehand to heat the bearing to 80 - 90 °C (176.0 -
194.0 °F) in an oven. It should then be mounted in the
bearing seat, where it should be allowed to cool. Al-
ways use a suitable extracting tool to remove bearings.
Before mounting, clean, inspect, and lubricate the bear-
ing.
Sprung dowel pins

Before mounting grooved pins, check that the grooves
are pointing in the direction of force. There is no special
mounting direction for spiral roll pins.
Sealant
Only use suitable sealants. Check that the surfaces are
clean, dry, and free of grease.
Draining oil
Before any work is performed on the assembly, drain
off the oil.
NOTICE: Dispose of used oil as required by regulations.
Clean
Clean all moving parts (gears, bearings, etc.) thor-
oughly with gas oil or kerosene.
Avoid using gasoline or alkaline solvents.
Do not use water or steam, which would leave the sur-
faces damp.
Dry off all parts with compressed air or a cleaning cloth,
to remove any residues that might scratch the surface.
To prevent oxidation, lightly grease all surfaces.
Inspection
Inspect all bearings, all outer rings that may still be in
place, and all bolts over which rollers move. Parts that
show signs of wear or damage should be replaced.
Inspect all gear teeth for wear or damage. No wear
should be visible on the tooth surfaces.
Check that the grooves are not damaged, and that they
do not show excessive wear. Replace worn parts with
original spare parts only.
It is recommended to replace the shaft seals after each
disassembly operation.
Flange and tool end pieces

When fitting flange and tool end pieces, take care to
prevent any deformation that might impair their func-
tional efficiency.
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Mounting methods
Use a suitable workbench for working on the assembly.
Use lifting gear when raising the assembly, when dis-
assembling/assembling gear pairs, and for supporting
the gear housing.
For an illustration of the disassembly/assembly pro-
cesses, refer to a drawing of the entire assembly.
Using lubricants
For correct lubrication, and to be able to reach the exact
operating temperature of the axles, it is important to use
only the recommended lubricants and to keep the oil
constantly at the levels described in this manual.
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Tandem axle - Change fluid

Oil change
SS14H021 1
NOTICE: Have oil collecting containers of sufficient size ready at the oil drain screws (3) and (5).
Tandem axles
1. Unscrew the oil filling screw plugs (1).
2. Unscrew the oil filling screw plugs (2).
3. Unscrew the oil drain screw plugs (3) and drain off the
used oil.
4. After all oil has been drained, replace the oil drain screw
plug (3).
Axle housing
1. Unscrew the oil fill/oil level screw plug (4).
2. Unscrew the oil drain screw plug (5) and drain off the
used oil.
3. After all oil has been drained, replace the oil drain screw
plug (5).
NOTICE: Dispose of the used oil as required by the local guidelines.
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Oil filling
1. Pour in the oil through the oil fill/oil level screw plug hole
until it overflows (filling quantity 31 l (8.2 US gal) for
836C/836C AWD and 36 l (9.5 US gal) for 856C/856C
AWD.
2. Screw in the screw plug (4) and tighten it.
3. Pour in the oil through the oil fill screw plug holes (1)
until it overflows at the oil level screw plug holes (2).
• 836C/836C AWD: 2x 60 l (15.9 US gal)
• 856C/856C AWD: 2x 64 l (16.9 US gal)
4. Screw in the screw plugs (1) and (2) and tighten them.
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Tandem axle - Check - Chain elongation

WARNING
Avoid injury!
W1036A
NOTE: Check the chain tension on all four chains.

It is recommended to remove the wheels to gain better access.
2. Press and hold the brake pedal and engage forward
gear. The forward movement is restrained by brake
force.
3. Now stop the grader with the gear engaged. The chain
is now stretched on the underside (sag = 0).
4. Switch off the engine.
5. Remove the covers on top and on the side. This makes
it easier to read the correct value on the measuring rod.
6. Raise the rear axle until the rear wheels are clear of the
ground.
7. Place squared timber under the axle to prevent it from
lowering.
SS14J048 1
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8. A straight rigid rod of length about 840 mm (33.1 in) is

required, in order to provide a reference point for the
measurement.
9. Pass the rod into the tandem housing and place it on
the highest tooth on the two related sprocket.
SS12J210 2
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10. Place an angle piece on the top of the tandem housing

in order to ensure that the measurement is taken at the
correct angle.
SS13A859 3
SS12J212 4
11. Now pass the rod through the top opening along the
angle piece in the tandem housing until it is resting on
the chain.
SS12J213 5
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12. Now read dimension (B) at side opening (A) (see fig-
ure 3) in the tandem housing.
13. The initial sag with a new chain/machine is indicated
by dimension (B).
14. The maximum sag is the maximum permitted value of
dimension (B) as shown in the following table. If the
sag is greater than the maximum allowed value, then
the chain must be replaced.
836C/836C AWD 856C/856C AWD

Initial sag (new chain) 0 - 10 mm (0.0 - 0.4 in) 0 - 10 mm (0.0 - 0.4 in)
Maximum allowed sag 60 - 65 mm (2.4 - 2.6 in) 70 - 75 mm (2.8 - 3.0 in)
NOTE: This calculation is based on the maximum elongation of about 1% on a new chain.
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Tandem axle - Remove

WARNING
Heavy objects!
W0398A
Prior operation:
Battery - Remove (55.302).
NOTICE: Hydraulic fluid may flow out when the brake lines are loosened. This fluid should be collected and properly
disposed of.
1. Remove the four wheel cover brackets from the rear
axle.
SS12J008 1
2. Remove the power transmission shaft (3) by loosening

the four cap bolts.
SS12J214 2
3. Detach the brake lines (4) on both sides and bind them
together.
4. Close off the remaining connections in the tandem
housing with stop plugs.
NOTE: Mark the brake lines if necessary.
SS12J215 3
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5. Using suitable lifting gear, raise the vehicle and support

it securely.
6. Set a hydraulic workshop vehicle jack with sufficient
load capacity under the tandem axle.
7. Loosen the 8 mounting bolts (8) that fix the tandem axle
to the rear frame.
8. Lower the tandem axle using the vehicle jack.
9. With the vehicle raised, guide the tandem axle out.
SS12J218 4
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Tandem axle - Install

WARNING
Heavy objects!
W0398A
CAUTION
Pinch hazard!
C0044A
NOTICE: Hydraulic fluid may flow out when the brake lines are loosened. This fluid should be collected and properly
disposed of.
1. With the vehicle raised, push the tandem axle under
the frame.
2. Raise the tandem axle and align the mounting bolt
holes on rear frame and tandem axle.
SS12J218 1
3. The rear axle is fixed to the rear frame using the eight
bolts (8) and the eight sleeves.
4. Take out the vehicle jack and release the lifting gear.
6. Connect the brake lines (4) on both sides (axle centre
section).
NOTE: Note the length required to compensate for swing-
ing movements of the rear axle. If the pipe clamp is to be
loosened, the brake lines must be fastened so that a gap
of min. 380 mm (15.0 in) is maintained between the pipe
clamp and the hose fitting.
SS12J215 2
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7. Attach the power transmission shaft (3) to the rear axle

with the four cap bolts.
SS12J214 3
8. Fasten the four wheel cover brackets (2) at the rear

axle.
SS12J008 4
Next operation:
Battery - Install (55.302).
Raise the vehicle, remove the supports, then lower the vehicle and remove the lifting accessories and lifting gear.
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Tandem axle - Troubleshooting

Oil leaking from wheel Bolts not tightened Tighten bolts to the specified torque.
drive
Faulty O-ring Replace O-ring
Oil leaking from shaft Mounted incorrectly Replace shaft seals
seals
Faulty shaft seals Replace shaft seals
Oil escaping from Oil level too high Check oil level, and drain off if necessary.
breather
Excessive foaming Incorrect operating fluid Change the oil.
Noises from axle drive Incorrect operating fluid Change the oil.
Oil level too low Check oil level, and top up if necessary.
Incorrect adjustment of bearing Check the bearing setting and adjust if nec-
essary.
Bearing damaged Check the bearing and replace if neces-
sary.
Gears damaged Check the gears and replace if necessary.
Noises from differential Incorrect operating fluid Change the oil.
Incorrect tooth flank play Check the tooth flank play and adjust if nec-
essary.
Incorrect bearing preload Check the bearing preload and adjust if
necessary.
Incorrect pinion setting Check the pinion setting and adjust if nec-
essary.
Thrust washers in swivel mechanism dam- Check the thrust washers and replace if
aged necessary.
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Index
Tandem axle - 600

Tandem axle - Change fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Tandem axle - Check - Chain elongation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Tandem axle - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Tandem axle - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tandem axle - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tandem axle - Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Tandem axle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Tandem axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Tandem axle - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Tandem axle - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tandem axle - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Tandem axle - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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Chain drive system - 650
836C AWD
836C
856C AWD
856C
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Contents
SERVICE
Chain drive
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Rear axle system - Chain drive system
Chain drive - Remove

WARNING
Heavy objects!
W0398A
Prior operation:
Drain the oil.
Raise the vehicle and support it.
1. Remove the screws (1), take off the chain inspection

cover (2) and the seal (3).
seal (6).
seal (9).
SS14H019 1
4. Bring the chain master link into position at the side ac-
cess opening.
5. Remove the two pins (a).
6. Remove the master link (b).
SS12J221 2
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7. Support the chain on the tandem housing and pull it out.

NOTE: Repeat steps 4 to 7 for the other 3 chains.
SS12J222 3
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Chain drive - Install

WARNING
Heavy objects!
W0398A
1. Guide the chain over the drive gear.
SS12J223 1
2. Join the two ends of the chain using the master link.
Attach the master link using the special tool (S)
4A95322.
NOTE: Align the chain link inward.
SS12J224 2
3. Remove the special tool (S) 4A95322 and insert the

pins (c).
NOTE: Check that the chain is aligned with the sprockets.
SS12J225 3
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tighten the screws.
tighten the screws.
tighten the screws.
10. Tighten the screws with 68.25 N·m (50.34 lb ft).
SS14H019 4
Next operation:
Pour oil into the tandem axles and axle housing.
Raise the rear end, remove the supports, and lower the rear of the grader.
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Index

Chain drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chain drive - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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47829048B 15/06/2016
EN
SERVICE MANUAL
Hydrostatic drive
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
29
Contents
Hydrostatic drive - 29
[29.204] Reservoir, cooler, and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.1
[29.218] Pump and motor components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.2
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29
Reservoir, cooler, and lines - 204
836C AWD
836C
856C AWD
856C
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Contents
FUNCTIONAL DATA
Reservoir, cooler, and lines

Hydraulic schematic frame 01 - Front drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Lines
Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE
Lines
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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Hydrostatic drive - Reservoir, cooler, and lines
Reservoir, cooler, and lines - Component identification
SS12E339 1
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1 Variable pump A4 VG 304 Intake line of feed pump "S" from tank "U"
2 Wheel motors MS 305 Forward high-pressure line return,
all-wheel pump "B” → 6/2 way valve "PAR"
3 Flow divider 306 Forward high-pressure line,
all-wheel pump "A” → 6/2 way valve "PAV"
16 6/2 way valve for front-wheel drive - cut-off 307 Oil feed line, all-wheel pump “Fe” → feed circuit
pressure filter
17 Solenoid valve block Y8.1/Y8.2 308 Return line,
feed circuit pressure filter → all-wheel pump “Fa”
18a 4/2 way valve for front-wheel drive ON/OFF 309 Control / purge line,
all-wheel pump "MA" → purge & feed pressure.
"A"
18b 4/2 way valve for wheel motor control 310 Control / purge line,
all-wheel pump "MB" → purge & feed pressure.
"B"
19 Pressure limiting valve 1.5 bar (21.8 psi) 311 Leak line,
all-wheel pump "T1" → tank "W"
20 Purge valve and feed pressure valve 16 bar 312 Return line,
(232.0 psi) purge & feed pressure. "T" → pressure holding
valve "01"
21 Feed pressure filter 313 Line,
measurement point “M01” → pressure holding
valve "01"
22 Pressure reservoir 314 Supply line,
feed circuit pressure filter → valve VA ON/ OFF
and displacement changeover "P"
23 Distributor block with nozzle 315 Control line,
valve VA ON /OFF “B” → 6/2 way valve "G"
69 Filling line, 316 Line,
feed pressure filter → pressure reservoir valve VA ON /OFF “A” → 6/2 way valve "F", spring
chamber filling
300 High-pressure line forward, 317 Tank line,
6/2 way valve "AV" outlet → flow divider "P" valve VA ON/OFF and displacement changeover
"T" → tank "X"
301 Forward high-pressure line return, 318 Tank line,
flow divider → 6/2 way valve "AR" pressure holding valve "1" → tank “V” return filter
302 Leak line, 319 Tank line,
wheel motors "1" → pressure holding valve "01" pressure holding valve "F" → tank.
303 Control line,
valve chamber “A” → flow divider/wheel motor “Y
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Reservoir, cooler, and lines - Static description

For hydrodynamic rear wheel drive, engageable hydrostatic front wheel drive with EDCV Electronic Drive Control.
Each of the wheel hub motors in the front wheels is driven hydrostatically in a sealed circuit by one helical gear pump
with 2 pumping directions (forward/backward).
A hydraulic differential lock prevents the front wheels from spinning on one side.
A microprocessor monitors and controls the adjustment of front wheel drive to rear wheel drive.
A step switch allows the driver to adjust the force of the front wheel drive to the operating conditions.
NOTE: Refer also to Pump - Static description (29.218) and Motor - Static description - Wheel motors (29.218).
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Reservoir, cooler, and lines - Hydraulic schematic frame 01 - Front

drive
Hydraulic diagram, front drive 836C AWD
47829048B 15/06/2016
SS12K618 1
29.1 [29.204] / 6

1 Pump assembly 64 Sol. valve block
Y8.1 all-wheel ON/OFF
Y8.2 displacement switchover
10 Hydro-reservoir 65 Pressure-limiting valve ( 1.5 bar (21.8 psi))
25 Pressure limiting valve, purge circuit 66 LS pressure valve ( 16 bar (232.0 psi))
60 Radial piston motor 67 Filter ( 3.5 bar (50.8 psi))
62 6/2 way valve 68 Pressure reservoir, all-wheel drive ( 14 bar
(203.0 psi))
63 Flow divider 69 Distributor block with nozzle ∅ 0.8 mm (0.03 in)
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Hydraulic diagram, front drive 856C AWD
SS12K619 2
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1 Pump assembly 64 Sol. valve block
10 Hydro-reservoir 65 Pressure-limiting valve ( 1.5 bar (21.8 psi))
25 Pressure limiting valve, purge circuit 66 LS pressure valve ( 16 bar (232.0 psi))
60 Radial piston motor 67 Filter ( 3.5 bar (50.8 psi))
62 6/2 way valve 68 Pressure reservoir, all-wheel drive ( 14 bar
(203.0 psi))
63 Flow divider 69 Distributor block with nozzle ∅ 0.8 mm (0.03 in)
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Lines - Component identification
SS12F099 1

1 Bolt 15 Screw
2 Valve 16 Pull rod
3 O-ring 17 Nut
4 Block 18 Joint
5 Tube 19 Retaining clamp
6 Valve 20 Protection
7 Screw 21 Bolt
8 Screw 22 Clamp
9 Hose 23 Tube
10 Hose 24 Seal
11 Hose 25 Clamp
12 Hose 26 O-ring
13 Hose 27 Clamp
14 Clamp
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Lines - Disassemble
NOTE: For more details refer to Lines - Component identification (29.204).
1. Detach the hose (13) from the valve (6).
SS13N001 1
SS12F101 2
SS12F102 3
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SS12F103 4
5. Detach the tube (5) from the block (4).
SS12F104 5
6. Detach the tube (5) from the valve (6) and remove it.
SS12F105 6
7. Detach the hose (9) from the block (4).
SS12F106 7
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SS12F107 8
9. Loosen the screws (7) and remove them.

10. Remove the valve (6).
SS12F108 9
11. Loosen the screws (8) and remove them.

12. Remove the block (4) with the valve (2).
SS12F109 10

14. Remove the valve (2) from the block (4).
SS12F110 11
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15. Remove the O-ring (3) from the valve (2).
SS12F112 12
16. Loosen the screws (15) with the nut (13) and remove
them.
SS12F113 13
18. Remove the pull rod (16) with the nut (17) and the joint
(18).
SS12F114 14

20. Remove the protection (20).
SS12F115 15
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21. Loosen the outer screws from the retaining clamp

(19).
SS12F116 16
22. Loosen the inner screws from the clamp (19) in order
to detach the hose and remove the clip.
SS12F117 17
23. Detach the hose (11) from the tube (23) and remove
the hose (11).
SS12F118 18
SS12F119 19
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SS12F120 20
26. Remove the tube (23).

27. Remove the seal (24) from the tube (23).
SS12F121 21
28. Detach the hose (12) from transmission and remove

it.
SS12F122 22
29. Detach the hose (13) from the transmission and re-
move it.
SS12F123 23
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SS12F124 24
31. Remove the hose (10).

32. Remove the O-ring (26) from the hose (10).
SS12F125 25
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Lines - Assemble
NOTE: For more details refer to Lines - Component identification (29.204).
1. Connect the hose (10) to the transmission.
2. Mount the clamp (27).
SS12F126 1
SS12F123 2
SS12F122 3
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5. Connect the tube (23) to the transmission and fasten it

with the clamp (22).
SS12F127 4
6. Mount the clamp (25).
SS12F119 5
7. Mount the hose (11) and connect it to the tube (23).
SS12F118 6
8. Place the hoses inside the clamp and mount the clamp
(19).
SS12F116 7
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9. Mount the protection (20).

10. Fasten the cover with the bolt (21).
SS12F115 8
11. Mount the clamp (14) on the hoses.

12. Mount the joint (18) on the axle, with the pull rod (16)
and the nut (17).
SS12F128 9
13. Place the O-ring (3) on the valve (2).
SS12F112 10
14. Connect the valve (2) to the block (4) using the screws
(1).
SS12F110 11
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15. Fasten the block (4) and attached the valve (2) to the
frame using the screws (8).
SS12F109 12
16. Fasten the valve (6) to the frame using the screws (7).
SS12F108 13
17. Connect the hose (9) to the valve (6).
SS12F107 14
18. Connect the hose (9) to the block (4).
SS12F106 15
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19. Connect the tube (5) to the valve (6).
SS12F105 16
20. Connect the tube (5) to the block (4).
SS12F104 17
SS12F103 18
SS12F102 19
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SS12F101 20
SS13N001 21
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Index

Lines - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lines - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Lines - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Reservoir, cooler, and lines - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Reservoir, cooler, and lines - Hydraulic schematic frame 01 - Front drive . . . . . . . . . . . . . . . . . . . . . . 6
Reservoir, cooler, and lines - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Pump and motor components - 218
836C AWD
836C
856C AWD
856C
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29.2 [29.218] / 1
Contents
TECHNICAL DATA
Pump
FUNCTIONAL DATA
Pump and motor components

Pump
Component identification - All-wheel pump (836C AWD and 856C AWD) . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Motor
Component identification - Radial piston motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Static description - Wheel motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SERVICE
Pump and motor components

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Service instruction - General information (836C AWD and 856C AWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Test - Setting and Testing the FWD with Creep mode (836C AWD and 856C AWD) . . . . . . . . . . . . . . . . 16
Test the pump pressure cut-off (836C AWD and 856C AWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Calibrate the pump (836C AWD and 856C AWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Program - FWD Parameter Adjustment (836C AWD and 856C AWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
View - FWD System Data (836C AWD and 856C AWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Program - FWD EOL (End of Line) Adjustment (836C AWD and 856C AWD) . . . . . . . . . . . . . . . . . . . . . . 32
Calibrate the Creep Mode (836C AWD and 856C AWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Check the general functions (836C AWD and 856C AWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Prepare the measurement connection (836C AWD and 856C AWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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Hydrostatic drive - Pump and motor components
Pump - General specification

Level A4VG 56EP2 A4VG 71EP2
Displacement 0 - 56 cm³/rev (0.0 - 3.4 in³/rev) 0 - 71 cm³/rev (0.0 - 4.3 in³/rev)
Wheel motor MS8 MS11
Min/max displacement 428 cm³ (26.1 in³) / 629 cm³ (38.4 in³) /
857 cm³ (52.3 in³) 1229 cm³ (75.0 in³)
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Pump and motor components - Component identification
SS12E342 1

1 Pump 21 Supply pressure filter
17 Diffuser 22 Pressure reservoir
18a Valve 23 Distributor
18b Valve a Solenoid valve
19 Pressure-limiting valve g Solenoid valve
20 Purge valve
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Pump - Component identification - All-wheel pump (836C AWD and

856C AWD)
SS12E314 1

21 Counterweight 302 Pressure-limiting valve
28 Nozzle 303 Valve
301 Pressure limiting valve 401 Inner transmission pump
NOTE: Refer also to Fixed displacement pump - Component identification - Double pump (35.104).
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Pump - Static description

All-wheel pump (836C AWD and 856C AWD)
The front drive is supplied by the all-wheel pump A4VG, which has an axial piston/swash plate design.
In the movable range, the pump can be set at pressures up to 315 bar (4567.5 psi). The geometric flow volume can
be continuously adjusted by changing the position of the swash plate.
Variable displacement pump

NOTE: Refer also to Pump and motor components - Component identification (29.218).
The delivered volume from the axial piston pump is controlled by the proportional solenoid valve (a) or (b).
Depending on the specified current strength I ( 200 - 600 mA) at the solenoids, the pump-actuating cylinder is supplied
with actuating pressure from the proportional valve. The swash plate, and therefore the delivered volume, are ad-
justed continuously by the actuating pressure or current strength. The flow direction changes depending on whether
"a" or "b" is actuated.
The set displacement volume, and therefore the front-wheel speed, are maintained irrespective of the pressure due
to air drag/rolling resistance and traction. The resulting load relief on the front axle in working conditions causes a
reduction of the working pressure while maintaining the same wheel speed.
At a specified wheel speed, the working pressure, and therefore the front wheel tractive force, are determined by
traction conditions and air drag/rolling resistance. If the allowed maximum working pressure of 420 bar (6090.0 psi)
is reached, the pressure cutoff in the axial piston pump diverts the flow to the return line. The reduced flow causes
the front-wheel speed to decrease. If the front-wheel speed is lower than the rear-wheel speed, the working pressure
to the front-wheel drive falls accordingly.
The pressure peaks produced by rapid swivelling motions and the maximum high pressure of the pump are limited to
450 bar (6525.0 psi) by the high-pressure limiting valves.
Feed pump (integrated)

Functions
• Oil feed to variable delivery pump
• Supplies actuating pressure to the actuating chamber
• Control oil supplied to valves (18a) and (18b)
• Purge oil
The feed pump flange-mounted on the variable delivery pump delivers through the feed pressure filter against the
25 bar (362.5 psi) feed pressure-limiting valve. The delivered oil is used first to purge the hydrostatic circuit, and
then to control the various functions. The oil quantity required for purging is fed into the low-pressure line through the
bypass valves integrated in the high-pressure limiting valves. The heated oil is rinsed out through the purge valve
(20), i.e. the oil temperature in the closed circuit should not go above 50 - 60 °C (122.0 - 140.0 °F).
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Valve VA On/Off
When the front-wheel drive is engaged, the 4/2-way valve
(18a) is actuated electrically, and this applies control pres-
sure to the 6/2-way valve (16) to bring it into the open posi-
tion. This connects the pump to the wheel motors through
the high-pressure lines. The 6/2-way valve is shut off by
spring pressure, assisted by the control pressure.
SS12E343 1
Pressure reservoir
The 0.75 l (0.2 US gal) pressure reservoir (22) simply prevents any undersupply to the all-wheel "On – Off" feed line
or displacement changeover.
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Flow divider
The flow divider (3) acts as a hydraulic differential lock. In the forward direction of travel, it divides the oil from the
pump into two equal quantities for the wheel motors. This prevents all the oil from being absorbed by one motor,
if there are different resistances at the wheel motors (for example, if there are different friction values at the front
wheels). This prevents wheel-spin from occurring at one of the wheels.
The transfer nozzle between the two outlets "A" and "B" allows limited pressure compensation, which prevents ex-
cessive imbalance in the stresses on the front two wheels. In the reverse direction of travel, the flow divider has no
function, since the oil flows through the two check valves and bypasses the flow divider function. The connections
"F" and "ZB" have a leak oil function.
SS12E344 2

DI Flow divider LM To left, Wheel motor
FO High-pressure line, forward RE High-pressure line reverse
LF Side view, Left front
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Wheel motor actuation/chamber switch-over valve

The volume absorbed by the wheel motors can be ad-
justed in two stages. Actuation of the "Y" connections with
control pressure through the 4/2-way valve (18b) causes
the delivered volume to be halved, so that the wheels can
turn twice as fast for the same pump delivery rate. This
feature is used when driving with front-wheel drive in the
4th and 5th forwards gears and in the 3rd reverse gear.
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Motor - Component identification - Radial piston motor
SS12M129 1

3 Cover 6 Cover
4 Control disk 7 Cover cpl.
5 Cylinder block 800 Seal set
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Motor - Static description - Wheel motors

The two wheel hub motors (2) operate according to the
radial piston principle. i.e. a certain number of working
pistons are arranged radially in the motors. When the
cylinder block is turning, they run out along a cam track,
which converts their movement to linear movement.
On the inside, the cylinder compartments are connected

through the distributor alternately to the high-pressure
feed and return lines. When the 6/2 way valve is actu-
ated, the working/feed pressure is applied from inside to
the piston surface, pushing the piston into the cam track.
Outside of the piston is the housing or leak pressure

which, in our system, is pre-loaded at 1.5 bar (21.8 psi)
by the wheel motor connections of pressure-limiting valve
(19).
The purpose of the preload pressure is to switch the wheel

motors to freewheel when the front wheel drive is switched
off, i.e. to push the radial pistons inward so that they are
no longer in contact with the cam track. To do this, the
pressure on the inside of the pistons, and therefore in the
high-pressure channels must fall to tank pressure. This is
done by connecting the wheel motor high-pressure con-
nections to the tank through the 6/2 way valve (16) when
the front wheel drive is shut off. To assist the wheel motor
shutoff, this line opens onto the intake line (connection) of
the working hydraulic pump.
SS12E345 1
The front wheel drive can only be switched on/off up to
a vehicle speed of 2 km/h (1.2 mph), because, at higher Pos. Designation
speeds, the wheel motor shutoff might cause damage. 2 Motor
NOTE: Refer also to Pump - Static description (29.218). BA High-pressure line backwards
BF Side view, before
CS Control line chamber switch-over
FO High-pressure line forwards
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Pump and motor components - Check

To test the main functions of the front-wheel drive, the
following conditions are required:
• No load on the front and rear axles (vehicle jacked
up). All wheels can turn freely.
• Transmission is in neutral
• Diesel engine is idling at low RPM
• Front-wheel drive is switched off
• Rotary feed switch is at "0" (parallel feed setting)
Check that the wheel hub motors are turning freely

Turn the front wheels forwards and backwards by hand.
The wheels must turn freely.
Check the function of the front-wheel drive

Start testing only when the engine is idling and ensure
that no persons or objects are near the turning wheels.
• Switch on the front-wheel drive
• Shift through all gears of the transmission:
NOTE: The direction of rotation of the front and rear wheels
must be the same in all gear stages.
NOTE: The rotational speed of the front and rear wheels
must increase uniformly as the gears are shifted up.
Check the function of the hydraulic differential lock

Select the forward gears 1 to 3, and the reverse gears
1 and 2. In all forward gears, the left and right front
wheels must turn synchronously.
The hydraulic differential lock does not function in the
reverse gears. The front wheel with the lower friction
and flow losses rotates at a higher speed relative to the
other wheel.
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Pump and motor components - Service instruction - General

information (836C AWD and 856C AWD)
For the programming and diagnosis of the front-wheel
drive, a laptop with Engineering Service Tool version
7.7.0.18 or higher shall be connected to the machine
via CAN 2 connector.
1. After starting the EST Tool, select the CASE Construc-
tion logo.
SS14K161 1
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2. Select then the correct machine and click “OK”.
SS14K062 2
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3. Selecting UCM controller and Pressing the button ‘Con-

figuration’ the following menu will be displayed.
SS14K063 3
4. First four options provide for Cut-Off Test, Pump Cal-

ibration, EOL (End of Line) Adjustment and FWD Pa-
rameter adjustment, last option provide for FWD Sys-
tem Data display.
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Pump and motor components - Test - Setting and Testing the FWD
with Creep mode (836C AWD and 856C AWD)
This is a summary of the necessary operations to test
and calibrate the FWD.
In order to fully adjust the FWD system all the follow-
ing test and calibration shall be performed in the order
below:
1. Pressure Cut-off test (refer to Pump and motor
components - Test the pump pressure cut-off
(836C AWD and 856C AWD) (29.218))
2. Pump Calibration (refer to Pump and motor com-
ponents - Calibrate the pump (836C AWD and
856C AWD) (29.218))
3. EOL (End of Line) Adjustment (refer to Pump and
motor components - Program - FWD EOL (End
of Line) Adjustment (836C AWD and 856C AWD)
(29.218))
If the system is equipped with Creep Mode function, in
addition to the above calibration also the following shall
be performed:
4. Creep Mode Calibration (refer to Pump and motor
components - Calibrate the Creep Mode (836C
AWD and 856C AWD) (29.218))
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Pump and motor components - Test the pump pressure cut-off

(836C AWD and 856C AWD)
The hydraulic pump is equipped with one pressure cut-
off and two pressure limiting valves (forward and re-
verse). The forward and reverse tests are the same.
The corresponding pump proportional valve is actuated
according to which direction is selected.
Select the “Calibration – Pressure Cut-Off Test” op-
tion (see Pump and motor components - Service
instruction - General information (836C AWD and
856C AWD) (29.218)).
This screen will appear and following information will
be displayed:
• FW Test Status defines the status of last Cut-Off FW
test (successfully or unsuccessfully performed)
• RV Test Status defines the status of last Cut-Off RV
test (successfully or unsuccessfully performed)
• Additional Test Information will be Off or will display,
eventually, an interlock not properly set or an error
affecting the system
• FW Pressure and RV Pressure box will be populated
as soon as EST will receive data from DataR
SS14K162 1
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1. Connect DataR measurement connection (refer to

Pump and motor components - Prepare the mea-
surement connection (836C AWD and 856C AWD)
(29.218)).
2. Crank the machine.
3. Set gearshift lever in Neutral Position.
4. Engage Park Brake.
5. Assure that hydraulic oil temperature is 20 - 55 °C (68
- 131 °F).
6. Raise engine speed over 1500 RPM.
7. Press ‘Start Test FW’ button to start the Pressure
Cut-Off Test Forward: the information on figure 1 will
change as follows:
• Additional Test Information will display ‘ON’ (Sole-
noid valve FW energized)
wait until
• Additional Test Information will display ‘Check FW
Pressure Ready’
8. Press ‘FW Pressure OK’ button if system reached 410
- 430 bar (5945 - 6235 psi), otherwise press ’FW Pres-
sure Not OK’ button.
NOTE: If system does not receive feedback within few sec-
onds the Additional Test Information will display ‘Disable
out of time’ and test results will be ignored.
9. Press ‘Start Test RV’ button to start the Pressure
Cut-Off Test Reverse: the information on figure 1 will
change as follows:
• Additional Test Information will display ‘ON’ (Sole-
noid valve RV energized)
wait until
• Additional Test Information will display ‘Check FW
Pressure Ready’
10. Press ‘RV Pressure OK’ button if system reached 410
- 430 bar (5945 - 6235 psi), otherwise press ’RV Pres-
sure Not OK’ button.
NOTE: If system does not receive feedback within few sec-
onds the Additional Test Information will display ‘Disable
out of time’ and test results will be ignored.
11. Choose one of the following options to complete the
Pressure Cut-Off Test procedure:
• press ‘EXIT AND SAVE’ button to exit and save the
results obtained during Cut-Off Tests
• press ‘ABORT CALIBRATION’ button to ignore the
results obtained during Cut-Off Tests, maintaining
the previous test results
12. Set the ignition key in Off position and wait until the
AIC cluster shutdown.
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Pump and motor components - Calibrate the pump (836C AWD

and 856C AWD)
Individual settings of Individual pump values according to pump characteristics (accep-
tance report)
This procedure allows the service operator to adjust the
characteristic of the pump.
The set points which characterize the pump are four:
Max Set Point FW = Maximum current value for
pump deflection - forward travel ( 600 mA)
Min Set Point FW = Initial current value for pump
deflection - forward travel ( 220 mA)
Max Set Point RV = Maximum current value for
pump deflection - reverse travel ( 600 mA)
Min Set Point RV = Initial current value for pump
deflection - reverse travel ( 220 mA)
NOTE: The values defined in parenthesis are the default
values.
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NOTICE: It is strongly recommended to successfully perform both pressure Cut-Off Tests before start this procedure.
Select the “Calibration – Forward and Reverse Pump”
option (see Pump and motor components - Service
856C AWD) (29.218)).
be displayed:
• Set points currently used by the controller
• Pump calibration Flag defines the status of last
Pump Calibration (OK or Not OK)
• Manual Calibration Active Flag set to Not Active
• Manual Calibration Active State set to No Activation
Request
SS14K163 1
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2. Lift the machine.
3. Assure that front axle is in horizontal position (wheel
shall not touch the ground).
6. Assure that Hydraulic Oil temperature is 30 - 90 °C (86
- 194 °F).
7. Raise engine speed to maximum rpm (engine speed
shall be higher than 2100 RPM to enter calibration).
8. Press ‘Start Calibration’ button to start the Pump Cal-
ibration procedure: the information on figure 1 will
change as follows:
• Manual Calibration Active Flag will be set to Active
or will display, eventually, an interlock not properly
set or an Error affecting the System
• Manual Calibration Active State will be set to Activa-
tion Request
9. To enter the new pump characteristic overwrite the Set
Points currently in use by the controller, while pressing
the ‘Restore Default’ buttons the relevant default Set
point will be restored and saved (Actually this opera-
tion is equivalent to overwrite the set point with default
values and press ‘exit and save’ button).
pump calibration procedure:
• press ‘EXIT AND SAVE’ button to make the modi-
fications actual, and set ‘Pump Calibration flag’ to
‘Pump Calibration OK’
• press ‘EXIT WITHOUT SAVE’ button to ignore the
modification done during calibration, and restore
last calibration set points and last Pump Calibration
Flag
• press ‘EXIT AND SET CALIBRATION NOT PER-
FORMED’ button to ignore the modification done
during calibration, and set Pump Calibration flag’ to
‘Pump Calibration Not OK’
NOTE: Note that in order to make the controller use the Set Point entered during this procedure the ‘Pump calibration
Flag’ shall be set to ‘Pump Calibration OK’ and both Pressure Cut-Off tests shall be successfully performed.
NOTE: If the Pump Calibration have been successfully performed but one of Pressure Cut-Off Tests is not, the Set
Point values will be saved but not used until all three of them will be set to successfully performed.
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Setting individual pump characteristic values if there is no acceptance report

If there is no acceptance report available for the axial
piston pump installed, the value settings for Max Set
Point FW, Min Set Point FW, Max Set Point RV and Min
Set Point RV shall be determined as follows.
Select the “Calibration – Forward and Reverse Pump”
option (see Pump and motor components - Service
856C AWD) (29.218)).
be displayed:
• Set points currently used by the controller
• Pump calibration Flag defines the status of last
Pump Calibration (OK or Not OK)
• Manual Calibration Active Flag set to Not Active
• Manual Calibration Active State will set to No Activa-
tion Request
SS14K164 2
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2. Lift the machine.
3. Assure that front axle is in horizontal position (wheel
shall not touch the ground).
6. Assure that Hydraulic Oil temperature is 30 - 90 °C (86
- 194 °F).
7. Raise engine speed to maximum rpm (engine speed
shall be higher than 2100 RPM to enter calibration).
8. Press ‘Start Calibration’ button to start the Pump Cal-
ibration procedure: the information on figure 2 will
change as follows:
• Manual Calibration Active Flag will be set to Active
or will display, eventually, an interlock not properly
set or an Error affecting the System
• Manual Calibration Active State will be set to Activa-
tion Request
9. On the EST screen set Min Set Points FW and RV to
180 mA.
10. To determine value settings Min Set Points FW and
RV (lower current value for proportional valve):
• raise the lower current value Min Set Points FW in
steps ( 5 mA) from 180 - 250 mA and press ‘Com-
mand’ button (Manual Calibration active flag will be
set to ‘Pump Solenoid Min Set Point FW Driven’).
The current value at which a front wheel begins
to move in the forward direction is the proportional
valve lower current value (Min Set Point FW) used
on an acceptance report.
• raise the lower current value Min Set Points RV in
steps ( 5 mA) from 180 - 250 mA and press ‘Com-
mand’ button (Manual Calibration active flag will be
set to ‘Pump Solenoid Min Set Point RV Driven’).
The current value at which a front wheel begins
to move in the reverse direction is the proportional
valve lower current value (Min Set Point RV) used
on an acceptance report.
11. Set Max set Point values as follow:
• Max Set Point FW = Min Set Point FW + 380 mA
• Max Set Point RV = Min Set Point RV + 380 mA
12. Overwrite Max Set Points FW and RV with values cal-
culated at previous step.
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pump calibration procedure:
• press ‘EXIT AND SAVE’ button to make the modi-
fications actual, and set ‘Pump Calibration flag’ to
‘Pump Calibration OK’
• press ‘EXIT WITHOUT SAVE’ button to ignore the
modification done during calibration, and restore
last calibration set points and last Pump Calibration
Flag
• press ‘EXIT AND SET CALIBRATION NOT PER-
FORMED’ button to ignore the modification done
during calibration, and set Pump Calibration flag’ to
‘Pump Calibration Not OK’
NOTE: Note that in order to make the controller use the Set
Point entered during this procedure the ‘Pump calibration
Flag’ shall be set to ‘Pump Calibration OK’ and both Pres-
sure Cut-Off tests shall be successfully performed.
NOTE: If the Pump Calibration have been successfully per-
formed but one of Pressure Cut-Off Test is not, the Set
Point values will be saved but not used until all three of
them will be set to successfully performed.
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Pump and motor components - Program - FWD Parameter

Adjustment (836C AWD and 856C AWD)
This section provide for overview and explanation on
how to modify FWD system parameter.
Select the “Configuration – System Parameters” op-
tion (see Pump and motor components - Service
856C AWD) (29.218)).
be displayed:
• Parameter description
• Current value of parameter
• Modified values column
SS14K165 1
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1. Press ‘Retrieve Controllers values’ button to repopu-

late the column Current values with parameter currently
used by the controller.
2. Overwrite values in column Modified values to activate
‘SEND MODIFIED VALUES TO CONTROLLER’ but-
ton.
3. Press ‘SEND MODIFIED VALUES TO CONTROLLER’
button to make the controller use the modified param-
eter.
4. Press ‘EXIT’ button to exit the parameter adjustment
procedure.
The following table provide all parameters and their meaning used by FWD Controller:
Parameter Name Description
Max. Pump Displacement Maximum nominal pump displacement
Min. Pump Current FW Minimum nominal pump current forward
Min. Pump Current RV Minimum nominal pump current reverse
Max. Pump Current FW Maximum nominal pump current forward
Max. Pump Current RV Maximum nominal pump current reverse
Min Solenoid Pump Current Minimum pump current for coil exciting
Max. Motor Displacement Maximum motor displacement
Motor Reduction Valve Delay On Time delay from detecting gear stage change to supplying the motor
displacement reduction valve (off → on)
Motor Reduction Effect Delay On Time delay from detecting gear stage change to evaluating the
reduced displacement for pump displacement calculation (off → on)
Motor Reduction Valve Delay Off Time delay from detecting gear stage change to stop supplying the
motor displacement reduction valve (on → off)
Motor Reduction Effect Delay Off Time delay from detecting gear stage change to evaluating the
reduced displacement for pump displacement calculation (on → off)
FWD Enable Speed Speed threshold for enabling front wheel drive
FWD Enable Speed Debounce Time Time threshold for enabling front wheel drive in Standstill
Transm. Wheel Ratio Ratio transmission output to wheel
Max. Gear FW Highest allowed gear to use with FWD in forward direction
Max. Gear RV Highest allowed gear to use with FWD in reverse direction
Full Displ. Gear Limit FW Last gear stage in forward direction where motor can be driven at full
displacement.
Full Displ. Gear Limit RV Last gear stage in reverse direction where motor can be driven at full
displacement.
Engine Pump Ratio Ratio diesel engine to pump
FWD Disable Engine Speed Engine rpm threshold for switching off FWD system
Selector Disable Engine Speed Engine rpm threshold for disabling rotary selector switch
Selector Enable Engine Speed Engine rpm threshold for enabling rotary selector switch
Selector Step Size FW 1 Pump displacement aggressiveness step sizes for gear stages F1
Selector Step Size RV 1 Pump displacement aggressiveness step sizes for gear stages R1
Gear Comp. Displ. FW 1 Pump displacement compensation for gear stages F1
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Gear Comp. Displ. RV 1 Pump displacement compensation for gear stages R1
Shift Up Comp. Delay FW 1 Pump displacement compensation delay for shifting up to gear F1
in forward direction
Shift Up Comp. Displ. FW 1 Pump displacement compensation value for shifting up to gear F1
Shift Up Comp. Slope FW 1 Pump displacement compensation slope for shifting up to gear F1
Shift Up Comp. Duration FW 1 Pump displacement compensation duration for shifting up to gear F1
Shift Down Comp. Delay FW 1 Pump displacement compensation delay for shifting down to gear N
Shift Down Comp. Delay FW 2 Pump displacement compensation delay for shifting down to gear F1
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Shift Down Comp. Displ. FW 1 Pump displacement compensation value for shifting down to gear N
Shift Down Comp. Displ. FW 2 Pump displacement compensation value for shifting down to gear F1
Shift Down Comp. Slope FW 1 Pump displacement compensation slope for shifting down to gear N
Shift Down Comp. Slope FW 2 Pump displacement compensation slope for shifting down to gear F1
Shift Down Comp. Duration FW 1 Pump displacement compensation duration for shifting down to gear
N in forward direction
F1 in forward direction
Shift Up Comp. Delay RV 1 Pump displacement compensation delay for shifting up to gear R1
in reverse direction
Shift Up Comp. Displ. RV 1 Pump displacement compensation value for shifting up to gear R1
Shift Up Comp. Slope RV 1 Pump displacement compensation slope for shifting up to gear R1
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Shift Up Comp. Duration RV 1 Pump displacement compensation duration for shifting up to gear R1
Shift Down Comp. Delay RV 1 Pump displacement compensation delay for shifting down to gear N
Shift Down Comp. Delay RV 2 Pump displacement compensation delay for shifting down to gear R1
Shift Down Comp. Delay RV 3 Pump displacement compensation delay for shifting down to gear R2
Shift Down Comp. Displ. RV 1 Pump displacement compensation value for shifting down to gear N
Shift Down Comp. Displ. RV 2 Pump displacement compensation value for shifting down to gear R1
Shift Down Comp. Displ. RV 3 Pump displacement compensation value for shifting down to gear R2
Shift Down Comp. Slope RV 1 Pump displacement compensation slope for shifting down to gear N
Shift Down Comp. Slope RV 2 Pump displacement compensation slope for shifting down to gear R1
Shift Down Comp. Slope RV 3 Pump displacement compensation slope for shifting down to gear R2
Shift Down Comp. Duration RV 1 Pump displacement compensation duration for shifting down to gear
N in reverse direction
R1 in reverse direction
R2 in reverse direction
Shuttle Comp. Delay FW Shuttle displacement compensation starting delay for shuttling RV
→ FW
Shuttle Comp. Displ. FW Shuttle displacement compensation value for shuttling RV → FW
Shuttle Comp. Delay RV Shuttle displacement compensation starting delay for shuttling FW
→ RV
Shuttle Comp. Displ. RV Shuttle displacement compensation value for shuttling FW → RV
Brake Comp. Displacement Braking displacement compensation value
Pump Low Offset FW Calibration offset current of minimum nominal current of pump valve
FW
Pump High Offset FW Calibration offset current of maximum nominal current of pump valve
FW
Pump Low Offset RV Calibration offset current of minimum nominal current of pump valve
RV
Pump High Offset RV Calibration offset current of maximum nominal current of pump valve
RV
CAN Timeout CAN Timeout period
Max Creep Mode Speed Maximum achievable speed in Creep Mode
creep mode percent speed detent 1 Percentage of maxiumum achievable speed (saturated at maximum
speed when >100) in detent 1
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CM Pump low speed offset Pump displacement offset for detent 1 (gradually applied to all detent)
CM Pump High speed offset Pump displacement offset for detent 16 (gradually applied to all
detent)
CM Pump Offset Pump displacement offset for Creep Mode
Cm Max Pump Current Rate
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Pump and motor components - View - FWD System Data (836C

AWD and 856C AWD)
This section provide for an overview on system data
screen.
Select the “View – System Data” option (see Pump and
motor components - Service instruction - General
information (836C AWD and 856C AWD) (29.218)).
This screen will appear and following information will be
displayed:
Parameter Name Designation

FWD Last Model Last selected model
FWD Last Wheel Circumference Last Selected Wheel Circumference
Pump Calibration Flag Last Calibration state of hydraulic pump
Cut Off Pump FW Calibration Flag Last result of Pressure cut off test
Cut Off Pump RV Calibration Flag Last result of Pressure cut off test
FWD Operating Hours FWD Operating Hours at step of 0.05 hours
SS14K166 1
1. Press ‘Retrieve Controllers values’ button to repopulate

the column Current values with current system data.
2. Press ‘EXIT’ button to exit.
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Pump and motor components - Program - FWD EOL (End of Line)

Adjustment (836C AWD and 856C AWD)
EOL (End of Line) Adjustment procedure allows the ma-
chine to reach the desired tractive effort performance in
each gear and aggressiveness stage.
Target of the procedure is to define the EOL parame-
ters in order to meet the pressure level defined in the
following tables:
At zero aggressiveness and full speed the pressure shall not exceed the following acceptable pressure values
range.
Gear Stage FW Pressure RV Pressure
F1 50 - 150 bar (725 - 2175 psi) 25 - 30 bar (362 - 435 psi)
F2 35 - 100 bar (508 - 1450 psi) 25 - 30 bar (362 - 435 psi)
F3 35 - 80 bar (508 - 1160 psi) 25 - 60 bar (362 - 870 psi)
F4 35 - 80 bar (508 - 1160 psi) 25 - 60 bar (362 - 870 psi)
F5 35 - 80 bar (508 - 1160 psi) 25 - 60 bar (362 - 870 psi)
R1 25 - 30 bar (362 - 435 psi) 50 - 150 bar (725 - 2175 psi)
R2 25 - 60 bar (362 - 870 psi) 35 - 80 bar (508 - 1160 psi)
R3 25 - 60 bar (362 - 870 psi) 35 - 80 bar (508 - 1160 psi)
At maximum aggressiveness and full speed the pressure shall not exceed the following acceptable pressure
values range.
Gear Stage FW Pressure RV Pressure
F1 50 - 300 bar (725 - 4350 psi) 25 - 30 bar (362 - 435 psi)
F2 35 - 200 bar (508 - 2900 psi) 25 - 30 bar (362 - 435 psi)
F3 35 - 150 bar (508 - 2175 psi) 25 - 30 bar (362 - 435 psi)
F4 35 - 150 bar (508 - 2175 psi) 25 - 30 bar (362 - 435 psi)
F5 35 - 150 bar (508 - 2175 psi) 25 - 30 bar (362 - 435 psi)
R1 25 - 30 bar (362 - 435 psi) 50 - 300 bar (725 - 4350 psi)
R2 25 - 33 bar (362 - 478 psi) 35 - 150 bar (508 - 2175 psi)
R3 25 - 33 bar (362 - 478 psi) 35 - 150 bar (508 - 2175 psi)
The following table provide for the EOL parameters to be tuned:

Parameters Unit Description
Selector Step Size FW 1 ccm/ounces Pump displacement aggressiveness step sizes
for gear stages F1
for gear stages F2
for gear stages F3
Selector Step Size RV 1 ccm/ounces Pump displacement aggressiveness step sizes
for gear stages R1
Selector Step Size RV 2 ccm/ounces Pump displacement aggressiveness step sizes
for gear stages R2
Gear Comp. Displ. FW 1 ccm/ounces Pump displacement compensation for gear
stages F1
stages F2
stages F3
stages F4
stages F5
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Parameters Unit Description

Gear Comp. Displ. RV 1 ccm/ounces Pump displacement compensation for gear
stages R1
stages R2
stages R3
Gear Compensation Displacement Parameter defines a

fixed displacement to be added or subtracted at Nom-
inal Displacement Pump Command for each gear, as
long as a gear is engaged the nominal pump displace-
ment is compensated using the relevant value.
Selector Step Size Parameter defines the step size for
Aggressiveness Selector, step size is gear dependent
so that each gear as uniform step size, but step size
could differ from gear to gear.
Aggressiveness Displacement is calculated as follow:
Aggressiveness Displacement = Encoder position
(from -5 to 10) x Selector Step Size Para.
Aggressiveness Displacement is added or subtracted
at Nominal Displacement Pump Command.
1. Before start the EOL Adjustment procedure cut-off test
and pump calibration (defined in previous sections)
shall be successfully performed.
2. To make the controller use the parameter setting en-
tered during this procedure Pump Calibration and both
Pressure Cut-Off tests shall be successfully performed.
3. Pressure measurement shall be performed after the
machine has reached the maximum speed in a straight
line and the pressures have stabilized (a long flat track
without up-downhill surfaces is needed).
4. Procedure shall be performed at Hydraulic Oil temper-
ature of 45 - 55 °C (113 - 131 °F).
5. Procedure shall be performed using the following EST
screen (EST/Configuration - EOL Adjustment)
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Select the “Configuration – EOL Adjustment” option

(see Pump and motor components - Service in-
struction - General information (836C AWD and
856C AWD) (29.218)).
This following information will be displayed:
• Parameter description
• Current value of parameter
• Modified values column
• Top-right Boxes provide for FW Pressure, RV Pres-
sure, Engine Speed, in the middle also following
information are shown: Hydraulic Oil Temperature,
Gear Engaged and aggressiveness selected.
SS14K167 1
6. Press ‘Retrieve Controllers values’ button to repopu-

late the column Current values with parameter currently
used by the controller.
7. Overwrite values in column Modified values to activate
‘SEND MODIFIED VALUES TO CONTROLLER’ but-
ton.
8. Press ‘SEND MODIFIED VALUES TO CONTROLLER’
button to make the controller use the modified param-
eter.
9. Press ‘EXIT’ button to exit the parameter adjustment
procedure.
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Part 1 FORWARD ZERO AGGRESSIVENESS

Check that hydraulic oil temperature is in the range 45
- 55 °C (113 - 131 °F).
Set aggressiveness to zero and FWD active (or re-
quested).
1. Preselect 1st gear when machine in neutral.
2. Starting from standstill drive the machine FW at maxi-
mum engine speed in 1st gear.
3. Measure FW and RV pressures.
4. Increase (decrease) Gear Compensation Displ. FW 1
value in step of 1 ccm (0.0338 ounces) if pressure FW
is below (above) 50 - 70 bar (725 - 1015 psi).
5. Repeat the maneuver until the measured pressures are
inside the range (decrease the step size if needed).
mum engine speed in 1st gear, then upshift to 2nd gear.
10. Repeat the maneuver until the measured pres-
sures are inside the range (decrease the step size if
needed).
12. Starting from standstill drive the machine FW at max-
imum engine speed in 1st gear, then upshift up to 3rd
gear (in each gear maximum speed shall be reached).
needed).
18. Downshift in 2nd gear.
20. Decrease Gear Compensation Displ. FW 2 value in
step of 0.2 ccm (0.0068 ounces) if pressure FW is
higher than 100 bar (1450 psi).
needed).
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25. Downshift in 1st gear.
needed).
29. Preselect 4th gear when machine in neutral.
imum engine speed in 4th gear.
needed).
mum engine speed in 4th gear, then upshift in 5th gear
(in each gear maximum speed shall be reached).
needed).
mum engine speed in 4th gear, then upshift in 5th gear
(in each gear maximum speed shall be reached).
41. Downshift in 4th gear.
needed).
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Part 2 REVERSE ZERO AGGRESSIVENESS

- 55 °C (113 - 131 °F).
Set aggressiveness to zero and FWD active (or re-
quested).
2. Starting from standstill drive the machine RV at maxi-
4. Increase (decrease) Gear Compensation Displ. RV 1
value in step of 1 ccm (0.0338 ounces) if pressure RV
needed).
mum engine speed in 1st gear, then upshift up to 3rd
NOTE: This step is applicable only for 856C AWD.
15. Increase (decrease) Gear Compensation Displ. RV
3 value in step of 1 ccm (0.0338 ounces) if pressure
RV is below (above) pressure FW (target is to get
RV pressure about 30 bar (435 psi) and FW pressure
about 25 bar (362 psi)).
NOTE: This step is applicable only for 836C AWD.
needed).
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21. Decrease Gear Compensation Displ. RV 2 value in

step of 0.2 ccm (0.0068 ounces) if pressure RV is
needed).
28. Decrease Gear Compensation Displ. RV 1 value in
step of 0.2 ccm (0.0068 ounces) if pressure RV is
needed).
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Part 3 FORWARD MAX AGGRESSIVENESS

- 55 °C (113 - 131 °F).
Set aggressiveness to maximum and FWD active (or
requested).
4. Increase (decrease) Selector Step Size FW 1 value in
step of 0.2 ccm (0.0068 ounces) if pressure FW is be-
low (above) 180 - 220 bar (2610 - 3190 psi).
9. Increase (decrease) Selector Step Size FW 2 value in
step of 0.2 ccm (0.0068 ounces) if pressure FW is be-
low (above) 80 - 120 bar (1160 - 1740 psi).
needed).
14. Increase (decrease) Selector Step Size FW 3 value
in step of 0.2 ccm (0.0068 ounces) if pressure FW is
below (above) 100 - 140 bar (1450 - 2030 psi).
needed).
20. Decrease Selector Step Size FW 2 value in step of 0.1
ccm (0.0034 ounces) if pressure FW is below higher
than 200 bar (2900 psi).
needed).
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NOTE: Only for 836C AWD: Decrease engine speed to
2100 RPM to allow downshift from 2nd to 1st gear.
27. Decrease Selector Step Size FW 1 value in step of
0.1 ccm (0.0034 ounces) if pressure FW is higher than
300 bar (4350 psi).
needed).
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Part 4 REVERSE MAX AGGRESSIVENESS

- 55 °C (113 - 131 °F).
Set aggressiveness to maximum and FWD active (or
requested).
4. Increase (decrease) Selector Step Size RV 1 value in
step of 0.2 ccm (0.0068 ounces) if pressure RV is below
(above) 180 - 220 bar (2610 - 3190 psi).
mum engine speed in 1st gear, then upshift to 2nd gear
9. Increase (decrease) Selector Step Size RV 2 value in
step of 0.2 ccm (0.0068 ounces) if pressure RV is below
(above) 100 - 140 bar (1450 - 2030 psi).
needed).
12. Starting from standstill drive the machine RV at max-
imum engine speed in 1st gear, then upshift to 2nd
15. Decrease Selector Step Size RV 1 value in step of
0.1 ccm (0.0034 ounces) if pressure RV is higher than
300 bar (4350 psi).
needed).
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The following tables provide a summary of the EOL procedure:

maneuver FNR Parameter Step target pressure pressure Aggressiveness
ccm/ounces requirements
N→1 FW gear 1.0/0.0338 50 - 70 bar 50 - 150 bar zero
compensation (725 - 1015 psi) (725 - 2175 psi)
displ. FW 1
N→1→2 FW gear 1.0/0.0338 35 - 55 bar 35 - 100 bar zero
displ. FW 2
N→1→2→3 FW gear 1.0/0.0338 35 - 55 bar 35 - 80 bar zero
displ. FW 3
N→1→2→3 FW gear 0.2/0.0068 < 100 bar 35 - 100 bar zero
→2 compensation (1450 psi) (508 - 1450 psi)
displ. FW 2
→2→1 compensation (2175 psi) (725 - 2175 psi)
displ. FW 1

N→4 FW gear 1.0/0.0338 35 - 55 bar 35 - 80 bar zero
displ. FW 4
N→4→5 FW gear 1.0/0.0338 60 - 80 bar 35 - 80 bar zero
displ. FW 5
compensation (1160 psi) (508 - 1160 psi)
displ. FW 4

N→1 RV gear 1.0/0.0338 50 - 70 bar 50 - 150 bar zero
displ. RV 1
N→1→2 RV gear 1.0/0.0338 35 - 55 bar 35 - 80 bar zero
displ. RV 2
N→1→2→3 RV gear 1.0/0.0338 60 - 80 bar 35 - 80 bar zero
(only 856C compensation (870 - 1160 psi) (508 - 1160 psi)
AWD) displ. RV 3
N→1→2→3 RV gear 1.0/0.0338 MA<MB 35 - 80 bar zero
(only 836C compensation (508 - 1160 psi)
AWD) displ. RV 3
N→1→2→3 RV gear 0.2/0.0068 < 80 bar 35 - 80 bar zero
→2 compensation (1160 psi) (508 - 1160 psi)
displ. RV 2
N→1→2→3 RV gear 0.2/0.0068 < 150 bar 50 - 150 bar zero
→2→1 compensation (2175 psi) (725 - 2175 psi)
displ. RV 1
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N→1 FW Selector Step 0.2/0.0068 180 - 220 bar 50 - 300 bar maximum
Size FW 1 (2610 - 3190 psi) (725 - 4350 psi)
N→1→2 FW Selector Step 0.2/0.0068 80 - 120 bar 35 - 200 bar maximum
Size FW 2 (1160 - 1740 psi) (508 - 2900 psi)
N→1→2→3 FW Selector Step 0.2/0.0068 100 - 140 bar 35 - 150 bar maximum
Size FW 3 (1450 - 2030 psi) (508 - 2175 psi)
N→1→2→3 FW Selector Step 0.1/0.0034 < 200 bar 35 - 200 bar maximum
→2 Size FW 2 (2900 psi) (508 - 2900 psi)
N→1→2→3 FW Selector Step 0.1/0.0034 < 300 bar 50 - 300 bar maximum
→2→1 Size FW 1 (4350 psi) (725 - 4350 psi)

N→1 RV Selector Step 0.2/0.0068 180 - 220 bar 50 - 300 bar maximum
Size RV 1 (2610 - 3190 psi) (725 - 4350 psi)
N→1→2 RV Selector Step 0.2/0.0068 100 - 140 bar 35 - 150 bar maximum
Size RV 2 (1450 - 2030 psi) (508 - 2175 psi)
N→1→2→1 RV Selector Step 0.1/0.0034 < 300 bar 50 - 300 bar maximum
Size RV 1 (4350 psi) (725 - 4350 psi)
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Pump and motor components - Calibrate the Creep Mode (836C

AWD and 856C AWD)
Creep Mode Calibration procedure allows the machine
to reach the required speed performance.
Target of the procedure is to define the Creep Mode
parameters to meet the Speed set point in first and last
detent.
Target Detent Parameters Accelerator pedal position Speed Set Point

1st Set Point 1 CM Pump Low speed offset 100 % 0.5 km/h (0.3 mph)
2nd Set Point 16 CM Pump High speed offset 100 % 5.0 km/h (3.1 mph)
Following pictures show how the nominal pump dis-

placement is modified using the compensation param-
eters:
Creep Mode, Pump displacement (B) versus accelerator pedal position (A) — Uncalibrated
SS14K064 1
Initial CM nominal pump displacement
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Creep Mode, Pump displacement (B) versus accelerator pedal position (A) — Calibrated
with CM pump low speed offset
SS14K065 2
Pump Displacement curves compensated with CM Pump Low Speed offset parameter (positive)
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Creep Mode, Pump displacement (B) versus accelerator pedal position (A) — Calibrated
with CM pump high speed offset
SS14K151 3
Pump Displacement curves compensated with CM Pump High Speed offset parameter (positive)
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• Before start the CM Calibration procedure cut-off test

and pump calibration (defined in previous sections)
shall be successfully performed.
• To make the controller use the parameter setting
entered during this procedure Pump Calibration and
both Pressure Cut-Off tests shall be successfully
performed.
• Speed measurement shall be performed after the
machine has reached the maximum speed in a
straight line (a long flat track without up-downhill
surfaces is needed).
• Procedure shall be performed using the EST/Con-
figuration – FWD Parameter Adjustment Screen
(refer to Pump and motor components - Program
- FWD Parameter Adjustment (836C AWD and
856C AWD) (29.218)).
1. Connect laptop with EST via CAN 2 Connector.
2. Ignition ON.
3. Start EST Tool.
4. EST → Select 'GR11 Grader' machine.
5. EST → Press 'Configuration' button.
6. EST → Select 'Configuration FWD System Parameter'
item.
9. Disengage Park Brake.
10. Press Creep Mode push button.
11. Select 1st Detent.
12. Press Accelerator pedal to maximum stroke.
13. Read reached vehicle speed on AIC display.
14. EST → Overwrite CM Pump Low speed offset value
in column 'Modified values' in order to reach 0.5 km/h
(0.3 mph) (taking into account that positive values will
increase the CM speed while negative will decrease
it).
15. EST → Press 'SEND MODIFIED VALUES TO CON-
TROLLER'.
16. Check that speed is equal to 0.30 - 0.70 km/h (0.19 -
0.43 mph), repeat steps 14 and 15 otherwise.
17. Select 16th detent.
18. Press Accelerator Pedal to maximum stroke.
19. Read vehicle speed reached on AIC display.
20. EST → Overwrite CM Pump high speed offset value
in column 'Modified values' in order to reach 5.0 km/h
(3.1 mph) (taking into account that positive values will
increase the CM speed while negative will decrease
it).
21. EST → Press 'SEND MODIFIED VALUES TO CON-
TROLLER'.
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22. Check that speed is equal to 4.8 - 5.2 km/h (3.0 -

3.2 mph), repeat steps 20 and 21 otherwise.
23. Ignition Off.
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Pump and motor components - Check the general functions (836C

AWD and 856C AWD)
For checking the basic functions of the front-wheel
drive the following initial conditions must be met:
1. The front and rear axles of the grader are load-
relieved (jacked up). All wheels can rotate freely.
2. Gear shift in neutral.
3. The engine runs at idle speed.
4. Front-wheel drive is turned off.
5. Selector switch for the variation of the pump re-
sponse curve in position "0“ (basic response set-
ting).
Checking the freewheeling of the wheel hub motor

1. Turn front wheels forwards and backwards by hand.
The wheels must rotate freely.
Checking the function of the front wheel drive

WARNING
Rotating wheels may cause accidents!
The engine must be idling when you start this procedure. Make sure that the area is clear of all persons
and objects.
W1375A
1. Switch on the front wheel drive.

2. Shift all gears successively.
The rotational direction of the front and rear wheels
must be identical, no matter which gear is engaged.
The speed of the front and rear wheels must increase
evenly with each higher gear engaged.
Checking the function of the hydraulic differential lock

Provided that the requirements mentioned above are
met, both front wheels must skid evenly when the 1st
forward gear is selected while the diesel engine is idling
at low speed.
The diesel engine must idle at high speed (approx.
2200 RPM).
1. Shift the 1st - 3rd forward gears and the 1st and 2nd
reverse gears. In each one of the forward gears, the
left and the right front wheel must rotate synchronously.
When a reverse gear is engaged, the hydraulic differen-
tial lock is inoperative. That front wheel featuring less
friction and flow losses rotates at higher speed as the
other front wheel does.
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Check by pressure sensor

The following section describes how the FWD front-
wheel drive can be checked using pressure sensors.
For gauging, the hydraulic oil must have been warmed
up to an operating temperature of 40 - 60 °C (104 -
140 °F). The grader must stand on all wheels, the diesel
engine is idling and the gear shift unit in neutral, unless
other conditions are required for a certain check (menu
setting).
Take the following actions for the various check-ups:
1. Check the FWD ON/OFF shifting pressure and the
chamber switching pressure.
Connecting the pressure sensors:
1. (1) → 1 on the solenoid valve combination = FWD
ON/OFF shifting pressure
2. (2) → 2 on the solenoid valve combination = Cham-
ber switching pressure
NOTE: Top view onto the solenoid valve, in travelling di-
rection right beneath the operator’s cabin.
SS14K152 1
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For this purpose, switch on the front wheel drive, lock

the grader by its wheel brakes, and shift through all
gears:
- Gear switch in neutral position
Switching status:
0. Neutral gear 950 RPM 0.0 km/h (0.0 mph)
Front-wheel drive - switch ON
FWD ON/OFF shifting pressure (1) 0.3 - 0.7 bar
(4.4 - 10.1 psi)
Chamber switching pressure (2) 0.3 - 0.7 bar (4.4
- 10.1 psi)
- 1st – 3rd forward gears and 1st – 2nd reverse
gears
Switching status:
1st forward gear 950 RPM 0.0 km/h (0.0 mph)
FWD ON/OFF shifting pressure (1) 25 - 30 bar
(362 - 435 psi) (856C AWD) or 20 - 30 bar (290 -
435 psi) (836C AWD).
Chamber switching pressure (2) 0.3 - 0.7 bar (4.4
- 10.1 psi)
- 4th – 5th forward gears and 3rd reverse gear
Switching status:
4th forward gear 950 RPM 0.0 km/h (0.0 mph)
FWD ON/OFF shifting pressure (1) 25 - 30 bar
(362 - 435 psi) (856C AWD) or 20 - 30 bar (290 -
435 psi) (836C AWD).
Chamber switching pressure (2) 25 - 35 bar (362
- 508 psi) (856C AWD) or 22 - 30 bar (319 -
435 psi) (836C AWD); both at high idle.
Checking the locking of the 6th gear with front-wheel drive ON:
1. Engage the 6th gear.
Desired condition: 5th forward gear
Checking the locking of the front-wheel drive in the 6th gear:

1. Front-wheel drive OFF, engage 6th gear, switch on the
front wheel drive.
Desired condition: Solenoid valve of the front-wheel
drive OFF (FWD icon blink)
2. Engage 5th gear.
Desired condition: Solenoid valve of the front wheel
drive ON (FWD icon ON)
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Checking the switching ON and OFF of the front-wheel drive at speeds over and less than
2.0 km/h (1.2 mph).
1. Drive the grader at a speed faster than 2.0 km/h
(1.2 mph) with the front-wheel drive switched off.
2. Engage the front-wheel drive while driving!
Desired condition: Front Wheels do not turn.
3. Reduce the speed so far that the front-wheel drive au-
tomatically engages at 2.0 km/h (1.2 mph).
Desired condition: Front Wheels turn.
4. Accelerate to exceed 2.0 km/h (1.2 mph).
5. Disengage the front-wheel drive while driving!
Desired condition: Front Wheels keep turning.
6. Reduce the speed so far that the front-wheel drive au-
tomatically disengages at 2.0 km/h (1.2 mph).
Desired condition: Front Wheels do not turn.
Testing the displacement reduction when braking:

At each brake application the hydraulic pump is dis-
placed backward by reduction of the pump flow rate,
in order to prevent front wheel caster or engine over-
loading.
If the "Brake Comp. Displ." parameter is set to zero,
this function is disabled!
Test procedure:
• Open the EOL Adjustment screen menu on EST and
check that “Brake.Comp.Displ” is set to –17.8 ccm.
• Machine lifted
• FWD switched on and first gear selected
• Diesel engine at maximum engine rpm
• Press service brake
Desired condition: Rear wheel shall reduce the speed
but keep turning, while the front wheels shall stop since
when brakes are applied the pump displacement is re-
duced by the value.
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Pump and motor components - Prepare the measurement

connection (836C AWD and 856C AWD)
Instruments needed:
• Two pressure transducers – DATAR Pressure Kit
• Workstation
• Interface hardware between the pressure transducer
and the workstation – DataR PicoScope
• Adaptation cable for the pressure transducers to the
standard European connection
• Connection cable from the DataR PicoScope to the
USB port
• DatarScope Software
SVIL14GRD0017AA 1
1. Connect first Pressure transducer to high Pressure

measurement Points MA (High Pressure Forward).
2. Connect Second Pressure transducer to high Pressure
measurement Points MB (High Pressure Reverse).
3. Set Both pressure transducers to higher pressure (
600 bar (8700 psi)).
4. Connect both Pressure transducers to PicoScope via
BNC connector, use Channel A for High pressure For-
ward and Channel B for High Pressure Reverse.
5. Connect PicoScope to workstation via USB Cable.
SVIL14GRD0018AA 2
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Index

Motor - Component identification - Radial piston motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Motor - Static description - Wheel motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pump - Component identification - All-wheel pump (836C AWD and 856C AWD) . . . . . . . . . . . . . . . 5
Pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pump - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pump and motor components - Calibrate the Creep Mode (836C AWD and 856C AWD) . . . . . . . . . 44
Pump and motor components - Calibrate the pump (836C AWD and 856C AWD) . . . . . . . . . . . . . . . 19
Pump and motor components - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pump and motor components - Check the general functions (836C AWD and 856C AWD) . . . . . . . 49
Pump and motor components - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pump and motor components - Prepare the measurement connection (836C AWD and 856C AWD) 53
Pump and motor components - Program - FWD EOL (End of Line) Adjustment (836C AWD and
856C AWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Pump and motor components - Program - FWD Parameter Adjustment (836C AWD and 856C AWD)
...................................................................................... 25
Pump and motor components - Service instruction - General information (836C AWD and 856C
AWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pump and motor components - Test - Setting and Testing the FWD with Creep mode (836C AWD
and 856C AWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pump and motor components - Test the pump pressure cut-off (836C AWD and 856C AWD) . . . . . 17
Pump and motor components - View - FWD System Data (836C AWD and 856C AWD) . . . . . . . . . 31
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47829048B 15/06/2016
EN
SERVICE MANUAL
Brakes and controls
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
33
Contents
Brakes and controls - 33
[33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1
[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2
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33
Hydraulic service brakes - 202
836C AWD
836C
856C AWD
856C
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Contents
TECHNICAL DATA
Hydraulic service brakes

FUNCTIONAL DATA

Hydraulic schematic frame 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Brake pedal control valve
Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Accumulator
Component identification - Reservoir charge valve/shut off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Dynamic description - Reservoir charge valve/shut off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Dynamic description - Warning and signalling equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SERVICE

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Brakes and controls - Hydraulic service brakes
Hydraulic service brakes - General specification

Hydraulic dual-circuit brake system pump-reservoir with 4 wet disk brakes acting on the tandem wheels.

Double pump
Type J. Barnes No. WP1509A2-C- J. Barnes No. WP15A2-C-
190-110-L-05-KA-151/150N-E246 230-160-L-05-KA-151/153N-E246
Flow volume 19 cm³/rev (1.2 in³/rev) 23 cm³/rev (1.4 in³/rev)
Multiple-disk brake
Largest friction diameter 236 mm (9.3 in) 245 mm (9.6 in)
Smallest friction diameter 165 mm (6.5 in) 165 mm (6.5 in)
Number of friction surfaces per wheel 10 8
Number of brake discs 5x4 4x4
Effective brake surface 4 x 2.236 cm² (0.347 in²) 4 x 2.060 cm² (0.319 in²)
Wheel cylinder
Annular surface
Largest diameter 290 mm (11.4 in) 240 mm (9.4 in)
Smallest diameter 260 mm (10.2 in) 228 mm (9.0 in)
Brake/wheel transmission ratio i = 1.0 i = 6.0
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Hydraulic service brakes - Static description

The brake system is made up of
• Service brake
• Park Brake
The grader has a 2-circuit hydraulic brake system with 4 oil-cooled multi-disk brakes acting on the rear wheels.
The brake system is supplied with a constant volume flow through stage 2 of the double gear pump at the diesel
engine.
The brake pressure can be measured at measuring points on the tandem housings. These include a measuring point
for each multi-disk brake.
When a brake application is complete, the brake pressure is released through the brake valve and the return line to
the hydraulic tank is depressurized.
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Hydraulic service brakes - Component identification
SS12E266 1
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2 Reservoir charge valve - shutoff valve 279 Connecting line, shutoff valve - brake valve brake
circuit II
4 Pressure reservoir, 50.0 bar (725.0 psi) preload 280 Connecting line, shutoff valve - brake valve brake
pressure circuit I
10 Double gear pump 281 Brake line, brake valve - tandem, brake circuit I
101 Brake valve 282 Brake line, brake valve - tandem, brake circuit II
102 Pressure switch S18 for brake lights 283 Brake line, brake valve - tandem, brake circuit II
275 Intake line, brake system / fan 284 Brake line, brake valve - tandem, brake circuit I
276 Pressure line, pump - shutoff valve 285 Brake line, brake valve - tandem, brake circuit I
277 Supply line to pressure reservoir, brake circuit I 286 Tank line
278 Supply line to pressure reservoir, brake circuit II 292 Tank line, brake valve
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Hydraulic service brakes - Dynamic description

NOTE: See also Hydraulic service brakes - Component identification (33.202).
The shutoff valve (2) is installed separately on the left under the cab floor. It regulates the pressure-filling of the brake
system nitrogen reservoir (4) to the 50 bar (725.0 psi) preload pressure. If the pressure is at 142 - 150 bar (2059 -
2175 psi), the oil feed is shut off. If the pressure falls to 120 - 128 bar (1740 - 1856 psi), the reservoir is refilled. The
actuation and shutoff pressures can be tested at a measuring point on the shutoff valve (outlet 28).
Two nitrogen reservoirs (4) are mounted on the rear frame, on the front left in the direction of travel. These provide
the reservoir pressure for the two brake circuits. The 3rd nitrogen reservoir (4) is attached directly to the shutoff valve
(2). It dampens switching knocks in the valve and provides additional reservoir pressure to the brake circuits.
The brake valve (101) is actuated directly by the brake pedal. When the brake pedal is operated, a 4 bar (58.0 psi)
pressure switch (102) (S18) at the brake valve (101) activates the power supply to the brake lights. In the brake valve,
the maximum brake pressure is limited to 56 - 64 bar (812 - 928 psi).
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Hydraulic service brakes - Hydraulic schematic frame 01

Pos. Designation Value
2 Reservoir charge valve - shutoff valve
Shutoff pressure 142 - 150 bar (2059 - 2175 psi)
Cut-in pressure 120.0 - 128.0 bar (1740.0 - 1856.0 psi)
4 Pressure reservoir 0.75 l (0.2 US gal)
Preload pressure 50 bar (725.0 psi)
8 Pressure switch 90 bar (1305.0 psi)
10 Double gear pump
11 Steering circuit
12 Internally toothed plate Ø 236 mm (9.3 in)
Operating pressure 56.0 - 64.0 bar (812.0 - 928.0 psi)
13 Parking brake
30 Solenoid valve P-brake, Y 16
33 Pressure switch 80 bar (1160.0 psi)
101 Brake valve 60 bar (870.0 psi)
102 Brake light switch 4 bar (58.0 psi)
M6 Measuring connection
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Brake diagram 836C and 836C AWD
SS12K538 1
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Brake diagram 856C and 856C AWD
SS12K539 2
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Hydraulic service brakes - Component localization

Components under cab floor
Pos. Designation
2 Reservoir charge valve – shutoff valve with
pressure reservoir
101 Brake valve
SS12E275 1
Brake valve
Pos. Designation
101 Brake valve
279 to reservoir charge valve – shutoff valve
280 to reservoir charge valve – shutoff valve
281 to multi-disk brakes
292 to parking brake solenoid valve
S18 Pressure switch for brake lights
SS12E276 2
Reservoir charge valve – shutoff valve

Pos. Designation
2 Reservoir charge valve – shutoff valve
4 Pressure reservoir 50 bar (725.0 psi)
276 from double gear pump
277 to pressure reservoir 50 bar (725.0 psi)
278 to pressure reservoir 50 bar (725.0 psi)
279 to brake valve
280 to brake valve
289 to solenoid valve P-brake
350 Hydraulic motor combination cooler
S17.1 Pressure switch – “brake reservoir pressure”
warning light
SS12E277 3
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Double gear pump

The double gear pump is flange-mounted on the left of the
engine.
Pos. Designation
10a Gear pump for steering system
10b Gear pump for brake system
275 Suction line – from hydraulic fluid tank
276 Pressure line – to reservoir charge valve –
shutoff valve (2), see figure 3.
SS12E278 4
Hydraulic brake line 282 – 285

Pos. Designation
282 from brake valve 2.2 – to rear left multi-disk
brake
283 from brake valve 2.2 – to rear right multi-disk
brake (not shown)
284 with green marking – brake valve 2.1 – through
hydraulic hose (281) to front left multi-disk brake
285 with green marking – brake valve 2.1 – through
hydraulic hose (281) to front right multi-disk
brake (not shown)
5
Hydraulic hoses fastened with hose clamp at a distance SS13J028
of L = 380 mm (15.0 in).
Measuring connections M7 – M8
Pos. Designation
M7 Measuring connection for front multi-disk brake
(not shown)
M8 Measuring connection for rear multi-disk brake
Measured operating pressure = 56.0 - 64.0 bar (812.0 -

928.0 psi)
SS12E280 6
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Brake pedal control valve - Component identification
SS12K534 1

A Spring pack 1.1 Shutoff valve inlet
B Pedal 1.2 Shutoff valve inlet
C1 Control valve 2.1 Front brake circuit
C2 Control valve 2.2 Rear brake circuit
D Pedal stop screw 2.4 Blind
E ? 2.5 Brake light switch 4 bar (58 psi) connection
L ? 5.1 Return line to tank
M ? 5.2 Return line to tank
N ?
P ?
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Brake pedal control valve - Dynamic description

Purpose
The function of the brake valve is to increase/decrease the brake pressure with precision when the step plate (or
operating lever) is actuated.
NOTE: Refer also to Brake pedal control valve - Component identification (33.202).
Ready position
When the brake system is in ready position, the reservoir pressure is applied directly to the Connection (1.1) / (1.2)
of the foot-brake valve.
There is a connection between the connections (2.1) / (2.2) and the connections (5.1) / (5.2), so that the wheel brakes
(connections (2.1)./ (2.2) are depressurized through the return lines (connections (5.1) / (5.2)).
Partial braking
When the brake valve is operated, hydraulic brake pressure is applied in proportion to the force applied with the foot.
The spring assembly (A) under the carrier plate (E) is designed so that brake pressure varies according to angle
position.
In the lower brake pressure range, vehicle braking is applied in fine steps. When the brake is applied, the upper slide
value (C1) is actuated mechanically by the spring assembly (A) and the lower slide valve (C2) is actuated hydrauli-
cally by the slide valve (C1). The slide valves (C1) and (C2) move backward and, with the control edges, close the
return lines (5.1) / (5.2) first, then connect the reservoir connections (1.1) / (1.2) to the wheel brake cylinder connec-
tions (2.1) / (2.2). The level of brake pressure depends on the foot pressure applied. The control valves (C1) and
(C2) are held in control position (equilibrium) by the foot pressure (spring assembly) through the slide valves and the
hydraulic pressure under the slide valves. When brake pressure is released, the slide valves (C1) and (C2) are in
partial braking position, so that the connections (1.1) / (1.2) and (5.1) / (5.2) are closed and hold the pressure applied
at the connections (2.1) / (2.2).
Full brake position

When the pedal (B) is applied fully, the brake end position is reached and the reservoir connections (1.1) / (1.2) are
connected to the brake cylinder connections (2.1) / (2.2). The return lines (5.1) / (5.2) are then shut off.
When brake application is ended, the brake cylinder connections (2.1) / (2.2) are connected again to the return line
connections (5.1) / (5.2) and the reservoir connections (1.1) / (1.2) are closed.
Because of the slide valve arrangement, if one of the brake circuits fails, the other one remains fully functional. This
is due to the mechanical actuation of both slide valves, which requires a little more pedal travel.
Brake pressure limiting

The pedal stop screw (D) at the carrier plate (E) under the step plate (B) is used to limit the brake pressure.
Circuit failure
If the lower brake circuit fails, the upper circuit remains functional. The slide valve (C1) is actuated mechanically by
the spring assembly (A). If the upper circuit fails, the lower circuit remains functional. In this case, the lower slide
value (C2) is actuated mechanically by the spring assembly (A) and the slide valve (C1) is actuated.
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Accumulator - Component identification - Reservoir charge

valve/shut off valve
SS12E270 1

A Main slide valve 1 Energy flow
B Control slide valve with 2 detent positions 5 Energy outflow
C Spring pack 21 Service brake (circuit I)
D Check valve 22 Service brake (circuit II)
E1 Locking positions 23 Service brake (circuit III)
E2 Locking positions 27 Hydraulic pressure reservoir
F Connecting hole 28 Pressure switch
G Hole
H Check valves for brake valve
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Accumulator - Dynamic description - Reservoir charge valve/shut

off valve
Purpose
The function of the shutoff valve is to regulate the pressure level in the pressure reservoirs.
Ready position
When the brake system is ready (i.e. the reservoirs are filled), the pump flow is applied directly to the connection
(1) of the shutoff valve. There is a connection between connection (1) and connection (5), so that the pump flow is
transmitted directly to the steering system with a low pressure differential. The return line chamber of the main slide
valve (A) is depressurized. The brake system pressure holds the control valve (B) in locked position (E1), in which the
return chamber of the main slide valve (A) is connected directly to the outlet (5) through a hole (G).Check valve (D) in
the hole to connection (27) protects the shift reservoir pressure. This provides additional brake volume to the brake
system and prevents over-frequent switching of the equipment due to leak oil. The check valves (H) also protect each
brake circuit from pressure loss if there is a break in the line.
NOTE: Refer also to Accumulator - Component identification - Reservoir charge valve/shut off valve (33.202).
SS12E271 1
• Control valve (B) in locked position (E1)

• Hydraulic pressure reservoir filled, shutoff pressure 142 - 150 bar (2059 - 2175 psi) reached
• (F) and (D) closed
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Charging process
If the reservoir pressure falls to the specified 120 bar (1740.0 psi) value, the control valve (B) overrides the existing
locking position (E1) with the force of the spring assembly (C) and engages in another locking position (E2). Oil flows
through the connecting hole (F) into the return chamber of the main slide valve (A). The pressure built up in the return
chamber of the main slide valve (A) and the pressure applied under the main slide valve (A) shift the main slide valve
(A) to floating position, so that there is a partial flow through the outlet (5) to the steering system and a residual flow
through the check valve (D) to the connections (21), (22), and (23) and to the brake system, until the pressure in the
brake system is about 150 bar (2175.0 psi). The control valve (B) engages in locking position (E1), which sets up a
connection between connection (1) and connection (5). All of the pump flow now flows directly to the steering system.
The check valve (D) again protects the shift reservoir pressure.
SS12E272 2
• Control valve (B) in locking position (E2)

• Main slide valve (A) in floating position
• (F) / (D) open
• Cut-in pressure 120 - 128 bar (1740 - 1856 psi) reached
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Accumulator - Dynamic description - Warning and signalling

equipment
Pressure switch (8, S17.1)
The output (DS2) of the pressure switch S17.1 is mounted on the left of the brake reservoir charge valves. The
pressure switch is set to 90 bar (1305.0 psi). If reservoir pressure falls below 90 bar (1305.0 psi), the pressure switch
closes and warns the driver that brake reservoir pressure is too low by means of the "brake reservoir pressure" warning
lamp on the control console, and by a continuous buzzer if the engine is running. When the reservoir is charging, the
pressure switch switches off the warning signals only when pressure has reached 115 bar (1667.5 psi).
Pressure switch (33, S16.1)

The pressure switch (33) is mounted in the supply line to the pressure reservoir of the parking brake. The switch is
closed if the pressure in the P-brake hydraulic circuit is over 80 bar (1160.0 psi). This causes the "Parking brake"
indicator lamp on the control console to go off.
Pressure switch (102, S18)

The pressure switch (102) is located on the right of the brake valves at the outlet (2.5). If the pressure in the brake
circuit 2 rises above 4 bar (58.0 psi), the pressure switch closes and the brake lamps come on.
SS12E274 1
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Hydraulic service brakes - Remove

NOTE: For all work on the brake system, proceed as follows:
1. Park the grader on stable level ground.
2. Lower the working equipment.
3. Secure the grader with wheel chocks.
4. Drain off the hydraulic fluid, or use a vacuum pump.
5. Mark the hydraulic lines that are to be disconnected.
NOTICE: A little amount of hydraulic fluid may flow out of the hydraulic lines when these are disconnected and con-
nected. This should be collected and properly disposed of.
6. Protect detached hydraulic lines and components from
dirt.
7. After the installation work, check the brake system for
leaks.
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Hydraulic service brakes - Bleed

WARNING
Unexpected machine movement!
Make sure that you secure the machine with wheel chocks before you perform this procedure.
W1221A
NOTE: Bleeding is always necessary if a brake system component was changed (brake valve, brake lines,.....). Also
after repair or leakage of brake system components, or after hydraulic oil change.
1. Secure the machine.
2. Attach a “DO NOT OPERATE” maintenance tag. This
tag has to be applied to both cab doors or to the steering
wheel.
SS12C522 1
3. Apply the parking brake.

4. Remove the plastic caps from all four air-bleeders. Two
on the left-hand side and two on the right-hand side
above the wheel hubs.
SVIL14GRD0024AA 2
WARNING
Before you start the engine, put the gearshift
lever in the neutral position. Be aware that the
gearshift lever will remain in the neutral posi-
tion throughout the complete bleed-off proce-
dure.
Failure to comply could result in death or seri-
ous injury.
W1388A

6. Check that all-wheel (option) is deactivated.
7. Keep the engine speed at high idle until brake accumu-
lators are fully charged.
8. Run the engine at low idle.
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9. Fully depress the brake pedal three times in 5 s cycles.
SVIL14GRD0022AA 3
10. To avoid oil contamination connect the first air-bleeder

with suitable hose and lay the other hose end to any
collection container.
11. With the brake pedal partially depressed, open the
first bleed screw (use a 13-jaw wrench, apply a 1/2
rotation counter clockwise). Hold the brake pedal in
position until the oil is clear (no bubbles). Close the
bleed screw. Remove the overflow hose.
SVIL14GRD0023AA 4
12. Repeat successively step 10 and 11 on the other three

air-bleeders.
13. Check the hydraulic fluid level at the hydraulic tank
and add if necessary.
14. Stop the engine.
15. Assemble the plastic caps and all four air-bleeders.
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Index

Accumulator - Component identification - Reservoir charge valve/shut off valve . . . . . . . . . . . . . . . . 15
Accumulator - Dynamic description - Reservoir charge valve/shut off valve . . . . . . . . . . . . . . . . . . . . 16
Accumulator - Dynamic description - Warning and signalling equipment . . . . . . . . . . . . . . . . . . . . . . . 18
Brake pedal control valve - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Brake pedal control valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Hydraulic service brakes - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hydraulic service brakes - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic service brakes - Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydraulic service brakes - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic service brakes - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic service brakes - Hydraulic schematic frame 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic service brakes - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Hydraulic service brakes - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Parking brake or parking lock - 110
836C AWD
836C
856C AWD
856C
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Contents
TECHNICAL DATA
Parking brake or parking lock

FUNCTIONAL DATA
Parking brake or parking lock

Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Parking brake caliper
Dynamic description - FSG 88 (spring loaded) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE
Parking brake caliper

Service instruction - Emergency release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install - FSG 88 (spring loaded) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Adjust - Air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Replace - Brake lining carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Replace - Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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Brakes and controls - Parking brake or parking lock
Parking brake or parking lock - General specification

A disk brake located at the rear output shaft of the power shift transmission is used as the parking brake. This is
locked in the neutral position by spring force (spring load principle).

Type FSG 88
Brake disk diameter 380 mm (15.0 in)
Brake disk thickness 12.50 - 12.70 mm (0.49 - 0.50 in)
Effective lining contact surface 102 cm² (15.8 in²)
Effective brake disk radius 167.5 mm (6.6 in)
Clamping force with 1 mm (0.039 in) 34000 N (7643.5 lb)
air gap
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Parking brake or parking lock - Component identification
SS12E267 1
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2 Reservoir charge valve - shutoff valve 275 Intake line, brake system / fan
10 Double gear pump 276 Pressure line, pump - shutoff valve
30 Solenoid valve P-brake, Y 16 286 Tank line
31 Pressure reservoir, 90 bar (1305.0 psi) preload 287 Supply line, pressure switch - parking brake
pressure
32 Pressure reservoir, 30 bar (435.0 psi) preload 288 Supply line, solenoid valve - pressure switch
pressure
33 Pressure switch 80 bar (1160.0 psi), S 16.1 289 Supply line, shutoff valve - T-piece for supply
lines (290) and (291)
39 Return restrictor ∅ = 0.8 mm (0.0315 in) 290 Supply line, shutoff valve - solenoid valve P-brake
65 P-brake locking switch, S 16 291 Supply line, shutoff valve - 90 bar (1305.0 psi)
pressure reservoir
101 Brake valve
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Parking brake or parking lock - Dynamic description

NOTE: See also Parking brake or parking lock - Component identification (33.110).
A disk brake located at the rear output shaft of the power shift transmission is used as the parking brake. This is
locked in the neutral position by spring force (spring load principle).
Like the service brake, the parking brake is supplied with volume flow by the double gear pump (10).
The shutoff valve (2) regulates the pressure-filling of the parking brake nitrogen reservoir (31) (on the right side in
direction of travel) to the 90 bar (1305.0 psi) preload pressure, and supplies oil to the P channel of the solenoid valve
Y 16, (30).
If the solenoid valve (30) is actuated, the 30 bar (435.0 psi) pressure reservoir (32) is filled, and then brake cylinder
P brake is supplied with oil. The parking brake is released.
When the solenoid valve is in the de-energized state, the brake cylinder is connected to the tank. The 30 bar
(435.0 psi) pressure reservoir (32) and the return line restrictor (39), ∅ = 0.8 mm (0.0315 in), installed in the tank
channel of the valve, control the flow of the hydraulic fluid from the brake cylinder. The parking brake is engaged
(brake movement is dampened) and locked.
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Parking brake or parking lock - Component localization

Pos. Designation
30 Solenoid valve P-brake Y 16
32 Pressure reservoir, 30 bar (435.0 psi)
39 Throttle valve
287 Hydraulic hose from parking brake pressure
switch
288 Hydraulic hose from P-brake solenoid valve to
pressure switch
S16.1 Pressure switch 80 bar (1160.0 psi)
SS12E281 1
Parking brake switch

The switch (S16) for the parking brake is located on the
front console.
NOTE: For more information, refer to Instrument cluster
- Component identification (55.512).
SS14E219 2
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Parking brake caliper - Dynamic description - FSG 88 (spring

loaded)
NOTE: The following instructions are taken directly from the manufacturer's original instructions.
NOTE: Therefore, ZF Passau GmbH and CASE CONSTRUCTION will not be liable for any errors in the assembly
instructions, and especially cannot be responsible for providing the user with more accurate information through a
new edition.
SS13J029 1

1 Housing 8 Brake lining carrier
2 Thrust ring 9 Guide pin
3 Thrust pin 10 Rubber spring element
4 Adjusting screw 11 Setting screw
5 Disk spring pack 12 Lining spring
6 Piston 13 Lock nut
7 Brake lining carrier
The two identical brake lining carriers (7) and (8) slide along the bearing surfaces in the top of the housing and are
held in position by a lining spring (12). The brake itself is bolted directly onto the vehicle transmission or axle by the
two guide pins (9).
The brake is positioned axially by the two rubber spring elements (10) between the brake housing and the guide pins
(9), and setting screw (11).
When the brake is operated (closed), a clamping force is produced at the brake lining carriers (7) and (8), and trans-
ferred to the brake disk. This causes the disk spring pack (5), piston (6) and adjusting screw (4), thrust pin (3,) and
brake lining carriers (7) to move towards the brake disk. If the brake lining carrier (7) comes into contact with the brake
disk, the reaction force pushes the brake onto guide pins (9), against the spring force of rubber spring elements (10),
until the second brake lining carrier (8) is also pressed against the brake disk. The braking effect (braking torque)
depends on the friction coefficient of the brake linings.
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The brake is released by the full pre-loading of the disk spring pack (5). The required minimum release pressure
causes the piston (6) back to the stop on the thrust ring (2).
During this process, the brake is moved by the two rubber spring elements (10) to the position set by the setting screw
(11). An equal air gap on both sides of the brake disk can only be ensured by proper adjustment.
Wear on the brake linings (7) and (8) and on the brake disk causes the clamping force to be reduced. In this case,
the brake must be adjusted.
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Parking brake caliper - Service instruction - Emergency release

WARNING
W1221A
NOTE: If the pressure supply fails, the parking brake can

be released mechanically.
SS12J177 1

1 Locknut G Ring spanner
2 Adjusting screw S Allen key
1. Loosen the screw cap by turning anti-clockwise, and

remove it.
2. Loosen the locknut (1) and unscrew it till it reaches the
end of the adjusting screw (2).
3. Turn the adjusting screw (2) anti-clockwise until the
brake disk is completely free.
NOTE: For emergency release, a minimum torque of
70 N·m (51.6 lb ft) must be applied to the adjusting screw
(2).
4. Screw in the locknut (1) up to the piston position and
slightly tighten with the adjusting screw (2).
5. Turn the screw cap clockwise by several thread turns.
(To protect from dirt).
NOTE: The brake must be set before starting up again.
Refer to Parking brake caliper - Install - FSG 88 (spring
loaded) (33.110), Parking brake caliper - Adjust (33.110)
and Parking brake caliper - Adjust - Air gap (33.110).
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Parking brake caliper - Install - FSG 88 (spring loaded)

WARNING
W1221A
WARNING
Hot surface possible!
Wait for all components to cool before performing any operation.
W0251A
NOTE: The brake is supplied by KNOTT GmbH as shown in the drawing. For the procedure for mounting the brake
on the transmission housing refer to Output shaft - Assemble - Output flange (21.155).
SS13J030 1

1 Locknut 6 Thrust pin
2 Adjusting screw 7 Guide pin
3 Setting screw 8 Bleed valve
4 Lock nut 9 Piston
5 Screw cap 10 Spring pack
1. Turn the screw cap (5) anti-clockwise and remove it.
2. Loosen the locknut (1) and turn the adjusting screw (2)
anti-clockwise until the plane surface of the thrust pin
(6) is against the piston (9).
3. In this way, you are pushing the brake across the brake
disk.
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4. Screw the two guide pins (7) into the transmission

housing, according to the assembly instructions of the
manufacturer of the transmission.
5. Make the pressure connection.
6. Apply the required release pressure to the brake (min.
130 bar (1885.0 psi)), in order to preload the disk
spring pack (10) fully at the end stop.
7. Vent the brake using the bleed valve (8).
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Parking brake caliper - Adjust

WARNING
W1221A
SS13J030 1

4 Lock nut 9 Piston
1. Release the parking brake by applying the required re-
lease pressure (min. 130 bar (1885.0 psi).
2. Turn the screw cap (5) anti-clockwise and remove it.
3. Loosen the locknut (1) of the adjusting screw (2).
4. On both sides between the brake lining carrier and the
brake disk, place a setting gauge and hold it in position.
NOTE: The setting gauge must be selected as indicated in
the table Air gap setting. Refer to Parking brake caliper -
Adjust - Air gap (33.110).
5. Turn the adjusting screw (2) clockwise until the two set-
ting gauges become clamped between brake lining car-
rier and brake disk.
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6. Lock the adjusting screw (2) using the locknut (1).

NOTE: The force used to clamp the setting gauges must
be chosen so that, after locking, the two gauges can be
removed again without having to apply too much force.
7. Loosen the locknut (4) and turn the setting screw (3)
clockwise until the front surface of the setting screw (3)
is against the surface provided for adjustment.
8. Hold the setting screw (3) in position and lock it with the
locknut (4).
9. Remove the setting gauges from both sides of the
brake disk.
10. Turn the screw cap (5) clockwise and hand-tighten it.
NOTE: Adjustment of the desired air gap is now complete.
The brake is now ready to operate.
NOTE: Operate the brake valve several times and check
the holding action of the parking brake on a suitable slope
or gradient.
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Parking brake caliper - Adjust - Air gap

WARNING
W1221A
SS13J030 1

4 Lock nut 9 Piston
Version Air gap Setting gauge

Minimal air gap 0.5 mm (0.02 in) 0.25 mm (0.01 in)
FSG 88 Nominal air gap 1 mm (0.04 in) 0.5 mm (0.02 in)
Maximal air gap 1.5 mm (0.06 in) 0.75 mm (0.03 in)
1. On both sides between the brake lining carrier and

brake disk, place a setting gauge and hold it in posi-
tion.
NOTE: The thickness of the setting gauge must be ad-
justed for the desired air gap.
2. Turn the adjusting screw (2) clockwise until the two set-
ting gauges become clamped between brake lining car-
rier and brake disk.
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3. Hold the adjusting screw (2) in position and lock it with

the locknut (1).
NOTE: The force used to clamp the setting gauges must
be chosen so that, after locking, the two gauges can be
removed again without having to apply too much force.
4. Loosen the locknut (4) and turn the setting screw (3)
clockwise until the front surface of the setting screw (3)
is against the surface provided for adjustment.
5. Hold the setting screw (3) in position and lock it with the
locknut (4).
6. Remove the setting gauges from both sides of the
brake disk.
7. Turn the screw cap (5) clockwise and hand-tighten it.
NOTE: Brake installation and setting of the desired air gap
is now complete. The brake is now ready to operate.
NOTE: To check the air gap and test the brake function,
apply and release the brake several times.
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Parking brake caliper - Replace - Brake lining carrier

WARNING
W1221A
NOTE: Depending on the type of application and use of the vehicle, the brake, and particularly the brake lining carriers,
must be submitted to a regular visual inspection. If there is little lining thickness remaining, the inspection intervals
should be shortened in order to avoid greater damage to the brake and/or brake disk.
NOTE: Use only KNOTT original replacement parts. If other replacement parts are used, KNOTT will no longer be
liable under warranty for the brake or brake function.
SS14A001 1

1 Locknut R Ring spanner
2 Adjusting screw S Allen key
3 Thrust pin S1 Screwdriver
4 Piston
NOTE: If the minimum lining thickness of 1 - 1.5 mm (0.04 - 0.06 in) is reached in each brake lining carrier, the brake
lining carrier must be replaced.
lease pressure (min. 130 bar (1885.0 psi)).
remove it.
thrust pin (3) can be pressed fully into the piston (4).
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5. Using a suitable screwdriver, turn (or lever) the thrust

pin (3) back up to the position at the piston (4).
6. Loosen the locknut and turn the setting screw out of the
brake housing.
NOTE: The lining spring (5) is pre-loaded. The lining spring
(5) must be held in position with a suitable tool during the
removal of the setting screw (2).
SS12J179 2

1 Lock nut 4 Brake lining carrier
2 Setting screw 5 Lining spring
3 Brake lining carrier
7. Remove the lining spring (5).

8. Take the two brake lining carriers (3) and (4) out of the
lining groove in the brake housing.
NOTE: If it is not possible to change the brake lining car-
riers (3) and (4) by the above method (insufficient room),
the brake must be removed completely.
NOTE: Check the pressure line. If the pressure line is too
short, it must be unscrewed in order to allow the brake to be
removed. Before detaching the pressure line, carry out an
emergency release of the parking brake. Refer to Parking
brake caliper - Service instruction - Emergency release
(33.110).
9. Change the brake lining carrier (3) and (4).
10. Press the lining spring (5) in position with a suitable
tool while screwing in the setting screw (2).
NOTE: After repairing or changing the brake lining carriers
(3) and (4), the brake must be adjusted.
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Parking brake caliper - Replace - Seals

WARNING
W1221A
Remove:
lease pressure (min. 130 bar (1885.0 psi)).
NOTE: If the required release pressure (min. 130 bar
(1885.0 psi)) cannot be applied to the brake because of
heavy leaking, an emergency release of the parking brake
MUST be carried out. Refer to Parking brake caliper -
Service instruction - Emergency release (33.110).
SS13J032 1

1 Piston 6 Seal
2 Adjusting screw 7 Thrust ring
4 Housing 9 Disk spring pack
5 Circlip 10 Dust cap
remove it.
thrust pin (8) can be pressed fully into the piston (1).
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5. Using a suitable screwdriver, turn (or lever) the thrust

pin (8) back up to the position at the piston (1).
6. Operate the brake valve and lower the release pressure
to 0 bar (0.0 psi).
NOTE: All tension has now been released from disk spring
pack (9).
7. Unscrew the pressure line and remove the brake com-
pletely.
8. Remove the circlip (5) and take the thrust ring (7) out
of housing (4).
9. Remove the disk spring pack (9) and the piston (1).
10. In all cases, change the two seals (A) and (B).
NOTE: Note the installation direction of the grooved rings,
and use a suitable mounting needle with rounded edges to
install the new grooved rings.
11. Also change the dust cap (10) if necessary.
NOTE: The dust cap (10) has a vulcanized steel ring, which
is used to press the cap into the mounting hole in the brake
housing (4).
To change the cap, use a suitable tool to pry it out, then
use a mounting device to press it into the housing (4).
NOTE: If defects or damage are found in any parts not
listed here, these must of course be repaired or replaced
with original KNOTT spare parts.
For more information or more detailed instructions, please
contact your authorized dealer.
Installation:
1. Install the disk spring pack (9) and the piston (1).
2. Install the circlip (5) and put the thrust ring (7) in the
housing (4).
3. Screw the pressure line and install the brake com-
pletely.
4. Install the locknut (3) of the adjusting screw (2).
5. Install the screw cap.
Next operation:
Parking brake caliper - Adjust (33.110).
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Index

Parking brake caliper - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Parking brake caliper - Adjust - Air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Parking brake caliper - Dynamic description - FSG 88 (spring loaded) . . . . . . . . . . . . . . . . . . . . . . . . . 8
Parking brake caliper - Install - FSG 88 (spring loaded) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Parking brake caliper - Replace - Brake lining carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Parking brake caliper - Replace - Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Parking brake caliper - Service instruction - Emergency release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Parking brake or parking lock - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Parking brake or parking lock - Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Parking brake or parking lock - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Parking brake or parking lock - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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47829048B 15/06/2016
EN
SERVICE MANUAL
Hydraulic systems
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
35
Contents
Hydraulic systems - 35
[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1
[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2
[35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3
[35.102] Pump control valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4
[35.105] Charge pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5
[35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6
[35.354] Hydraulic central joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7
[35.739] Swing arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8
[35.741] Dozer blade cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9
[35.742] Ripper hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10
[35.310] Distributor and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.11
47829048B 15/06/2016
35
836C AWD
836C
856C AWD
856C
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35.1 [35.000] / 1
Contents
TECHNICAL DATA
Hydraulic systems
FUNCTIONAL DATA
Hydraulic systems
Dynamic description - Main functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic schematic frame 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydraulic schematic frame 02 - Floating position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Hydraulic schematic frame 03 - Front-wheel drive (836C AWD and 856C AWD) . . . . . . . . . . . . . . . . . . . 26
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Hydraulic systems - Hydraulic systems
Hydraulic systems - General specification

Implement pump
Pump A 10 VO 45 DFR A 10 VO 60 DFR1
Flow volume Vg max. 45 cm³ (2.7 in³) 60 cm³ (3.7 in³)
Pump for front wheel drive (for 836C AWD/856C AWD only)
Designation 836C AWD 856C AWD
Type A4VG 56EP2 AV4VG 71 EP2
Displacement 0 - 56 cm³/rev (0.0 - 3.4 in³/rev) 0 - 71 cm³/rev (0.0 - 4.3 in³/rev)
Radial piston motor (for 836C AWD/856C AWD only)

Designation 836C AWD 856C AWD
Type MS8 MS11
Min. displacement 428 cm³ (26.1 in³) 629 cm³ (38.4 in³)
Max. displacement 857 cm³ (52.3 in³) 1229 cm³ (75.0 in³)
Motor for blade turning gear

Type OMR 80 OMR 100
Displacement 80.3 cm³ (4.9 in³) 99.8 cm³ (6.1 in³)
Weight 6.9 kg (15.2 lb) 7 kg (15.4 lb)
Max. RPM 750 RPM 600 RPM
Max. torque 155 N·m (114.3 lb ft) 200 N·m (147.5 lb ft)
Max. oil flow 60 l/min (15.9 US gpm) 60 l/min (15.9 US gpm)
Max entry pressure 140 bar (2030.0 psi) 140 bar (2030.0 psi)
Min. starting torque 130 N·m (95.9 lb ft) 170 N·m (125.4 lb ft)
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Cylinder on 836C/836C AWD

Cylinder Piston ø Piston rod ø Stroke
Blade lift cylinder 70 mm (2.8 in) 40 mm (1.6 in) 870 mm (34.3 in)
Blade swivel cylinder 70 mm (2.8 in) 40 mm (1.6 in) 348 mm (13.7 in)
Blade translational movement 70 mm (2.8 in) 40 mm (1.6 in) 1200 mm (47.2 in)
cylinder
Pitch adjustment cylinder 80 mm (3.1 in) 45 mm (1.8 in) 260 mm (10.2 in)
Articulation cylinder 80 mm (3.1 in) 45 mm (1.8 in) 319 mm (12.6 in)
Rear ripper cylinder (optional) 70 mm (2.8 in) 40 mm (1.6 in) 870 mm (34.3 in)
Front grading plate cylinder 100 mm (3.9 in) 50 mm (2.0 in) 360 mm (14.2 in)
(optional)
Wheel lean cylinder 70 mm (2.8 in) 38 mm (1.5 in) 157 mm (6.2 in)
Steering cylinder 45 mm (1.8 in) 22 mm (0.9 in) 250 mm (9.8 in)
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Cylinder on 856C/856C AWD

Cylinder Piston ø Piston rod ø Stroke
Blade lift cylinder 100 mm (3.9 in) 50 mm (2.0 in) 1010 mm (39.8 in)
Blade swivel cylinder 100 mm (3.9 in) 50 mm (2.0 in) 450 mm (17.7 in)
Blade translational movement 80 mm (3.1 in) 45 mm (1.8 in) 1400 mm (55.1 in)
cylinder
Pitch adjustment cylinder 100 mm (3.9 in) 50 mm (2.0 in) 300 mm (11.8 in)
Articulation cylinder 100 mm (3.9 in) 50 mm (2.0 in) 367 mm (14.4 in)
Rear ripper cylinder (optional) 100 mm (3.9 in) 50 mm (2.0 in) 1010 mm (39.8 in)
Front grading plate cylinder 120 mm (4.7 in) 60 mm (2.4 in) 428 mm (16.9 in)
(optional)
Wheel lean cylinder 80 mm (3.1 in) 45 mm (1.8 in) 203 mm (8.0 in)
Steering cylinder 50 mm (2.0 in) 25 mm (1.0 in) 301 mm (11.9 in)
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Hydraulic systems - Component identification

Working equipment
The working equipment is adjusted hydraulically by the following components:
• Moldboard extend cylinder
• Hydraulic motor of blade rotation mechanism
• Moldboard swing cylinder
• Stop bolt cylinder
• Blade lift cylinder, right
• Blade lift cylinder, left
• Pitch adjustment cylinder
• Articulated-frame-steering cylinder
• Rear ripper cylinder (optional)
• Dozer blade cylinder (optional)
Steering/front drive (836C AWD and 856C AWD)

The steering/front drive is adjusted hydraulically by the following components:
• Wheel lean cylinder
• Steering cylinder
• Radial piston motor right/left
Hydraulics system oil cooling

The fan drive oil circuit consists of the following components:
• Double gear pump
• Shutoff valve
• Fan motor
• Hydraulic fluid tank
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SS14E220 1

1 Wheel lean cylinder 8 Pitch adjustment cylinder
2 Moldboard extend cylinder 9 Articulated-frame-steering cylinder
3 Hydraulic motor of blade rotation mechanism 10 Rear ripper cylinder (optional)
4 Moldboard swing cylinder 11 Dozer blade cylinder (optional)
5 Stop bolt cylinder 12 Steering cylinder
6 Blade lift cylinder, right 13 Radial piston motor, right/left
7 Blade lift cylinder, left
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Hydraulic systems - Static description

Intended use
The hydraulic system receives control signals from the driver and converts them to hydraulic power values, which are
used by the valve and/or hydraulic cylinders to drive the working equipment.
The hydraulic equipment consists mainly of a hydraulic system that generates all the hydraulic power, and various
hydraulic circuits for the:
• Brake
• Steering
• Working equipment control
• Front drive (836C AWD and 856C AWD)
Drive unit
The drive unit consists mainly of the diesel engine (1),
transmission (2), adjustment double pump (3) and (4),
double gear pump (5), and hydraulic fluid reservoir (6).
The diesel engine (1) is an IVECO engine from the "New

Engine Family" (abbreviation NEF). It is a 6-cylinder
in-line engine with turbocharger and downstream charge
air cooler. Emission values correspond to Emissions
Level 3 (TIER 3).
The power shift transmission (2) is driven by the engine.

The adjustment double pump is flange-mounted on the
live power take-off (PTO). On all-wheel machines, it
consists of the all-wheel pump (3) A4VG and the working SS12E284 1
pump (4) A10VO. On the standard machine, only the
working pump is installed.
A double gear pump (5) for the brake, steering and fan cir-
cuits is attached to the diesel engine PTO. The hydraulic
pumps installed in grader models differ only in layout and
displacement volume. The hydraulic fluid reservoir (6)
supplies the pumps with clean, cooled oil. The feed pump
integrated with the all-wheel system pump draws in fluid
through the connection S. The working pump has a sep-
arate oil intake line.
SS12E285 2
SS12E286 3
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Hydraulic systems - Dynamic description - Main functions

General information
The hydraulic system is divided into the following areas:
• Working hydraulics
• Brakes / steering
• Oil cooling
• All-wheel drive (836C AWD and 856C AWD)
Working equipment
The working equipment is adjusted hydraulically by the hydraulic cylinders, which are controlled by the operator
through the control blocks.
All-wheel drive (836C AWD and 856C AWD)

On Graders 836C AWD and 856C AWD, a front wheel drive can be engaged in addition to the rear axle drive.
Brakes / steering
Please refer to Hydraulic service brakes - General specification (33.202) for the brake and Hydraulic control
components - General specification (41.200) for the steering.
Oil cooling
The fan drive oil circuit consists of the following components:
• Double gear pump
• Shutoff valve
• Fan motor
The fan drive oil circuit is part of the brake and fan circuit. Oil is supplied at stage 1 of the double gear pump (Dis-
placement value = 19 cm³ (1.2 in³) (for 836C/836C AWD) or 23 cm³ (1.4 in³) (for 856C/856C AWD)). This delivers oil
to the shutoff valve, which supplies the fan motor according to the oil requirement of the brake system.
The fan motor consists of a fixed-displacement motor with a specific direction of rotation (left-hand). It is equipped
with a pressure-limiting valve cartridge.
The pressure relief valve controls the maximum pressure in the fan motor. The opening pressure is adjusted according
to the required cooling output.
The speed at the fan wheel at high idle speed and with the hood closed is 1840 - 1860 RPM.
If there is insufficient oil supply through the motor's P channel, an integrated replenishing valve allows oil intake from
the hydraulic fluid tank.
A measurement coupling is provided on the motor housing for monitoring the prevalent pressure level. The oil return
from the fan motor passes directly through a hose to the tank.
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SS12E293 1

1 Hydraulic fluid tank 4 Fan hydraulic motor
2 4-circuit cooler 350 Supply line to fan motor
3 Reservoir charge & shutoff valve 351 Tank line
Special functions
Working speed adjustment
• The working speed of the working equipment can be accelerated using a fast-feed circuit. The full effect of the
fast-feed circuit is obtained only at the higher rotational speeds. The working equipment operates at higher speed
as long as the fast-feed button is pressed and held.
Emergency lowering function

• It must be possible to raise or lower the grader's working equipment even when there is an engine fault. Emergency
lowering of the blade can be actuated by operating the valves mounted on the blade lift cylinders (right and left).
If the machine is equipped with front scraper blade and/or rear scarifier, emergency lowering is actuated with the
control lever.
Blade floating position

• For the grader, a floating position can be provided as an optional feature. The floating position makes it easier to
work when clearing snow, for example, as it allows the main blade to ride over irregular surfaces.
How It Works
Front-wheel drive
The hydraulic system consists essentially of an adjustable axial piston pump (A4VG), two radial piston motors (MS11),
one feed pump (gear pump), 4/2 and 6/2-way valve, and a flow divider. These main components operate in a closed
circuit and form the hydrostatic drive for the front wheels. The displacement volume of the axial piston pump is con-
trolled by the proportional solenoid valve. The functional relationships between individual components are shown on
the hydraulic diagram.
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Working hydraulics
The working hydraulics consist of a load-sensing system. Oil is supplied by an adjustment pump, which is controlled
according to the requirement (load sensing) through control blocks actuated directly. Two hydraulic functions can be
operated at the same time. These functions have no effect on each other.
The hydraulic system is protected from overload by pressure-limiting valves. The double pump ( (5) draws hydraulic
fluid from the hydraulic tank (4)) mounted at the back of the rear frame. It supplies the LS valve block (6) with pressure
oil through the hose line (201). The line (205) from the LS valve block is used as the LS signal line and leads directly
to the pressure displacement controller of the double pump. The pump leak oil can flow directly back to the tank
through the leak oil line (204). The return line collector (3) is mounted in the rear frame on the right side of the vehicle.
It collects the return flows from the control blocks, blade turning motor, detent pin cylinder, and LS valve block. From
the collector block, oil can flow through the hoses (202)/ (203) to the return filter (2) in the hydraulic fluid tank. The oil
filter has an integrated bypass valve 1.5 bar (21.8 psi) and filters any dirt out of the return oil flow.
SS12E294 2

2 Return filter 201 Hose line
3 Return collector 202 Hose line to return filter
4 Hydro-reservoir 203 Hose line to return filter
5 Double pump 204 Leak oil line
6 LS valve block 205 LS valve block hose line
200 Suction line
The working pump A10VO supplies the LS valve block with pressure oil. At the LS valve block, the volume flow is
divided into two partial flows. The upper control block is supplied through the outlet S1 and the lower control block
through the outlet S2. The control blocks are mounted one above the other in the steering console. They control the
oil flow to the individual consumers in the working hydraulics.
The hydraulic fluid flows through the hoses in the front frame to the hydraulic cylinders mounted at the swing arm:
these perform the "blade lift, blade swivel, and swing arm lock" functions. At the front of the frame, oil is supplied
to the hydraulic cylinders that perform the "front blade (optional) and wheel camber adjustment" functions. From the
swing arm, the hose lines pass through a protective boot to the blade swivel seat. On the blade swivel seat, the turn
control valve block and the fluid motor for the "blade turn" function are connected to the lower control block. The rotary
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oil feed allows the volume flow to be transferred to the consumers at the center blade. The hydraulic cylinders for the
"tilt angle adjustment" and "blade extend" functions are mounted directly at the blade.
LS signal lines
The load pressures detected at the control blocks are sent from the control blocks to the LS valve block over LS signal
lines (228)/ (229).
Tank return line

The return lines from the detent pin hydraulic cylinder, the control blocks, the fluid motor and the LS valve block are
brought together in the collector block. The return line collector is mounted on the right of the rear frame. From the
return line collector, the oil flows through a hose line and through the return filter to the hydraulic fluid tank.

1 LS valve block 220 Lift cylinder left (upward)
20.010 Return collector 221 Lift cylinder left (downward)
22.501 Rotary oil feed 222 Moldboard swing cylinder (right turn)
61 Orifice plate 223 Moldboard swing cylinder (left turn)
62 Screw plug 224 Moldboard extend cylinder (left)
63 Connection 225 Moldboard extend cylinder (right)
69.200 Lowering control valve 226 Return line from upper control block
69.230 Hydraulic cylinder, detent pin 227 Return line from lower control block
75 Screw connection 228 LS signal line from upper control block
85 Lowering control valve 229 LS signal line from lower control block
86 Tube 230 P line to upper control block
210 Wheel lean cylinder - (up to –17 °) 231 P line to lower control block
211 Wheel lean cylinder - (up to +17 °) 232 Articulated-frame-steering cylinder
212 Lift cylinder right (downward) 233 Articulated-frame-steering cylinder
213 Lift cylinder right (upward) 234 Hydraulic cylinder, detent pin
214 Pitch adjustment cylinder (+) (blade tilt angle) 235 Return line from detent pin cylinder
215 Pitch adjustment cylinder (+) (blade tilt angle) 236 Return line from LS valve block T1
216 Blade turn (right) 237 Fluid motor leak oil line
217 Blade turn (left) 238 Return line from LS valve block T2
218 Articulated-frame-steering cylinder (right) 239 Lift cylinder right
219 Articulated-frame-steering cylinder (left) 240 Lift cylinder left
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SS13N024 3
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Floating position (optional)

For the grader, a floating position can be provided as an optional feature. The floating position makes it easier to work
when clearing snow, for example, as it allows the main blade to ride over irregular surfaces.
The floating position function is protected by the fuses 2F14 and 2F15, and is made up of the following elements:
• Two lowering control valves (1) with four solenoid valves (Y3.1 to Y3.4),
• Switch (S38.1) in the side panel for activating the floating position,
• Pull switch (S77.5) in the steering column, for operating the floating position.
• Wiring (4) with connector X68.4.
SS12E297 4
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SS12E296 5
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Hydraulic systems - Hydraulic schematic frame 01

836C
SS14J035 1
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Pos. Designation
1 Pump assembly
4 Gear pump
10 Hydro-reservoir
11.1 4-circuit cooler
11.2 Fan motor
20 Steering assistance
21 Steering/emergency steering collector block with pressure switches S17 ( 2.5 bar (36.3 psi))
and 17.6 ( 2.5 bar (36.3 psi))
22 Steering cylinder
23 Emergency steering pump
25 Pressure-limiting valve, purge circuit
30 LS valve block
31 Control block, lower installation position
32 Control block, upper installation position
36 Lowering control valve, Pitch adjustment cylinder
40 Brake valve with pressure switch S18 ( 4 bar (58.0 psi))
41 Brake valve with pressure switch S17.1 ( 90 bar (1305.0 psi))
Cut-in pressure ( 120 - 128 bar (1740 - 1856 psi))
Shutoff pressure ( 142 - 150 bar (2059 - 2175 psi))
42 Pressure reservoir, brake system
43 Pressure reservoir, parking brake ( 30 bar (435.0 psi))
45 Parking brake, solenoid valve with pressure switch S16 ( 80 bar (1160.0 psi))
46 Fitting with nozzle ∅ 0.8 mm (0.03 in)
47 Parking brake release pressure ( 150 bar (2175.0 psi))
48 Wet multi-disk brake max. operating pressure ( 60 bar (870.0 psi))
80 Blade lift cylinder, left and right
81 Lowering control valve
82 Scraper blade cylinder
83 Hydraulic cylinder, articulated steering
84 Pitch adjustment cylinder
85 Hydraulic cylinder, blade extend
86 Hydraulic cylinder, blade swivel
87 Rotary oil feed rotor
88 Hydraulic cylinder, wheel lean
89 Hydraulic cylinder, rear ripper
90 Hydraulic motor, blade turn
91 Lowering control valve, blade turn
92 Hydraulic cylinder, detent pin
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836C AWD
SS14J036 2
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Pos. Designation
1 Pump assembly
4 Gear pump
10 Hydro-reservoir
11.2 Fan motor
and 17.6 ( 2.5 bar (36.3 psi))
25 Pressure limiting valve, purge circuit
30 LS valve block
48 Wet multi-disk brake (max. operating pressure 60 bar (870.0 psi))
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856C
SS14H037 3
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Pos. Designation
1 Pump assembly
4 Gear pump
10 Hydro-reservoir
11.2 Fan motor
and 17.6 ( 2.5 bar (36.3 psi))
30 LS valve block
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856C AWD
SS14H038 4
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Pos. Designation
1 Pump assembly
4 Gear pump
10 Hydro-reservoir
11.2 Fan motor
and 17.6 ( 2.5 bar (36.3 psi))
30 LS valve block
46 Fitting with nozzle ∅ ( 0.8 mm (0.03 in))
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Hydraulic systems - Hydraulic schematic frame 02 - Floating

position
SS13J039 1
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Pos. Designation
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Hydraulic systems - Hydraulic schematic frame 03 - Front-wheel

drive (836C AWD and 856C AWD)
836C AWD
SS13J037 1
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Pos. Designation
1 Pump assembly
10 Hydro-reservoir
60 Radial piston motor
62 6/2 way valve
63 Flow divider
64 Sol. valve block
65 Pressure limiting valve ( 1.5 bar (21.8 psi))
66 LS pressure valve ( 16 bar (232 psi))
67 Filter ( 3.5 bar (50.8 psi))
68 Pressure reservoir, all-wheel drive ( 14 bar (203 psi))
69 Distributor block with nozzle ∅ 0.800 mm (0.031 in)
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856C AWD
SS13J038 2
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Pos. Designation
1 Pump assembly
10 Hydro-reservoir
60 Radial piston motor
62 6/2 way valve
63 Flow divider
64 Sol. valve block
65 Pressure limiting valve ( 1.5 bar (21.8 psi))
66 LS pressure valve ( 16 bar (232 psi))
67 Filter ( 3.5 bar (50.8 psi))
68 Pressure reservoir, all-wheel drive ( 14 bar (203 psi))
69 Distributor block with nozzle ∅ 0.800 mm (0.031 in)
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Index

Hydraulic systems - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic systems - Dynamic description - Main functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic systems - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic systems - Hydraulic schematic frame 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydraulic systems - Hydraulic schematic frame 02 - Floating position . . . . . . . . . . . . . . . . . . . . . . . . . 24
Hydraulic systems - Hydraulic schematic frame 03 - Front-wheel drive (836C AWD and 856C AWD) 26
Hydraulic systems - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Reservoir, cooler, and filters - 300
836C AWD
836C
856C AWD
856C
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Contents
TECHNICAL DATA
Oil filters
FUNCTIONAL DATA
Oil filters
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Hydraulic systems - Reservoir, cooler, and filters
Oil filters - General specification

Designation Value
Permitted operating overpressure 10 bar (145.0 psi)
Permitted operating temperature -40 - 100 °C (-40.0 - 212.0 °F)
Dirt absorption capacity (Δp 1.5 bar (21.8 psi)) about 93 g (3.3 oz),
as per ISO 4572 (ISO MTD)
Connection G 1" 1/4
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Hydraulic systems - Reservoir, cooler, and filters
Oil filters - Component identification
SS12E317 1

101 Filter element 104 O-ring
102 Cover 800 Repair set
103 O-ring
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Index

Oil filters - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil filters - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Fixed displacement pump - 104
836C AWD
836C
856C AWD
856C
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Contents
FUNCTIONAL DATA
Fixed displacement pump

Component identification - Double pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dynamic description - Pump control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Hydraulic systems - Fixed displacement pump
Fixed displacement pump - Component identification - Double

pump
The double pump B2946289-000 consists of the all-wheel pump (1) and the working pump (2).
SS12E311 1

1 All-wheel pump FR Volume flow regulator
∆p = 24 bar (348.0 psi)
Standard min.
∆p = 24 bar (348.0 psi)
2 Working pump L Leak oil connection
B High-pressure connection S Intake connection
DR Pressure regulator X Connection
Standard - min.
A10VODFR: 200 bar (2900.0 psi)
NOTE: Refer also to Pump - Component identification - All-wheel pump (836C AWD and 856C AWD) (29.218).
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Fixed displacement pump - Static description

Working pump
The hydraulic system (working equipment) is supplied by the adjustment pump A10VO, which is the axial piston/swash
plate type. In the mobile range, the pump can be used for pressures up to 315 bar (4567.5 psi). The geometric flow
volume can be continuously adjusted by changing the position of the swash plate. Pumps with different geometric
flow volumes are installed on the graders.

Level A 10 VO 45 DFR A 10 VO 60 DFR1
Flow volume VG max. 45 l/min (11.9 US gpm) 60 l/min (15.9 US gpm)
The pump is equipped with the pressure/volume flow regulator DFR/DFR1.
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Fixed displacement pump - Dynamic description - Pump control

Volume flow regulator (FR)
The volume flow regulator (A) controls the oil delivery from the pump according to load pressure. On the piston of the
volume flow regulator, the pump pressure is applied to one side. Counteracting this pressure is the load pressure and
the adjusted spring force of the regulator spring. If the volume flow regulator is actuated on the channel X with load
pressure (LS signal), the regulator starts to change the actuating pressure accordingly for the swash plate adjustment,
until the system comes back into equilibrium. The pump therefore only delivers the oil quantity actually needed by
the consumer.
Pressure regulator (DR)

The pressure regulator (B) sets the maximum permitted pump pressure. On the piston of the pressure regulator,
the pump pressure is applied to one side. Counteracting this pressure is the adjusted spring force of the regulator
spring. If the pump pressure exceeds the allowed value ( 200 bar (2900.0 psi)), the piston is pushed against the
spring force and creates a direct connection between the pump pressure channel and the swash plate adjustment
piston. The pressure regulator therefore prevents further deflection, or causes backward deflection of the adjustment
pump (towards pressure shutoff), and holds this position until the pump pressure is below the set pressure value of
the pressure regulator.
SS12E312 1

A Volume flow regulator (FR) F High-pressure console
B Pressure regulator (DR) G Orifice plate in LS control block
C Load signal line H Suction line
D LS load pressure I Leakage oil line
E Pressure line console
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Regulator types DFR and DFR1

The illustration shows the difference between the regulator types DFR and DFR
DFR design
With load relief plate!
(DFR: Default: ø 0.35 mm (0.014 in))
DFR1 design
Without load relief plate!
(DFR1: closed, no hole)
SS12E313 2
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Index

Fixed displacement pump - Component identification - Double pump . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fixed displacement pump - Dynamic description - Pump control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fixed displacement pump - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Pump control valves - 102
836C AWD
836C
856C AWD
856C
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Contents
FUNCTIONAL DATA
Pump control valves

Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Hydraulic systems - Pump control valves
Pump control valves - Component identification
SS13J040 1

1 Upper solenoid valve fast feed 5 Check valves
Detent pin solenoid valve, lower
2 DBV 215 bar (3117.5 psi) 6 Restrictor ø 2 mm (0.08 in)
3 Pressure-reducing valve 25 bar (362.5 psi) 7 Screw plug
4 Shuttle valve
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Pump control valves - Dynamic description

Installation position
The valve block is attached by a bracket to the rear frame in the engine compartment, on the left side of the vehicle.
Function
The valve block (Item 30 hydraulic diagram) is the linking element between the adjustment pump and the control
blocks.
The adjustment pump supplies oil to the inlet (P) on the valve block. The maximum pressure of the working hydraulics
is also ensured by the pressure-limiting valve DBV (2) mounted on the block. The control blocks are supplied with
oil from the valve block through the outlets (S1) / (S2). The pressure-reducing valve (3) creates a reduced working
pressure of 25 bar (362.5 psi) for the detent pin function.
The LS signals from the control blocks are transmitted to the pump controller. To de-couple these LS signal pressures,
two check valves (5) and one shuttle valve (4) are placed in the valve block housing.
There are also two solenoid valves (1), which open to the tank in neutral position. The additional fast feed and detent
pin functions are also activated by a foot switch on the cab floor.
If the solenoid valve (Y28) is activated by the 24 V on-board voltage, the pump pressure passes through the check
valves (5) or through the shuttle valve (4) directly to the pressure-displacement controller. The applied pump pres-
sure allows maximum deflection of the adjustment pump. This allows the individual hydraulic functions to be used at
maximum speed. This system allows the working functions to be performed at a rapid rate.
If the solenoid valve (Y27) is activated by the 24 V on-board voltage, the pump pressure, reduced to 25 bar (362.5 psi),
is released through the outlet N3 to the detent pin function.
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Pump control valves - Hydraulic schema
SS12E316 1

M1 Measuring point 200 bar (2900.0 psi) (pump rear) Valve block:
M2 Measuring point 25 bar (362.5 psi) (Saddle lock 1 Solenoid valve Y28 (fast feed)
pin) Solenoid valve Y27 (detent pin)
P Volume flow inlet from pump 2 DBV 215 bar (3117.5 psi)
S1 Outlet to upper control block 3 Pressure reducing valve 25 bar (362.5 psi)
S2 Outlet to lower control block 4 Shuttle valve
T1 Tank line 5 Check valve
/T2
XP LS line outlet to pump controller 6 Restrictor
XV1 LS line from upper control block
XV2 LS line from lower control block
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Index

Pump control valves - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pump control valves - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pump control valves - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Charge pump - 105
836C AWD
836C
856C AWD
856C
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Contents
Charge pump - 105
TECHNICAL DATA
Charge pump
General specification - Rotary oil feed rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Charge pump
Component identification - Rotary oil feed rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Hydraulic systems - Charge pump
Charge pump - General specification - Rotary oil feed rotor

Designation Value
Max. rotational speed 12 RPM
Starting torque 100 N·m (73.8 lb ft)
Angular momentum 80 N·m (59.0 lb ft)
Permitted operating temperature -20 - 90 °C (-4.0 - 194.0 °F)
Connection M22 x 1.5
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Hydraulic systems - Charge pump
Charge pump - Component identification - Rotary oil feed rotor
SS12E330 1

A Hose 247 from lowering control valve, Pitch 1 Hose 242 to tilt cylinder (-) (blade tilt angle)
adjustment cylinder
B Hose 225 from upper control block 2 Hose 245 to moldboard extend cylinder (left)
C Hose 224 from upper control block 3 Hose 244 to moldboard extend cylinder (right)
D Hose 246 from lowering control valve, Pitch 4 Hose 243 to tilt cylinder (+) (blade tilt angle)
adjustment cylinder
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Index
Charge pump - 105

Charge pump - Component identification - Rotary oil feed rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Charge pump - General specification - Rotary oil feed rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Remote control valves - 204
836C AWD
836C
856C AWD
856C
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Contents
SERVICE
Electro-hydraulic control valve

Disassemble - Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assemble - Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assemble - Converter coupling valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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Hydraulic systems - Remote control valves
Electro-hydraulic control valve - Disassemble - Control unit

WARNING
Avoid injury!
W1036A
Prior operation:
1. Loosen the torx screws (2) and the separate gearshift

housing (1) from the intermediate panel.
Use the special tool 5873 042 002 and 5870 204 063.
SS12H089 1
2. Remove the circuit (1), seals (2) and (4), and the inter-
mediate panel (3).
SS12H090 2
3. Remove the ZF fine filter differential pressure switch

with the O-ring (1), piston (2), and push spring (3) from
the transfer plate (4).
SS12H091 3
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4. Loosen the hexagon nuts and the torx screws and sep-
arate the transfer plate (1) and the seal (2) from the
housing rear section.
SS12H092 4
5. Pull the converter safety valve (1) out of the bore in the
housing.
SS12H093 5
6. Mark the installation of the wiring harness (1) on the

valve block (2).
SS12H094 6
7. Loosen the torx screws (1).

SS12H095 7
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8. Remove the transfer plate (1), the seals (2) and (4), and
the intermediate panel (3) from the valve block (5).
SS12H096 8
9. Remove the retaining clamp (1).
SS12H097 9
10. Loosen the torx screws (1) and remove the cover (2).
11. Remove the cover (3) on the opposite side.
SS12H098 10
12. Remove the wiring harness (1).

13. Loosen the cap bolts (3), take off the retaining plates,
and remove the pressure regulator (2).
SS12J362 11
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14. Loosen the cap bolts on the opposite side, take off the
retaining plates, and remove the pressure regulator
(1).
SS12J363 12
15. Loosen the two torx screws (1) and fasten the hous-
ing temporarily using the adjusting screws (S). (The
housing is held under spring tension).
16. Loose the other torx screws.
SS12H101 13
17. Separate the housing from the valve housing by uni-

formly loosening the adjusting screws (S) 5870 204
036.
SS12H102 14
18. Remove the individual parts:

• Pressure reduction valve (1)
• Vibration damper (2)
• Slide valve (3)
SS12H103 15
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19. Remove the individual parts on the other side in the

same way:
• Main pressure valve (1)
• Slide valve (3)
SS12H104 16
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Electro-hydraulic control valve - Assemble - Control unit

NOTE: Different versions are possible regarding the position of the wiring harness!
Refer to the documentation supplied by the vehicle manufacturer!
The following illustrations show sectional views of the electro-hydraulic control.
SS12J144 1

C Main pressure valve I Cover
16 - 18 bar (232 - 261 psi)
D Pressure reducing valve 9 bar (130.5 psi) J Proportional valve P5
E Wiring harness K Vibration damper
F Cover L Transfer plate
G Housing M Slide valve
H Valve block N Pressure regulator
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1. Place the cover (1) in position with the concave side

facing upward.
NOTE: Check all individual parts for damage, and replace
if necessary!
Before installing, check that moving parts in the valve block
are moving freely!
The pistons can be replaced separately.
Before assembling, lubricate individual parts as indicated
on ZF lubricants list TE-ML 03!
SS12J145 2
2. The illustration opposite shows the following parts:

• Pressure-reducing valve (1)
• Slide valve (3)
SS12H103 3
3. Install the pressure-reducing valve, the vibration

damper, and the slide valve as shown in the illustration
3.
NOTE: Pre-tension the slide valve pressure springs and fix
the piston temporarily using cylinder pin ∅ 5 mm (0.2 in)
(assembling aid) – see (S).
SS12J146 4
4. Mount the 2 adjusting screws (S).

5. Place the seal (1) and the housing (2).
6. Bring the housing evenly into position using the torx
adjusting screws.
SS12J147 5
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7. Bring the housing (1) into position with the torx screws;
this pre-tensions the pistons and the cylinder pins (as-
sembling aid) can then be removed.
SS12J148 6
8. Fasten the housing with the torx screws (1).

9. Tighten the torx screws (M5/10.9x30) with 5.5 N·m
(4.1 lb ft)
SS12J149 7
10. Mount the pressure regulator (1) and fix with the re-
taining plates (2) and the cap bolts (3).
11. Tighten the cap bolts (M5/8.8x12) with 5.5 N·m (4.1 lb
ft).
SS12J150 8
12. Preassemble the opposite side:

• Main pressure valve (1)
• Slide valve (3)
SS12H104 9
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13. Mount the individual parts as shown in illustration 9.

15. Place the seal (1) and the housing (2).
16. Bring the housing evenly into position using the ad-
justing screws.
NOTE: Pre-tension the slide valve pressure springs and fix
the piston temporarily using cylinder pin ∅ 5 mm (0.2 in)
(assembling aid) – see (S).
SS12J151 10
17. Bring the housing (1) into position with the torx screws;
this pre-tensions the pistons and the cylinder pins (as-
sembling aid) can then be removed.
18. Fasten the housing with the torx screws.
(4.1 lb ft).
SS12J152 11
20. Mount the pressure regulator (1) and fix with the re-
taining plates and the cap bolts.
ft).
NOTE: Retaining plates are mounted with the claw facing
downward! Note the radial installation position of the pres-
sure regulator.
SS12J153 12
22. Mount the wiring harness (1) and the connect pres-
sure regulator (6x).
NOTE: For the installation position of the pressure regula-
tor, refer to the sectional drawings at step 29.
NOTE: Note the installation position of the wiring harness!
Refer to the markings made when disassembling!
SS12J154 13
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23. Place the seal (1).

24. Mount the connector socket in the position, with the
groove for the cover guide lug facing upward.
25. Fasten the cover with the torx screws.
(4.1 lb ft).
SS12J155 14
27. Fasten the wiring harness with the retaining clamp (1).
NOTE: Mount the cover on the opposite side.
SS12J156 15

SS12J157 16
29. Insert the strainers (1) flush in the holes in the inter-
mediate plate.
NOTE: Note the installation position - strainers facing up-
ward (toward transfer plate)!
SS12J158 17
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30. Place the seal (1).

NOTE: Note the differences in the seals!
SS12J159 18
31. Place the intermediate plate (1).

NOTE: Strainers (2) must face upward!
SS12J160 19
32. Place the seal (1) and the transfer plate (2).
SS12J161 20
33. Place the transfer plate (1) and fasten evenly with the
torx screws (2).
34. Tighten the torx screws (M6/10.9x25) with 12 N·m
(8.9 lb ft).
SS12J162 21
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35. Fit the screw plugs (1) with new 8 mm (0.31 in) x
1.5 mm (0.06 in) the O-rings, and mount them.
36. Tighten the screw plugs (M10x1) with 6 N·m (4.4 lb
ft).
SS12J163 22
37. Place the converter safety valve (1) in position in the

housing bore.
SS12H093 23
38. Mount the stud bolts (1).

39. Tighten the stud bolts (M8/10.9x25) with 6 N·m (4.4 lb
ft).
40. Bring the seal (2) and transfer the plate (3) into posi-
tion on the housing rear section.
NOTE: Smear the screw-in thread with Loctite No. 243!
SS12J164 24
41. Fasten the transfer plate (1) with the torx screws (2)
and the hexagon nuts (3).
(7.0 lb ft).
43. Tighten the screw plug (M8) with 23 N·m (17.0 lb ft).
44. Mount the screw plug (4) with the new O-ring 13 mm
(0.51 in) x 2 mm (0.08 in).
45. Tighten the screw plug (16x1.5) with 6 N·m (4.4 lb ft).
SS12J165 25
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46. Mount the push spring (4), the piston (3), and the
switch (2) with the new O-ring 13 mm (0.51 in) x 2 mm
(0.08 in).
Tighten the switch with 30 N·m (22.1 lb ft).
• Filter pressure differential valve (1)
• Switch with O-ring (2)
• Piston (3)
• Push spring (4)
NOTE: On versions without filter pressure differential
valve, mount the screw plug in place of the switch (2).
SS12J166 26
47. Mount the adjusting screws (S).

48. Tighten the adjusting screws (M16x1.5) with 30 N·m
(22.1 lb ft).
49. Mount the seals (4) and (2), the intermediate panel
(3), and the circuit (1).
SS12H090 27
50. Fasten the electro-hydraulic control unit (1) evenly, us-

ing the torx screws (2).
51. Tighten the torx screws (M6/10.9x80) with 12 N·m
(8.9 lb ft)
SS12H089 28
Next operation:
Electro-hydraulic control valve - Assemble - Converter coupling valve (35.204)
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Electro-hydraulic control valve - Assemble - Converter coupling

valve
WARNING
Avoid injury!
W1036A
1. Insert the grub screw M8x8 (1) in the cover with Loctite
No. 649.
2. Tighten the grub screw with 18 N·m (13.3 lb ft).
SS12J167 1
3. Mount the individual parts of the converter coupling

valve:
• Cap bolt M5x12 (1)
• Lock washer A5 (2)
• Solenoid valve (3)
• Circuit housing (4)
• Piston (5)
• Shims (6)
4 mm (0.16 in) x 8 mm (0.31 in) x 0.5 mm (0.02 in)
(empirical value: 3 pcs.)
• Push spring (7) SS12J168 2
• End stop (8)

• O-ring (9)
13 mm (0.51 in) x 2 mm (0.08 in)
• Connection fitting L12A-M (10)
ft).
5. Tighten the connection fitting L12-m (M16x1.5) with
46 N·m (33.9 lb ft).
NOTE: The shims (6) determine the converter coupling
pressure of 15 bar (217.5 psi) + 1 bar (14.5 psi).
Mount the end stop (9) with the undercut face turned to-
wards the push spring.
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6. Mount the seal (2) and the pre-assembled converter

coupling valve (3) on the cover (1) and fasten with cap
bolts and washers (4) and (5).
SS12J169 3
7. Fasten the converter coupling valve with the cap bolts

(1) and (2) and mount the screw plug (3) with the new
O-ring 8 mm (0.31 in) x 1.5 mm (0.06 in).
8. Tighten the cap bolts (M5/8.8x40) and (M5/8.8x20) with
9.5 N·m (7.0 lb ft).
9. Tighten the screw plug (10x1) with 6 N·m (4.4 lb ft).
SS12J170 4
10. Fasten the plate (1) to the housing with the cap bolts
(2).
11. Tighten the cap bolts (M10/8.8x50) with 46 N·m
(33.9 lb ft).
12. Fasten the converter coupling valve to the plate (1)
with the hexagon head bolts and the hexagon nuts (3).
25 N·m (18.4 lb ft).
SS12J171 5
14. Mount the hoses with new O-rings:

• System pressure to converter coupling valve (1)
• System pressure to converter coupling (2)
• Return line to sump (3)
• Power takeoff lubricating line (4)
• Hose clamp (5)
SS12J172 6
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Tightening torque hose (1):

• Banjo bolt (6) (M12x1.5) with 35 N·m (25.8 lb ft)
SS12J173 7

• Connection fitting L12A-M (M16x1.5) with 46 N·m
(33.9 lb ft)
• Hose with 35 N·m (25.8 lb ft)
SS12J172 8

• Insert the threaded bushing with the O-ring 23 mm
(0.91 in) x 2 mm (0.08 in) in the housing.
Tighten the threaded bushing (M26x1.5) with 80 N·m
(59.0 lb ft).
SS12J173 9
Next operation:
Transmission oil filter - Install - ZF fine filter (21.105).
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Index

Electro-hydraulic control valve - Assemble - Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electro-hydraulic control valve - Assemble - Converter coupling valve . . . . . . . . . . . . . . . . . . . . . . . . . 16
Electro-hydraulic control valve - Disassemble - Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Hydraulic central joint - 354
836C AWD
836C
856C AWD
856C
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Contents
FUNCTIONAL DATA
Hydraulic central joint

Component identification - Articulated-frame-steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Hydraulic systems - Hydraulic central joint
Hydraulic central joint - Component identification -

Articulated-frame-steering cylinder
SS12E324 1

2 Piston rod 14 Circlip
3 Guide 15 Circlip
4 Piston 16 Hexagon nut
11 Circlip 17 Lubricating nipple
12 Joint bearing 50 Seal set
13 Joint bearing
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Index

Hydraulic central joint - Component identification - Articulated-frame-steering cylinder . . . . . . . . . . . 3
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Swing arm hydraulic system - 739
836C AWD
836C
856C AWD
856C
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Contents
FUNCTIONAL DATA
Swing cylinder
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Hydraulic systems - Swing arm hydraulic system
Swing cylinder - Component identification

Stop bolt cylinder
SS12E321 1

1 Stop bolt cylinder 3 Front frame
2 Swing arm
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Index

Swing cylinder - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Dozer blade cylinders - 741
836C AWD
836C
856C AWD
856C
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Contents
FUNCTIONAL DATA
Dozer blade cylinders

Component identification - Hydraulic motor of blade rotation mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Blade lifting cylinder
Blade side shift cylinder
Blade swiveling cylinder
Blade tilt cylinder
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Hydraulic systems - Dozer blade cylinders
Dozer blade cylinders - Component identification
SS12E326 1

10 Cylinder tube 130 Scraper
20 Piston rod 140 Rod seal
60 Joint bearing 160 Guide ring
70 Guide 170 Grooved ring
80 Piston 210 Guide ring
120 Lubricating nipple 220 Seal set
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Dozer blade cylinders - Component identification - Hydraulic motor

of blade rotation mechanism
SS12E318 1

1 Screw 14 Drive shaft
2 Lock washer 15 O-ring
3 Seal ring 16 Plate
4 Flange 17 Spur gear set
5 Seal ring 18 Cover
6 O-ring 19 Disk
7 Race 20 Screw
8 Needle bearing 23 Valve
9 Passenger 24 O-ring
10 Bearing 25 Seal ring
11 Housing 26 Screw plug
12 Separator 29 Repair set
13 Shaft
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Blade lifting cylinder - Component identification

Left and right
SS12E319 1

10 Cylinder liner 180 Support ring
20 Piston rod 190 O-ring
70 Guide 200 O-ring
80 Piston 210 Piston guide ring
90 Hexagon nut 220 Gasket
100 Snap ring 230 Hexagon screw
130 Scraper 250 Nut
140 Rod seal 260 Flange
150 O-ring 310 Disk/washer
160 Piston guide ring 340 Grease nipple
170 Grooved ring
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Blade side shift cylinder - Component identification

Moldboard extend cylinder
SS12E322 1

2 Piston rod 12 Serrated lock washer
3 Guide 13 Roll pin
4 Piston 15 Disk
6 Flange 16 Circlip
10 Hexagon nut 50 Seal set
11 Cylinder head screw
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Blade swiveling cylinder - Component identification
SS12E320 1

2 Piston rod 16 Lock washer
3 Guide 17 Lubricating nipple
14 Hexagon nut 20 Circlip
15 Hexagon head bolt 50 Seal set
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Blade tilt cylinder - Component identification

Pitch adjustment cylinder
SS12E323 1

2 Piston rod 14 Circlip
3 Guide 15 Hexagon nut
4 Piston 16 Lubricating nipple
12 Circlip 50 Seal set
13 Joint bearing
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Index

Blade lifting cylinder - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Blade side shift cylinder - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Blade swiveling cylinder - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Blade tilt cylinder - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dozer blade cylinders - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dozer blade cylinders - Component identification - Hydraulic motor of blade rotation mechanism . 4
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Ripper hydraulic system - 742
836C AWD
836C
856C AWD
856C
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Contents
FUNCTIONAL DATA
Ripper control cylinder

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Hydraulic systems - Ripper hydraulic system
Ripper control cylinder - Component identification

Rear ripper cylinder (optional)
SS12E325 1

2 Piston rod 23 Joint bearing
3 Guide 25 Circlip
4 Piston 26 Support disk
5 Snap ring 27 Circlip
21 Circlip 28 Hexagon nut
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Index

Ripper control cylinder - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Distributor and lines - 310
836C AWD
836C
856C AWD
856C
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Contents
FUNCTIONAL DATA
Distributor and lines

Static description - Control block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Control valve
Supply and pressure check valve
Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fitting
Component identification - Inlet element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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Hydraulic systems - Distributor and lines
Distributor and lines - Static description - Control block

The control block is located in the steering console and is divided into two parts:
• Lower LS control block
• Upper LS control block
The main functions of the control blocks are:
Upper control block Lower control block

P; LS; TS - connection P; LS; TS - connection
Extend blade Turn blade
Blade tilt angle adjustment Rear scarifier
Articulated steering Wheel camber
Scraper blade Swivel blade
Blade lift, left Blade lift, right
T. TS - outlet T. TS - outlet
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Distributor and lines - Component identification

1 Steering console 3 LS control block,
upper
2 LS control block,
lower
SS12E300 1
SS12E301 2
Pos. Designation Function

2 Inlet element P; LS; TS - connection
3 Replenishing valve
4 Control valve element with load-holding valve Extend blade
5 Connection extension
6 Control valve element with A/B/T connection Tilt angle adjustment (blade)
8 Control valve element with load-holding valve Articulated steering
10 Control valve element with load-holding valve Scraper blade
11 Control valve element with load-holding valve Blade lift, left
12 Outlet element T. TS - outlet
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SS12E302 3
Pos. Designation Function

2 Inlet element P; LS; TS - connection
3 Control valve element with load-holding valve Turn blade
5 Control valve element with load-holding valve Rear scarifier
6 Twin check valve Tilt angle adjustment (blade)
7 Control valve element A/B/T connection Wheel camber
9 Control valve element with load-holding valve Swivel blade
10 Control valve element with load-holding valve Blade lift, right
11 Outlet element T. TS - outlet
12 Restrictor
13 Restrictor
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SS12E303 4

1 P-channel inlet from LS valve block 4 TS outlet
2 LS signal output to LS valve block 5 Tank channel
3 TS-channel inlet from steering servo control
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Control block connections
SS12E304 5
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Upper control block Lower control block

214 Pitch adjustment cylinder (+) 210 Wheel lean cylinder (-) up to -17 °C (1.4 °F)
Rear ripper cylinder (optional) (upward)
Rear ripper cylinder (optional) (downward)
215 Pitch adjustment cylinder (-) 211 Wheel lean cylinder (+) up to 17 °C (62.6 °F)
218 Articulated-frame-steering cylinder (right) 212 Blade lift cylinder, right (downward)
219 Articulated-frame-steering cylinder (left) 213 Blade lift cylinder, right (upward)
220 Blade lift cylinder, left (upward) 216 Blade turn (right)
221 Blade lift cylinder, left (downward) 217 Blade turn (left)
Dozer blade cylinder (optional) (upward)
Dozer blade cylinder (optional) (downward)
224 Moldboard extend cylinder (to right) 222 Moldboard swing cylinder (right turn)
225 Moldboard extend cylinder (to left) 223 Moldboard swing cylinder (left turn)
226 Return line from control block 227 Return line from control block
(upper installation position) (lower installation position)
228 LS signal line from control block 229 LS signal line from control block
230 P line from control block 231 P line from control block
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Control valve - Static description

Directional control valve
The directional control valve is a three-position valve, actuated directly by the operator, which allows the hydraulic
pressure to reach the actuator (hydraulic cylinder and motors), thus causing it to move.
The directional control valve can have two configurations:

• Directional control valve with closed neutral position (A).
• Directional control valve with open neutral position (B).
The directional control valve (A) controls the following functions:

• Moldboard extend cylinder
• Articulated-frame-steering cylinder
• Dozer blade cylinder (optional)
• Rear ripper cylinder (optional)
• Moldboard swing cylinder
The directional control valve (B) controls the following functions:

• Pitch adjustment cylinder
• Turn blade
• Wheel lean cylinder
NOTE: Refer also to Control valve - Component identification (35.310).
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Control valve - Component identification

Directional control valve
SS12E306 1

A Closed neutral position 2 Coil
B Open neutral position 3 Control rod
1 Valve housing
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Supply and pressure check valve - Static description

Replenishing valve
This valve is mounted on the following control valve elements:
• Blade extend function
• Articulated steering function
• Scraper blade function
• Rear scarifier function
• Blade swivel function
Lock valve
Wheel camber adjustment function.
Hydraulically released twin check valve in taper seat design.
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Supply and pressure check valve - Component identification

Ball - Spring design (old)
SS12E307 1

1 ? 6 Cylinder head screw
2 Screw plug 7 O-ring
3 O-ring 8 Connection to T channel of control valve block
4 O-ring 9 Connection channel to control valve block A/B
channel
5 Screw plug
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Taper seat design (new)
SS12E308 2
SS12E309 3
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1 Screw plug 4 O-ring
2 Valve cone 5 O-ring
3 Cylinder head screw 6 Push spring, conical
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Lock valve
SS12E310 4

1 Valve housing 8 Ball
2 Screw plug 9 Cylinder head screw
3 Ball guide 10 O-ring
4 Spring cap 11 O-ring
5 Valve seat 12 O-ring
6 Piston 13 O-ring
7 ?
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Fitting - Component identification - Inlet element
SS12E305 1

2 Injector 7 Inlet element with inlet pressure scale
3 Spring 401 O-ring
5 Inlet for purge line 4401 Screw plug
6 Injector LS Output for load signal line to LS valve block
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Index

Control valve - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Control valve - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Distributor and lines - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Distributor and lines - Static description - Control block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fitting - Component identification - Inlet element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Supply and pressure check valve - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Supply and pressure check valve - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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EN
SERVICE MANUAL
Frames and ballasting
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
39
Contents
Frames and ballasting - 39
[39.100] Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1
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39
Frame - 100
836C AWD
836C
856C AWD
856C
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39.1 [39.100] / 1
Contents
Frame - 100
FUNCTIONAL DATA
Frame
SERVICE
Frame
Remove - Front frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install - Front frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Frames and ballasting - Frame
Frame - Component identification
SS13J005 1
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1 Hexagon nut 13 Pin
2 Cylinder head screw 14 Hexagon bolt
3 Pin 15 Lid
4 Ring 16 Pin
5 Scraper 17 Grease nipple
6 Bolt 18 Felt ring
7 Lid 19 Bearing
8 Scraper 20 Bushing
9 Cylinder 218 Hydraulic lines
10 Drawbar 219 Hydraulic lines
11 Nut 232 Hydraulic lines
12 Cylinder head screw 233 Hydraulic lines
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Frame - Remove - Front frame

Prior operation:
Before separating the front and rear frames, we recommend removing the cab and cab floor.
Refer to Moldboard blade - Remove (86.112).
Dozer blade - Remove (86.110).
Cab - Remove (90.150).
Cab floor - Remove (90.150).
WARNING
Heavy objects!
W0398A
WARNING
Avoid injury!
Secure and support the front frame and the rear frame with suitable lifting equipment.
W1223A
NOTE: Use a suitable drift punch for removing the bolts.

1. Disconnect all hydraulic lines and electrical lines be-
tween the front frame and rear frame.
SS12G013 1
2. Release the articulation lock (10) on both sides.
SS13J006 2
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3. Unscrew the self-locking nut (1) from the cap bolt (2).
4. Pull out the cap bolt (2) and drive out the bolt (3).
5. Place the washers (4) and the dirt scraper rings (5)
aside.
SS13J009 3
6. Detach the hydraulic lines (218), (219), (232), and

(233) from the hydraulic cylinders.
NOTE: Steps 6 to 9 are only necessary when the articula-
tion cylinder has to be removed.
SS12G016 4
7. Secure the articulation cylinder (9) with suitable lifting

gear.
8. Remove the 2 hexagon head bolts (6) and the washer
(7).
9. Take off the dirt scraper ring (8) and lift the hydraulic
cylinder away from the pin.
SS13J011 5
10. Loosen the self-locking nut (11) and remove the cap
bolt (12) from the upper frame-connecting pin.
SS13J012 6
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11. Secure the front frame with suitable lifting gear.

12. Remove the upper frame-connecting pin (13).
SS12G019 7
13. Loosen the cap bolts (14) from the retaining flange
(15) of the lower frame-connecting pin (16).
SS12G020 8
14. Remove the lower frame-connecting pin (16).

15. Separate the front frame from the rear frame.
SS12G021 9
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Frame - Install - Front frame

WARNING
Heavy objects!
W0398A
WARNING
Avoid injury!
Secure and support the front frame and the rear frame with suitable lifting equipment.
W1223A
CAUTION
Pinch hazard!
C0044A
NOTE: Use a suitable drift punch for mounting the bolts.

1. Check that the lubricating nipple (17) is working prop-
erly.
2. Check the mounting (18) and the sealing rings (19) for
damage or wear.
SS13J013 1
3. Check the bushing (20) in the front frame (for damage

or wear).
SS12G023 2
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4. Bring the front and rear frames into line.

5. Lubricate the mountings.
6. Drive in the lower frame-connecting pin (16).
SS12G021 3
7. Using the two appropriately machined bolts of the cor-

rect length, center the lower frame-connecting pin on
the flange and drive it in fully.
SS12G024 4
8. Fit the retaining flange (15) of the lower frame-connect-

ing pin (16) and tighten the cap bolts (14).
SS12G020 5
10. Insert the upper frame-connecting pin (13).
SS12G019 6
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11. After inserting the upper frame-connecting pin (13),

align the pin’s hole with the hole in the front frame.
SS12G025 7
12. Insert the cap bolt (12).

13. Screw on the new self-locking nut (11) and tighten it.
14. Tighten the nut with 250 N·m (184.4 lb ft).
SS13J012 8
15. Place the articulation cylinder (9) in the correct posi-

tion on the pin in the rear frame (connections facing
toward the vehicle center and piston rod side towards
the front frame).
16. Place the dirt scraper ring (8) and the disk (7) on the
pin.
17. Fasten the disk with the two hexagon head bolts (6).
NOTE: Applies in cases where the articulation cylinder (9)
was removed.
SS13J011 9
19. Align the piston rod eye with the mounting hole in the
front frame.
20. Place the dirt scraper rings (5) and the washers (4).
21. Insert the bolt (3) and secure it with the cap bolt (2)
and a new self-locking hexagon nut (1).
SS13J009 10
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22. Attach the hydraulic lines (218), (219), (232), and

(233) to the two hydraulic cylinders.
23. Install the cab floor and the cab (see Cab floor - In-
stall (90.150) and Cab - Install (90.150)).
24. Connect all hydraulic lines and attach the electrical
line connectors.
25. Move the hydraulic cylinders several times to the two
end positions to vent the hydraulic circuit.
SS12G016 11
26. Align the front-rear frame and block the frame parts for
road transport using the two articulation locks (10).
SS13J006 12
Next operation:
Dozer blade - Install (86.110).
Moldboard blade - Install (86.112).
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Index
Frame - 100
Frame - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Frame - Install - Front frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Frame - Remove - Front frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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EN
SERVICE MANUAL
Steering
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
41
Contents
Steering - 41
[41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1
[41.206] Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2
[41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3
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41
Steering - 41
Hydraulic control components - 200
836C AWD
836C
856C AWD
856C
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41.1 [41.200] / 1
Contents
Steering - 41
TECHNICAL DATA
Hydraulic control components

FUNCTIONAL DATA
Hydraulic control components

Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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Steering - Hydraulic control components
Hydraulic control components - General specification

Specifications for 836C/836C AWD
Designation 836C 836C AWD
Wheel camber const. 0° 0°
Inclination 8° 8°
Caster 2 ° 30 ' 0°
Toe-in 3 - 6 mm (0.12 - 0.24 in) 3 - 6 mm (0.12 - 0.24 in)
Steering wheel Ø 407 mm (16.0 in) 407 mm (16.0 in)
Double pump J. Barnes No. WP1509A2-C- J. Barnes No. WP09A2-110-
190-110-L-05-KA-151/150-NE246 190-L-03-GA-250/153-N-E803
Emergency steering pump flow 16 cm³/rev (0.98 in³/rev) / 16 cm³/rev (0.98 in³/rev) /
volume max. 25 l/min (6.6 US gpm) max. 25 l/min (6.6 US gpm)
Servo control Rexroth No. LAGC100n12-R-
0M150-000S
Rotor width 13.2 mm (0.5 in) 13.2 mm (0.5 in)
Flow volume / steering wheel turn 100 cm³ (6.1 in³) 100 cm³ (6.1 in³)
Pressure 150 bar (2175.0 psi) 150 bar (2175.0 psi)
Steering cylinder lift ø 45 mm (1.8 in) / ø 45 mm (1.8 in) /
22 - 250 mm (0.9 - 9.8 in) 22 - 250 mm (0.9 - 9.8 in)
Steering angle left / right 40 ° 40 °
Articulation angle +/- 28 ° +/- 28 °
Minimum turning radius
on tires 6500 mm (255.9 in) 6700 mm (263.8 in)
on front blade 7250 mm (285.4 in) 7450 mm (293.3 in)
Specifications 856C/856C AWD

Designation 856C 856C AWD
Wheel camber const. 0° 0°
Inclination 0° 0°
Caster 0° 0°
Toe-in 3 - 6 mm (0.12 - 0.24 in) 3 - 6 mm (0.12 - 0.24 in)
Steering wheel Ø 407 mm (16.0 in) 407 mm (16.0 in)
Double pump J. Barnes No. WP09A2-C-160- J. Barnes No. WP09A2-C-160-
230-L-03-GA-250/153-N-E803 230-L-03-GA-250/153-N-E803
Emergency steering pump flow 16 cm³/rev (1.0 in³/rev); 16 cm³/rev (1.0 in³/rev);
volume max. 25 l/min (6.6 US gpm) max. 25 l/min (6.6 US gpm)
Servo control Rexroth No. LAGC160n12-R- Rexroth No. LAGC160n12-R-
150M01-000S 150M01-000S
Rotor width 21.1 mm (0.8 in) 21.1 mm (0.8 in)
Flow volume / steering wheel turn 160 cm³ (9.8 in³) 160 cm³ (9.8 in³)
Pressure 150 bar (2175.0 psi) 150 bar (2175.0 psi)
Steering cylinder lift ø 50 mm (2.0 in) / ø 50 mm (2.0 in) /
25 - 300 mm (1.0 - 11.8 in) 25 - 300 mm (1.0 - 11.8 in)
Steering angle left / right 42.5 ° 42.5 °
Articulation angle +/- 28 ° +/- 28 °
Minimum turning radius
on tires 7350 mm (289.4 in) 7500 mm (295.3 in)
on front blade 8110 mm (319.3 in) 8250 mm (324.8 in)
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Hydraulic control components - Component identification
SS13J020 1
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1 Steering pump 255 Supply line, steering servo - steering cylinder for
left side control
2 Emergency steering pump 256 Pressure line, steering pump - collector block
3 Pressure switch S 17 257 Pressure line, collector block - steering servo
4 Pressure switch S 17.6 258 Tank line, steering servo - safety valve
10 Safety valve 12 bar (174.0 psi) 259 Tank line
11 Collector block 260 Tank line, control block - safety valve
13 Working hydraulic system control blocks 261 Tank line, control block - safety valve
18 Steering servo 262 Tank line, control block - cooler
22 Steering pressure measuring point 263 Tank line, control block - cooler
250 Supply line to right side steering cylinder for left 264 Tank line
side control
251 Supply line to right side steering cylinder for right 265 Tank line, control block - cooler
side control
252 Supply line to left side steering cylinder for right 266 Intake line, steering system
side control
253 Supply line to left side steering cylinder for left 267 Intake line, emergency steering system
side control
254 Supply line, steering servo - steering cylinder for 268 Pressure line, emergency steering pump -
right side control collector block
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Hydraulic control components - Static description

General
The graders are equipped with a hydrostatic front-wheel
steering system, which is controlled by the steering wheel.
The steering systems of the various grader models differ
mainly in their components and their dimensions. How-
ever, the principle of operation is the same.
The steering system includes:

• Steering servo control (assembly consisting of metering
pump and control valve)
• Two steering cylinders
• Steering pump (P1)
11 cm³ (0.67 in³) / rev (836C/836C AWD)
16 cm³ (1.0 in³) / rev (856C/856C AWD) SS12G225 1
• Collector block
• Emergency steering pump (P2) at transmission
16 cm³/rev (1.0 in³/rev)
• Radiator
• Safety valve 12 bar (174.0 psi)
Steering hydraulic system

NOTE: Refer also to Hydraulic control components -
Component identification (41.200).
On both grader models, the pressure oil is supplied by a

separate gear pump. The steering pump, mounted at the
diesel engine power takeoff, draws oil from the hydraulic
fluid tanks through the line (266) and delivers it through
the collector block to the inlet of the steering servo.
The steering servo controls the oil supply to both steering

cylinders according to the steering movement.
Measurement connections (22) are provided in the frame
for monitoring pressure in the corresponding steering
cylinder and checking that the steering pump is function-
ing correctly.
This measurement connection can be used to check

the steering pressure (max. 145.0 - 155.0 bar (2102.5 -
2247.5 psi).
Depending on the oil temperature, the return flow from

the steering servo passes through the safety valve (10)
to the control block TS purge channels or into the tank.
The two return lines (262) and (263) pass the oil from the
TS channels into the 4-circuit cooler. After cooling, the oil SS12G226 2
flows unfiltered into the hydraulic fluid tank (259).
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Hydraulic control components - Dynamic description

Steering / emergency steering collector block
Pressure oil from the steering pump is fed through the inlet (A). Correct operation of the steering pump is monitored
by the pressure switch (D1). The safety valve (RV1) is a spring-loaded check valve in the steering pump pressure
channel. It prevents oil from flowing out of the steering system if there is a break in the pressure line. The volume
flow passes through the outlet (C) and the pressure line (257) to the inlet channel of the steering servo.
NOTE: Refer also to Hydraulic control components - Component identification (41.200).
SS12M139 1

A Steering pump pressure line connection J 105 mm (4.1 in)
B Emergency steering pump pressure line K 20 mm (0.8 in)
connection
C Outlet to steering servo L 60 mm (2.4 in)
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D1 Pressure switch, steering pump failure warning M 80 mm (3.1 in)
switch S 17
D2 Pressure switch, emergency steering pump failure N M18x1,5
warning switch S 17.6
E 55 mm (2.2 in) O M22x1,5
F 33 mm (1.3 in) P M12x1,5
G 30 mm (1.2 in) Q M8
H 40 mm (1.6 in) RV1 Safety valve
I 85 mm (3.3 in) RV2 Safety valve
Steering assistance
The steering cylinders at the front axle are actuated by the steering servo. An "open design" steering servo is used
on all graders.
Open design:
In neutral position of the control valve, the control edges in the channels open an annular gap, so that both steering
cylinder channels (L) and (R) are connected to those of the metering pump. This allows the steering system to be
moved from the steered wheels, for example through the return line when cornering. The servo control ensures a
steering pressure of 145 - 155 bar (2102 - 2248 psi).
Steering servo – ZF design

The servo control housing contains, (see also figure 2):
• Metering pump (1), delivery in left and right direction of rotation
• Control slide valve (2), axially variable
• 2 replenishing valves (3), to prevent cavitation in the steering system
• Bypass valve (4), through which the metering pump draws oil from the return line when the steering is not hydrauli-
cally assisted.
• Check valve (5) in the pressure connection, which prevents oil from escaping if there is a break in the pressure line,
• Pressure-limiting valve (6), which limits the delivery pressure of the motor-driven steering pump to a maximum
145.0 - 155.0 bar (2102.5 - 2247.5 psi).
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Function description of control valve neutral position:

When the steering wheel is released, the control slide valve (2) goes into neutral position. This allows oil from the
flow volume delivered by the steering pump to flow off to the tank from the pressure channel (P) to the return channel
(T), through the TS channels of the two control slide valve blocks. In this case, the oil in the other channels does not
move. Because of the open design, there is a direct connection between the metering pump and the steering cylinder.
SS12G268 2

1 Metering pump 6 Pressure-limiting valve
2 Slide valve L Steering cylinder channels
3 Replenishing valve P Pressure channel
4 Bypass valve R Steering cylinder channels
5 Check valve T Return channel
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Function description of control valve working position:

The control slide valve (2) moves axially to the right or left, depending on the turning movements of the steering
column. Oil then flows from the steering pump channel (P) through the distribution slots of the control slide valve (2)
on the intake side of the metering pump (1). From the pressure side of the metering pump, oil flows through similar
distribution slots to the corresponding outlets ( (L) or (R) – the picture shows a demand flow through), actuating the
steering cylinders at the front axle. The side of the steering cylinder to which pressure oil is not applied can be relieved
by the opening return channel (T).
SS12G269 3

1 Metering pump 6 Pressure-limiting valve
2 Slide valve L Steering cylinder channels
3 Replenishing valve P Pressure channel
4 Bypass valve R Steering cylinder channels
5 Check valve T Return channel
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Cross-flushing
The oil return flow from the steering cylinders first passes through the servo (258) to the cross fitting, which acts as a
distributor. The upper control slide valve block is supplied with flushing oil through the line (260) and the lower control
slide through the line (261). By flowing through the cross-flush channels, the return oil heats the control slide valve
housing. This prevents an excessive temperature differential between the working hydraulic fluid and the housing
temperature. When cross-flushing is complete, the oil (262) and (263) flows to the combination cooler (265) in the
engine compartment. There it is cooled in the hydraulic fluid cooler from about 90 °C (194.0 °F) by the motor exhaust
air and flows back to the hydraulic fluid tank through the line (259).
Safety valve 12 bar (174.0 psi)

To ensure a specified return pressure from the steering servo, a safety valve is installed in the return line (258) of the
servo control. In the cold operating phase, at a return pressure of 22 bar (319.0 psi), the valve returns almost the
entire oil flow and, at 12 bar (174.0 psi), a partial flow to the tank. At normal operating temperature, the return flow
passes through the control slide valve blocks.
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Hydraulic control components - Hydraulic schema

Condition Pressure Pressure Warning light on instrument panel
switch
Engine speed 0 RPM S17 0 bar each press of the button
(0.0 psi)
S17.6 0 bar
(0.0 psi)
Engine speed > 550 RPM S17 0 bar ON
(0.0 psi)
after 4 s Engine speed > 550 RPM S17 0 bar ON + buzzer + message
(0.0 psi)
S17 2 bar each press of the button
(29.0 psi)
Speed < 1.5 km/h (0.93 mph) S17.6 0 bar flashes (battery charging)
(0.0 psi)
Speed < 1.5 km/h (0.93 mph) S17.6 5.5 bar each press of the button
(79.8 psi)
Speed > 3 km/h (1.86 mph) S17.6 0 bar ON + buzzer + message
(0.0 psi)
Speed > 3 km/h (1.86 mph) S17.6 5.5 bar each press of the button
(79.8 psi)
S17 has first priority
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Steering diagram 836C
SS14K169 1
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1 Steering pump A Steering pressure warning indicator on the
instrument panel
2 Emergency steering pump B Track Width:
3 Pressure switch S17 ( 2 bar (29.0 psi) NC contact) 1900 mm (74.8 in) (R = 96) - 405/70 R20
4 Pressure switch S17.6 ( 5.5 bar (79.8 psi) NC
contact)
6 Oil reservoir
10 Safety valve 12 bar (174.0 psi) C Wheel camber adjustment range
11 Collector block ± 14 ° 24 '
13 Working hydraulic system control blocks D Direction of travel
18 Steering servo E Toe-in L -6 / -3
F R = 290 mm (11.4 in)
G R = 288 mm (11.3 in)
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Steering diagram 836C AWD
SS14K313 2
47829048B 15/06/2016
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instrument panel
3 Pressure switch S17 ( 2 bar (29.0 psi) NC contact) 1923 mm (75.7 in) (R = 96) - 405/70 R20
contact)
6 Oil reservoir
11 Collector block ± 14 ° 24 '
F R = 290 mm (11.4 in)
G R = 288 mm (11.3 in)
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Steering diagram 856C
SS14K060 3
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instrument panel
3 Pressure switch S17 ( 2 bar (29.0 psi) NC contact) 2094 mm (82.4 in) (R = 144) - 17.5 - 25 EM
contact)
6 Oil reservoir
11 Collector block ± 12 °
F R = 290 mm (11.4 in)
G R = 288 mm (11.3 in)
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Steering diagram 856C AWD
SS14K061 4
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instrument panel
3 Pressure switch S17 ( 2 bar (29.0 psi) NC contact) 2100 mm (82.7 in) (R = 238.3) - 17.5 - 25 EM
contact)
6 Oil reservoir
11 Collector block ± 12 °
F R = 290 mm (11.4 in)
G R = 288 mm (11.3 in)
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Index
Steering - 41

Hydraulic control components - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic control components - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic control components - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic control components - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hydraulic control components - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Steering - 41
Pump - 206
836C AWD
836C
856C AWD
856C
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Contents
Steering - 41
Pump - 206
FUNCTIONAL DATA
Emergency steering pump

SERVICE
Emergency steering pump

Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Steering - Pump
Emergency steering pump - Static description

If the steering pump or the motor fails, the grader can still
be steered. The emergency steering pump on the ERGO -
POWER transmission then takes over the oil supply func-
tion. Starting from speeds of about 3 km/h (1.9 mph), fail-
ure of the supply to the steering system is indicated on
the control console by the "Steering/Emergency steering"
warning lamp and by a continuous warning tone.
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Steering - Pump
Emergency steering pump - Disassemble

Prior operation:
1. Loosen the cap bolts (1) and separate the emergency

steering pump (2) from the cover.
NOTE: Mark the radial installed position of the cover/hous-
ing front section.
SS12J138 1
2. Loosen the union (1) cover/housing front section and

take off the cover (2) with the seal.
SS12J365 2
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Steering - Pump
Emergency steering pump - Assemble

WARNING
Avoid injury!
W1036A
1. Press the plain bearing into the cover (1), until flush
with the face surface.
SS12J135 1
2. Insert the O-ring (1) 100 mm (3.94 in) x 3 mm (0.12 in)

in the radial groove in the piston pump (2), and grease
it.
SS12J136 2
3. Mount the adjusting screws (S) and place the seal (1)
and the cover (2).
SS12J133 3
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Steering - Pump
4. Fasten the cover (1) with the torx screws (2).
SS12J137 4
5. Tighten the torx screws (M8/10.9x30) with

34 N·m (25.1 lb ft).
6. Insert the emergency steering pump (3) and fasten it
with cap bolts (4).
7. Tighten the cap bolts (M8/8x135) with
23 N·m (17.0 lb ft).
NOTE: Note the radial installation position! Refer to the
markings made when disassembling.
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Index
Steering - 41
Pump - 206
Emergency steering pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Emergency steering pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Emergency steering pump - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Steering - 41
Cylinders - 216
836C AWD
836C
856C AWD
856C
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Contents
Steering - 41
Cylinders - 216
FUNCTIONAL DATA
Cylinders
Component identification - Wheel lean cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Steering cylinder
SERVICE
Cylinders
Disassemble - Wheel lean cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assemble - Wheel lean cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Steering cylinder
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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Steering - Cylinders
Cylinders - Component identification - Wheel lean cylinder
SS12E327 1

2 Piston rod 14 Lubricating nipple
3 Guide 15 Circlip
12 Joint bearing 19 Circlip
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SS12F087 2

1 Joint bearing 9 Seal ring
2 Stem 10 Piston
3 Ring 11 Ring
4 Head 12 Ring
5 O-ring 13 Nut
6 Seal ring 14 Cylinder liner
7 Seal 15 Joint bearing
8 Seal
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Steering cylinder - Component identification
SS12E328 1

2 Piston rod 9 Hexagon nut
3 Guide 50 Seal set
4 Piston
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SS12F077 2

1 Seal 7 Piston
2 Head 8 Ring
3 Seal 9 Rings
4 Seal 10 Nut
5 Stem 11 Cylinder liner
6 O-ring 12 Joint bearing
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Cylinders - Disassemble - Wheel lean cylinder

Prior operation:
Remove the wheel lean cylinder from the axle casing.
Refer to Final drive hub, steering knuckles, and shafts - Disassemble - Casing (25.108).
NOTE: For more details refer to Cylinders - Component identification - Wheel lean cylinder (41.216).
1. Loosen the head (4).
2. Remove the complete stem (2) from the cylinder liner
(14).
SS12F088 1
3. Remove the joint bearing (15) from the cylinder liner

(14).
SS12F089 2
4. Loosen the nut (13).

5. Remove the complete piston (10) from the head (4)
together with the stem (2).
SS12F090 3
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6. Remove the joint bearing (1) from the stem (2).

SS12F091 4
7. Remove the seal ring (9) from the piston (10).
SS12F092 5
8. Remove the rings (12) and (11) from the piston (10).
SS12F093 6
9. Remove the inner seals (8) from the head (4).
SS12F094 7
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10. Remove the seal (7) from the head (4).
SS12F095 8
11. Remove the seal ring (6) from the head (4).
SS12F096 9
12. Remove the O-ring (5) from the head (4).
SS12F097 10
13. Remove the seal ring (3) from the head (4).
SS12F098 11
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Cylinders - Assemble - Wheel lean cylinder

NOTE: For more details refer to Cylinders - Component identification - Wheel lean cylinder (41.216).
1. Insert the seal ring (3) in the head (4).
SS12F098 1
2. Mount the O-ring (5) on the head (4).
SS12F097 2
3. Mount the ring (6) on the head.
SS12F096 3
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4. Mount the seals (7) on the head (4).
SS12F095 4
5. Insert the inner seals (8) in the head (4).
SS12F094 5
6. Mount the rings (11) and (12) on the piston (10).
SS12F093 6
7. Insert the O-ring (9) in the piston (10).
SS12F092 7
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8. Mount the joint bearing (1) on the stem (2).

SS12F091 8
9. Mount the pre-assembled head (4) and the pre-assem-

bled piston (10) on the stem (2).
10. Tighten the nut (13).
SS12F090 9
11. Mount the joint bearing (15) in the cylinder liner (14).
SS12F089 10
12. Insert the pre-assembled stem (2) in the cylinder liner

(14).
13. Tighten the head (4).
SS12F088 11
Next operation:
Install the wheel lean cylinder in the axle casing.
Refer to Final drive hub, steering knuckles, and shafts - Assemble - Casing (25.108).
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Steering cylinder - Disassemble

Prior operation:
Remove the steering cylinder from the axle casing.
Refer to Final drive hub, steering knuckles, and shafts - Disassemble - Casing (25.108).
NOTE: For more details refer to Steering cylinder - Component identification (41.216).
1. Loosen the head (2).
2. Remove the complete stem (5) from the cylinder liner
(11).
SS12F078 1
3. Remove the head (2)

SS12F079 2
SS12F080 3
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6. Remove the inner seals (4) from the head (2).
SS12F081 4
7. Remove the stem (5), the complete piston (7), and the
nut (10).
SS12F082 5
8. Remove the rings (9) from the piston (7).
SS12F083 6
9. Remove the O-ring (6) from the piston (7).
SS12F084 7
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10. Remove the joint bearing (12) from the cylinder liner
(11).
SS12F085 8
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Steering cylinder - Assemble

NOTE: For more details refer to Steering cylinder - Component identification (41.216).
1. Insert the joint bearing (12) in the cylinder liner (11).
SS12F085 1
2. Mount the O-ring (6) on the piston (7).
SS12F084 2
3. Mount the rings (9) on the piston (7).
SS12F083 3
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4. Install the nut (10), the complete piston (7) and the stem
(5).
SS12F082 4
5. Mount the inner seals (4) of the head (2).
SS12F081 5
6. Mount the seal (3) on the head (2).
SS12F080 6
7. Insert the seal ring (1) in the head (2).
SS12F079 7
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8. Push the assembled head (2) onto the stem (5) com-
plete with the piston (7) and the nut (10).
SS12F086 8
9. Push the assembled stem into the cylinder liner (11).

Screw in the head (2) and tighten it.
SS12F078 9
Next operation:
Install the steering cylinder in the axle casing.
Refer to Final drive hub, steering knuckles, and shafts - Assemble - Casing (25.108).
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Index
Steering - 41
Cylinders - 216
Cylinders - Assemble - Wheel lean cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cylinders - Component identification - Wheel lean cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cylinders - Disassemble - Wheel lean cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Steering cylinder - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Steering cylinder - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Steering cylinder - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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EN
SERVICE MANUAL
Wheels
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
44
Contents
Wheels - 44
[44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1
[44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2
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44
Wheels - 44
Front wheels - 511
836C AWD
836C
856C AWD
856C
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Contents
Wheels - 44
Front wheels - 511
TECHNICAL DATA
Front wheels
Tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Front wheels
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Wheels - Front wheels
Front wheels - Tire pressure

The machine can be equipped with different tires from various manufacturers.
Permitted tires for 836C/836C AWD

Designation Manufacturer Tread Air pressure
405/70 R20 EM Dunlop SPT9 3 bar (43.5 psi)
455/70 R20 EM Dunlop SPT9 2.5 bar (36.3 psi)
420/75 R20 Michelin XMCL 2 bar (29.0 psi)
405/70 R24 Dunlop SPT9 2.5 bar (36.2 psi)

17.5–25 EM Goodyear SGL 2 bar
(29.0 psi)
17.5 R25 EM Michelin XHA 2 bar (29.0 psi)
17.5 R25 EM Michelin XTLA 2 bar (29.0 psi)
17.5 R25 Pirelli RM94 2.4 bar (34.8 psi)
NOTE: Tires with ballast should not be used on machines traveling from one working site to another.
After 80.0 km (50.0 miles) drive or 2 h of continuous driving (neither limit should be surpassed) it is necessary to stop
at least for 30 min to let the tires cool off. After 4 h of travel it will be necessary to stop for at least 1 h for the same
reason.
The tire pressures are valid for graders equipped with one of the above tire sizes, equipment attached, fuel tank full,
and weights.
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Front wheels - Remove

WARNING
Heavy objects!
W0398A
1. Lift and jack up the vehicle using suitable lifting gear.

2. Remove the wheels.
SS14J049 1
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Front wheels - Install

WARNING
Heavy objects!
W0398A
Tightening torques 836C/836C AWD 856C/856C AWD

With lock washer 450 N·m (331.9 lb ft) 550 N·m (406 lb ft)
With pressure plate 500 N·m (368.8 lb ft) 600 N·m (442.5 lb ft)
1. Mount the wheels.

2. Lower the machine to the ground and remove the lifting
gear.
SS14J049 1
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Index
Wheels - 44
Front wheels - 511

Front wheels - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front wheels - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Front wheels - Tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Wheels - 44
Rear wheels - 520
836C AWD
836C
856C AWD
856C
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Contents
Wheels - 44
Rear wheels - 520
TECHNICAL DATA
Rear wheels
Tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Rear wheels
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Wheels - Rear wheels
Rear wheels - Tire pressure

The machine can be equipped with different tires from various manufacturers.

420/75 R20 Michelin XMCL 2 bar (29.0 psi)
405/70 R24 Dunlop SPT9 3.25 bar (47.12 psi)

17.5–25 EM Goodyear SGL 2.35 bar (34.08 psi)
17.5 R25 EM Michelin XHA 2.1 bar (30.5 psi)
17.5 R25 EM Michelin XTLA 2.1 bar (30.5 psi)
17.5 R25 Pirelli RM94 2.4 bar (34.8 psi)
NOTE: Tires with ballast should not be used on machines traveling from one working site to another.
After 80.0 km (50.0 miles) drive or 2 h of continuous driving (neither limit should be surpassed) it is necessary to stop
at least for 30 min to let the tires cool off. After 4 h of travel it will be necessary to stop for at least 1 h for the same
reason.
The tire pressures are valid for graders equipped with one of the above tire sizes, equipment attached, fuel tank full,
and weights.
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Rear wheels - Remove

WARNING
Heavy objects!
W0398A
1. Lift and jack up the vehicle using suitable lifting gear.

Loosen the mounting bolts (1) and remove the two rear
wheel covers.
SS14E208 1
2. Remove all four rear wheels.
SS13J041 2
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Rear wheels - Install

WARNING
Heavy objects!
W0398A
Tightening torques 836C/836C AWD 856C/856C AWD

With lock washer 450 N·m (331.9 lb ft) 550 N·m (406 lb ft)
With pressure plate 500 N·m (368.8 lb ft) 600 N·m (442.5 lb ft)
1. Mount all four rear wheels.
SS13J041 1
2. Lower the machine to the ground and remove the lifting

gear.
Attach the two rear wheel covers to the previously
mounted brackets using mounting bolts (1).
SS14E208 2
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Index
Wheels - 44
Rear wheels - 520

Rear wheels - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear wheels - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rear wheels - Tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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47829048B 15/06/2016
EN
SERVICE MANUAL
Cab climate control
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
50
Contents
Cab climate control - 50
[50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1
47829048B 15/06/2016
50
Heating - 100
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
50.1 [50.100] / 1
Contents
Heating - 100
SERVICE
Heating
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Cab climate control - Heating
Heating - Remove
WARNING
Heavy objects!
W0398A
Prior operation:
Mechanically-adjusted operator seat - Remove (90.120).
NOTE: Disconnect the batteries.

1. Loosen the four screws and remove the cover (1).
SS12G216 1
2. Remove the cover (2) from the front air shaft.

3. Remove the four screws from the heater (1).
SS12G217 2
4. Carefully lift the switch plate (3) for the heating/ventila-

tion/air conditioning out of the slide-in console.
SS12G218 3
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50.1 [50.100] / 3
5. Disconnect the cable to the fan switch (X23), to the air

recirculation switch X213, and to the air conditioning
switch (X72.3) (optional).
6. Loosen the bowden cable screw (4) and detach the
bowden cable (5) from the control unit.
SS12G219 4
7. Loosen the hose clamps on the heater feed line (6) and
the return line (7) and pull off the lines.
8. Separate the heater cable from the cab floor cable set
(connector (X19)).
9. Remove the heater.
SS12G220 5
SS12J022 6
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Heating - Install
WARNING
Heavy objects!
W0398A
1. Have the new or repaired heater ready.
SS12J023 1
2. Push the bowden cable from the heater compartment

through to the side console.
NOTE: A hole is provided for this purpose.
SS12G223 2
3. Insert the heater, taking care with the bowden cable

and the heater cable.
4. Check that the foam ring (8) is correctly seated and that
there is no air gap.
SS12G224 3
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5. Fasten the heater (1) with the four screws.

6. Mount the cover (2) on the front air shaft, and fasten it.
SS12G217 4
7. Fasten the cover (1) to the housing with the four

screws.
8. Install the driver seat.
Refer to Mechanically-adjusted operator seat - In-
stall (90.120).
SS12G216 5
9. Attach the heater feed line (6) and the return line (7) to
the heater and fasten them with the hose clamps.
Bind the heater cable together with the cab floor cable
set (connector (X19)).
SS12G220 6
10. Pass the bowden cable to the slide-in side console.

11. Attach the bowden cable (5) to the control unit and
clamp the bowden cable sheath with the screw (4).
12. Connect the cable to the fan switch (X23), air re-
circulation switch (X213), and air conditioning switch
(X72.3) (optional).
SS12G219 7
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13. Carefully insert the switch plate (3) for the heating/
ventilation/air conditioning into the slide-in console.
SS12G218 8
Next operation:
Connect the batteries.
Refer to Battery - Install (55.302).
Carry out a function test on the heating and/or air conditioning system.
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Index
Heating - 100
Heating - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Heating - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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EN
SERVICE MANUAL
Electrical systems
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
55
Contents
Electrical systems - 55
[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1
[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
[55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.988] Selective Catalytic Reduction (SCR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
[55.989] Exhaust Gas Recirculation (EGR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5
[55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
[55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7
[55.530] Camera. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8
[55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9
[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10
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55
Electrical system - 000
836C AWD
836C
856C AWD
856C
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Contents
TECHNICAL DATA
Electrical system
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Electrical systems - Electrical system
Electrical system - General specification

Operating voltage 24 V 24 V
Battery 2 x 100 A·h 2 x 100 A·h
Alternator 90 A 90 A
Starter motor 4 kW 4 kW
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Index

Electrical system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Harnesses and connectors - 100
836C AWD
836C
856C AWD
856C
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Contents
FUNCTIONAL DATA
Harnesses and connectors

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrical schematic sheet 01 - Diagram Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Electrical schematic sheet 02 - Power distribution - Battery/Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical schematic sheet 03 - Power distribution (Fuse block 1F/1K) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electrical schematic sheet 06 - Power distribution /Fuse block 4F/4K) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electrical schematic sheet 08 - Power distribution 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Electrical schematic sheet 12 - Engine control unit 1, Grid heater, Filter heater . . . . . . . . . . . . . . . . . . . . 30
Electrical schematic sheet 13 - Engine control unit 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Electrical schematic sheet 14 - Engine control unit 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Electrical schematic sheet 15 - ECU - AIC 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Electrical schematic sheet 16 - ECU - AIC 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Electrical schematic sheet 17 CAN structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Electrical schematic sheet 18 - Gear control unit 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Electrical schematic sheet 19 - Gear control unit 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Electrical schematic sheet 20 - ECU - UCM power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Electrical schematic sheet 21 ECU - UCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Electrical schematic sheet 22 - Floating position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Electrical schematic sheet 23 - Engager pin, rapid hydraulic, plug operator seat . . . . . . . . . . . . . . . . . . . 52
Electrical schematic sheet 24 - Lighting steering column switch, domelight . . . . . . . . . . . . . . . . . . . . . . . . 54
Electrical schematic sheet 25 - Lighting hazard warning, blinkers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Electrical schematic sheet 26 - Lighting headlight, full beam, tail, parking, side marker light . . . . . . . . . 58
Electrical schematic sheet 27 - Lighting back up, reverse light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Electrical schematic sheet 28 - Lighting working lights cab roof, front and rear . . . . . . . . . . . . . . . . . . . . . 62
Electrical schematic sheet 29 - Cab wiper/washer front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Electrical schematic sheet 30 - Cab wiper/washer rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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Electrical schematic sheet 31 - Heating blower heater, HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Electrical schematic sheet 32 - Cabin defrost rear windscreen, beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Electrical schematic sheet 33 - Cabin radio loudspeaker 12V power outlet . . . . . . . . . . . . . . . . . . . . . . . . 72
Electrical schematic sheet 34 - Miscellaneous, Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Electrical schematic sheet 35 - Miscellaneous, Creep mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Electrical schematic sheet 36 - Miscellaneous, Blade control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Electrical schematic sheet 37 - Miscellaneous, Telematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Electrical schematic sheet 38 - Miscellaneous, Rear camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Component localization - Main connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Component diagram 01 - Engine / Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Component diagram 02 - Engine / Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Component diagram 03 - Engine / Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Component diagram 04 - Cab floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Component diagram 05 - Cab floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Component diagram 06 - Cab roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Component diagram 07 - Cab roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Component diagram 08 - Side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Component diagram 09 - Side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Component diagram 10 - Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Component diagram 11 - Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Component diagram 12 - Front light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Component diagram 13 - Front frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Component diagram 14 - Rear frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Component diagram 15 - License plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Component diagram 16 - Floating position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Component diagram 17 - Switchboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Component diagram 18 - UCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Component diagram 19 - Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Component diagram 20 - Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Component diagram 21 - Grid heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Component diagram 22 - Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Component diagram 23 - Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Component diagram 24 - Adapter 12V power outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Fuse and relay box
Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
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Electrical systems - Harnesses and connectors
Harnesses and connectors - Identification

The following abbreviations are used for wire colors on the wiring diagram sheets:

BK Black PK Pink
BN Brown RD Red
BU Blue TQ Turquoise
GN Green VT Violet
GY Grey WH White
OG Orange YE Yellow
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Harnesses and connectors - Electrical schematic sheet 01 -

Diagram Overview
Sheet Diagram
1 Overview
2 Power distribution – Battery/Starter (see Harnesses and connectors - Electrical schematic sheet
02 - Power distribution - Battery/Starter (55.100))
3 Power distribution (Fuse block 1F/1K) (see Harnesses and connectors - Electrical schematic
sheet 03 - Power distribution (Fuse block 1F/1K) (55.100))
sheet 06 - Power distribution /Fuse block 4F/4K) (55.100))
8 Power distribution 1 (see Harnesses and connectors - Electrical schematic sheet 08 - Power
distribution 1 (55.100))
12 Engine control unit 1, Grid heater, Filter heater (see Harnesses and connectors - Electrical
schematic sheet 12 - Engine control unit 1, Grid heater, Filter heater (55.100))
13 Engine control unit 2 (see Harnesses and connectors - Electrical schematic sheet 13 - Engine
control unit 2 (55.100))
14 Engine control unit 3 (see Harnesses and connectors - Electrical schematic sheet 14 - Engine
control unit 3 (55.100))
15 ECU – AIC 1 (see Harnesses and connectors - Electrical schematic sheet 15 - ECU - AIC
1 (55.100))
16 ECU – AIC 2 (see Harnesses and connectors - Electrical schematic sheet 16 - ECU - AIC
2 (55.100))
17 CAN structure (see Harnesses and connectors - Electrical schematic sheet 17 CAN structure
(55.100))
18 Gear control unit 1 (see Harnesses and connectors - Electrical schematic sheet 18 - Gear control
unit 1 (55.100))
19 Gear control unit 2 (see Harnesses and connectors - Electrical schematic sheet 19 - Gear control
unit 2 (55.100))
20 ECU – UCM power supply (see Harnesses and connectors - Electrical schematic sheet 20 -
ECU - UCM power supply (55.100))
21 ECU – UCM (see Harnesses and connectors - Electrical schematic sheet 21 ECU - UCM (55.100))
22 Floating position (see Harnesses and connectors - Electrical schematic sheet 22 - Floating
position (55.100))
23 Engager pin, Rapid hydraulic, Plug operator seat (see Harnesses and connectors - Electrical
schematic sheet 23 - Engager pin, rapid hydraulic, plug operator seat (55.100))
24 Lighting steering column switch, Domelight (see Harnesses and connectors - Electrical schematic
sheet 24 - Lighting steering column switch, domelight (55.100))
25 Lighting hazard warning, Blinkers (see Harnesses and connectors - Electrical schematic sheet 25
- Lighting hazard warning, blinkers (55.100))
26 Lighting headlight, Full beam, Tail, Parking, Side marker light (see Harnesses and connectors -
Electrical schematic sheet 26 - Lighting headlight, full beam, tail, parking, side marker light
(55.100))
27 Lighting back up, Reverse light (see Harnesses and connectors - Electrical schematic sheet
27 - Lighting back up, reverse light (55.100))
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Sheet Diagram
28 Lighting working lights cab roof, front and rear (see Harnesses and connectors - Electrical
schematic sheet 28 - Lighting working lights cab roof, front and rear (55.100))
29 Cab wiper/washer front (see Harnesses and connectors - Electrical schematic sheet 29 - Cab
wiper/washer front (55.100))
30 Cab wiper/washer rear (see Harnesses and connectors - Electrical schematic sheet 30 - Cab
wiper/washer rear (55.100))
31 Heating blower heater, HVAC (see Harnesses and connectors - Electrical schematic sheet 31 -
Heating blower heater, HVAC (55.100))
32 Cabin defrost rear windscreen, Beacon (see Harnesses and connectors - Electrical schematic
sheet 32 - Cabin defrost rear windscreen, beacon (55.100))
33 Cabin radio load speaker 12 V power outlet (see Harnesses and connectors - Electrical schematic
sheet 33 - Cabin radio loudspeaker 12V power outlet (55.100))
34 Miscellaneous, Fuel system (see Harnesses and connectors - Electrical schematic sheet 34 -
Miscellaneous, Fuel system (55.100))
35 Miscellaneous, Creep mode (see Harnesses and connectors - Electrical schematic sheet 35 -
Miscellaneous, Creep mode (55.100))
36 Miscellaneous, Blade control (see Harnesses and connectors - Electrical schematic sheet 36 -
Miscellaneous, Blade control (55.100))
37 Miscellaneous, Telematics (see Harnesses and connectors - Electrical schematic sheet 37 -
Miscellaneous, Telematics (55.100))
38 Miscellaneous, Rear camera (see Harnesses and connectors - Electrical schematic sheet 38 -
Miscellaneous, Rear camera (55.100))
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Harnesses and connectors - Electrical schematic sheet 02 - Power

distribution - Battery/Starter
Location Component
A2 Alternator G1
A3 Starter Motor M-1
A4 Starting Rely K1-5
A6 Battery G-002
B3 Cab Lower Power Stud M6 (15)
B5 Gov. Key Switch K10-1
B6 Battery G-001
D5 Cab Upper Power Stud M6 (30)
D6 Ignition Switch S1
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distribution (Fuse block 1F/1K)
Location Component
A3 Fuel Filter Heater 1K20-3
A3 OK to Start 1KCC
B3 AUX 1KAUX
B3 After Run IGN Power 1K AR IGN PWR
B3 Rear Defrost 1K17
C3 Fuse 1F10: After Run ( 5 A)
C3 Fuse 1F9: Alternator ( 5 A)
C3 Fuse 1F8: Start Relays ( 7.5 A)
C3 Fuse 1F7: Domelight ( 7.5 A)
C3 Fuse 1F6: Power Converter ( 15 A)
D3 Fuse 1F5 :Filter Heater ( 20 A)
D3 Fuse 1F4: Power Relays ( 2 A)
D3 Fuse 1F3: Key Switch S1 ( 5 A)
D3 Fuse 1F2: ECU ( 30 A)
D3 Fuse 1F1: AIC-2 ( 10 A)
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Location Component
A3 Parking Brake Solenoid 2K115
A3 Option Float Position 2K42
B3 Brake Lights 2K19
B3 Horn 2K14
B3 Reserve
C3 Fuse 2F20: Engine AUX ( 20 A)
C3 Fuse 2F19: Lights ( 10 A)
C3 Fuse 2F18: Horn / Lights ( 10 A)
C3 Fuse 2F17: Flashers ( 7.5 A)
C3 Fuse 2F16: Hazard Warning ( 7.5 A)
B3 Fuse 2F15: Floating Position ( 10 A)
B3 Fuse 2F14: Floating Position ( 5 A)
B3 Fuse 2F13: Brake Light ( 10 A)
B3 Fuse 2F12: Fueling System ( 2 A)
B3 Fuse 2F11: Parking Brake ( 5 A)
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Location Component
A3 Option BU Alarm Reserve Lights 3K81-2
B3 Headlamp High Beam 3K118
B3 Headlamp Low Beam 3K117
B3 Key SW Power Delay AIC 3K116
C3 Fuse 3F30: Telematic Module ( 5 A)
C3 Fuse 3F29: Beacon ( 7.5 A)
C3 Fuse 3F28: Front Washer ( 15 A)
C3 Fuse 3F27: Operators Seat ( 10 A)
C3 Fuse 3F26: Engine AUX Relay ( 25 A)
C3 Fuse 3F25: Reverse Light ( 5 A)
D3 Fuse 3F24: Cab Worklights Option ( 15 A)
D3 Fuse 3F23: Cab Roof Worklights ( 15 A)
D3 Fuse 3F22: Headlight Full Left ( 7.5 A)
D3 Fuse 3F21: Headlight Full Right ( 7.5 A)
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distribution /Fuse block 4F/4K)
Location Component
A3 Work Lights Cab Opt 4K12
A3 Work Lights Cab Roof 4K10
B3 Option AUX Fuel Fill 4K67-1
B3 Option AUX Fuel Fill 4K67
B3 Neutral Gearshift to OK to Start 4K111
C3 Fuse 4F40 ( 5 A)
C3 Fuse 4F39: Lights ( 5 A)
C3 Fuse 4F38: Defrost Rear ( 15 A)
C3 Fuse 4F37: Pre Fuel Filter ( 15 A)
C3 Fuse 4F36: Fuel Pump ( 20 A)
C3 Fuse 4F35: Engager Pin ( 5 A)
D3 Fuse 4F34: Telematic Key Input ( 2 A)
D3 Fuse 4F33: Gear Control ( 7.5 A)
D3 Fuse 4F32: Gear Control ( 7.5 A)
D3 Fuse 4F31: HVAC ( 15 A)
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SS14M179 1
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Location Component
C3 Fuse 5F6: Supply UCM ( 7.5 A)
C3 Fuse 5F5: Supply UCM ( 7.5 A)
D3 Fuse 5F4: Supply UCM ( 7.5 A)
D3 Fuse 5F3: Supply UCM ( 7.5 A)
D3 Fuse 5F2: Supply UCM ( 10 A)
D3 Fuse 5F1: Supply UCM ( 10 A)
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SS14M180 1
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distribution 1
Location Component
C6 Cab Ground Block
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SS14M181 1
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distribution 2
Location Component
A6 Cab Ground Near Boss for UCM Ground Cable
B6 Cab Ground Outer Hole
D6 Steering Column Ground Upper Stud
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SS14M182 1
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distribution 3
Location Component
B6 Ground Steering Column
D6 Cab Ground Block
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SS14M183 1
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distribution 4
Location Component
B1 LH Rear Cab Floor Ground
B6 LH Rear Cab Mount Frame Ground
C6 Frame Ground Continued SH02
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SS14M184 1
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Harnesses and connectors - Electrical schematic sheet 12 - Engine

control unit 1, Grid heater, Filter heater
Location Component
A3 XR19-2 Thermostat S100
A3 Filter Heater R19
A4 Fuel Filter Heater R19-1
B2 Grid Heater Relay K1-7
B4 Fuse F20–1: Grid heater fuse ( 125 A)
B5 Grid Heater R17
C1 ECU A158
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SS14M185 1
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control unit 2
Location Component
A1 SCR Tank Heating Valve Y-063
A6 Air Filter Switch S15-1
B1 Sensor Tank Level & Temp B-020
B6 Throttle Control R10
C1 SCR Downstream Exhaust Gas Temp Sensor (T7) B-022
C1 DOC Upstream Exhaust Gas Temp Sensor (T4) B-049
C4 ECU A158
C6 Sensor Humidity and Temperature B-055
D1 SCRUpstream Exhaust Gas Temp Sensor (T6) B-021
D1 UREA Dosing Valve Y-007
D6 Water in Fuel S158-5
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SS14M186 1
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control unit 3
Location Component
A1 SCR Downstream NOX Sensor B-054
B1 DOC Upstream NOX Sensor B-056
C1 NH3 Module B-057
C3 ECU A158
D1 DEF Quality Sensor (UQS) B-050
D1 Controller Area Network R-020
D6 DENOX Control Unit A-037
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SS14M187 1
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Harnesses and connectors - Electrical schematic sheet 15 - ECU - AIC 1

Location Component
A6 Fan Control Y138
B1 Parking Brake Solenoid Y16
B6 Hydraulic Oil Temp R14
B6 Fuel Level Sensor R2
C1 Parking Brake S16
C3 AIC
D2 Brake Warning S17-1
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SS14M188 1
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Harnesses and connectors - Electrical schematic sheet 16 - ECU - AIC 2

Location Component
A6 Buzzer H1
C3 AIC
C6 Steering Pressure 2.0 bar (29.0 psi) S-17
D6 Emergency Steering 2.0 bar (29.0 psi) S17-6
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SS14M189 1
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Harnesses and connectors - Electrical schematic sheet 17 CAN structure

Location Component
A1 Switchpad C5-9
A6 Diagnostic Plug X123
A6 CAN Terminator R-022
B1 Speed LTD C5-F
B1 Adapter Harness
C2 Coding Plug
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SS14M190 1
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Harnesses and connectors - Electrical schematic sheet 18 - Gear control

unit 1
Location Component
A4 Parking Brake S16-1
A4 Speed Sensor Gear Trans B4
B4 Gear Selector Lever B12
C1 Gear Control Unit EST 37A
C5 ZF Diagnostic XA5
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SS14M191 1
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Harnesses and connectors - Electrical schematic sheet 19 - Gear control

unit 2
Location Component
A4 Gearshift A9
A5 Gear Oil Temp B15
B4 Middle Wheel Chain Speed Sensor B3
B6 Oil FLTR Press SW S17-9
C1 Gear Control Unit EST 37A
C4 Turbine Speed Sensor B2
C4 Engine Speed Sensor B1
D4 Auto / Manual S87-8
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SS14M192 1
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Harnesses and connectors - Electrical schematic sheet 20 - ECU - UCM

power supply
Location Component
C1 UCM A157
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SS14M193 1
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Harnesses and connectors - Electrical schematic sheet 21 ECU - UCM

Location Component
A5 Reverse Y8-6
B5 Forward Y8-5
B5 Wheel Motor Y8-2
B5 FWD ON / OFF Y8-1
C1 UCM A157
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SS14M194 1
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Harnesses and connectors - Electrical schematic sheet 22 - Floating

position
Location Component
A3 Floating Position Y3-4
C3 Floating Position S77-5
D5 Floating Position S38-1
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SS14M195 1
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Harnesses and connectors - Electrical schematic sheet 23 - Engager pin,

rapid hydraulic, plug operator seat
Location Component
B3 Operators Presence
B2 Rapid Working Hydraulic Y28
C2 Engager Pin Y27
C4 Rapid Working Hydraulic S28
D4 Engager Pin S27
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SS14M196 1
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Harnesses and connectors - Electrical schematic sheet 24 - Lighting

steering column switch, domelight
Location Component
A1 Domelight left E9-2
A2 Domelight right E9-1
B4 Steering Column Switch S23
C3 Parking Light / Head Light S5
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SS14M197 1
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hazard warning, blinkers
Location Component
A3 Flasher Cab right E8
A3 Flasher Cab left E7
A4 Flasher Front right E23
B4 Flasher Front left E22
B4 Flasher Rear right E6E3
B4 Flasher Rear left E5E3
C2 Steering Column Switch S23
C4 Hazard Warning S20
C5 Flasher Relay K20-1
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SS14M198 1
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headlight, full beam, tail, parking, side marker light
Location Component
A2 Side Marker Light right E23E1
A2 Side Marker Light left E22E1
A2 Parking Light right E2E2
B2 Tail Light right E6E1
B2 Parking Light left E1E2
C2 Tail Light left E5E1
C2 License Plate Light E12-2
C2 License Plate Holder Assembly E12-1
D2 Full Beam left E1E1
D2 Full Beam right E2E1
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SS14M199 1
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back up, reverse light
Location Component
A2 Brakelight right E63E2
A2 Brakelight left E5E2
A4 Brake Pressure 4 bar S18
B4 Transmission Neutral S26-4
C2 Reverse Light right E51
C2 Reverse Light left E50
C2 Back up Alarm H81
D4 Back up Alarm S77-4
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SS14M200 1
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working lights cab roof, front and rear
Location Component
A1 WL Rear Frame right E4-8
A1 WL Rear Frame left E3-8
A4 Working Light Rear S77-3
B1 WL Cab Front right E4-9
B1 WL Cab Front left E3-9
B4 Working Light Front S77-2
C1 WL Cab Roof Rear E4-6
C1 WL Cab Roof Rear E3-6
C1 WL Cab Roof Front E4-1
C1 WL Cab Roof Front E3-1
D4 Working Lights Cab Roof S77-1
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SS14M201 1
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Harnesses and connectors - Electrical schematic sheet 29 - Cab

wiper/washer front
Location Component
A4 Washer Front M4
B1 Wiper Front M3
B3 Interval Relay K23
C2 Wiper Washer Front S3
D4 Washer Front S50-1
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SS14M202 1
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Harnesses and connectors - Electrical schematic sheet 30 - Cab

wiper/washer rear
Location Component
A4 Washer Rear M4-1
B1 Wiper Rear M3-1
B3 Interval Relay Rear K23-1
C2 Wiper Washer Rear S3-2
D4 Washer Rear S50-3
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SS14M203 1
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Harnesses and connectors - Electrical schematic sheet 31 - Heating

blower heater, HVAC
Location Component
A2 MAG Coupling Compressor E19Y1
A3 AC Press SW 3 bar - 21 bar E19B1
B2 Blower Heating M19
B5 Air Actuator M19-1
D4 HVAC Control Panel E72
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SS14M204 1
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Harnesses and connectors - Electrical schematic sheet 32 - Cabin

defrost rear windscreen, beacon
Location Component
A3 Beacon Light E36
B4 Beacon Light Switch S36
C2 Defrost R61
D4 Defrost S2
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SS14M205 1
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Harnesses and connectors - Electrical schematic sheet 33 - Cabin radio

loudspeaker 12V power outlet
Location Component
A1 Power Outlet 12V E12-P
A1 Loudspeaker left LP2
B1 Loudspeaker right LP1
B2 Radio A91
C6 Power Converter A90-1
D2 Horn H7
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SS14M206 1
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Miscellaneous, Fuel system
Location Component
A4 Fueling Pump M67
B4 Level Switch S67-1
B4 Filler Tube S15-5
C4 Fueling System S67
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SS14M207 1
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Miscellaneous, Creep mode
Location Component
B2 C6.9 Module Rotary Switch FWD/CM
C3 Controller Area Network R-021
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SS14M208 1
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Miscellaneous, Blade control
Location Component
B2 Blade Control
B4 Fuse BC–F30A: Blade control fuse holder ( 30 A)
B4 Fuse BC–F5A: Blade control fuse holder ( 5 A)
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SS14M209 1
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Miscellaneous, Telematics
Location Component
C2 Diagnostics Telematics Connector
C4 Telematic Module AM50
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SS14M210 1
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Miscellaneous, Rear camera
Location Component
B4 Rear Camera Cable Adapter
D2 Camera 1
D5 Monitor
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SS14M211 1
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Harnesses and connectors - Component localization - Main

connectors
X33–20 – Engine-Gear / Cab floor
SS14K318 1
NOTE: For detailed connector information see: Harnesses and connectors - Component diagram 01 - Engine /
Gear (55.100) and Harnesses and connectors - Component diagram 05 - Cab floor (55.100).
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SS14K317 2
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SS14K319 3
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X38-8 – Rear frame / Cab floor
SS14K316 4
NOTE: For detailed connector information see: Harnesses and connectors - Component diagram 05 - Cab floor
(55.100) and Harnesses and connectors - Component diagram 14 - Rear frame (55.100).
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XA158 – ECU
SS14K320 5
Gear (55.100).
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Harnesses and connectors - Component diagram 01 - Engine / Gear

Connector GND_R19 – Filter heater ground
84140737 1
Cavity Wire ID Circuit Cavity Wire ID Circuit

(1) 421–4 Fuel filter heater GND
Connector GND_R19-1 – GND-Thermostat
84140737 2

(1) 422–4 Water seperator SW GND
Connector GND_X31EN2 – GND for sensors
84426126 3

(1) 123–4 Ground
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Connector K10-1-30 – Power relay
84163398 4

(1) 30 Battery B+
Connecor K10-1-87 – Power relay
84313702 5

(1) 87 Battery unswitched
Connector K10-1-B – Power relay
84301912 6

(1) 14–6 Power relay B
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Connector K10-1-E – Power relay
84301912 7

(1) 14–7 Key switch relay GND
Connector K10-1-L – Power relay
84301912 8

(1) 14–5 Power relay L
Connector K1-5-30 – Starting relay
84426136 9

(1) 303 Start signal
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Connector K1-5-87 – Starting relay
84426136 10

(1) 302 Start relay
Connector X_CNW_B – ECM Flashing only
87696093 11

(1) 671 CAN HI proto only (2) 695 CAN LO proto only
Connector X_GND_INTERFACE_PLUG_C – X-GND-Interface plug-C
84426126 12

(1) CN42–4 X_INF_C GND
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Connector X_GROUND_ECU – GND-ECU
84426126 13

(1) ECU1 ECU Ground
Connector X_GROUND_ECU_1 – X-GND-ECU-1
84426126 14

(1) ECU_1 ECU Ground
Connector X_INF_C – Interface wiring harness plug C
84152563 15

(1) CN42–1 AUX relay (5) CAN_O_ CAN LO
X2 L-2
(2) CN42–4 X_INF_C GND (6) CAN_O_ CAN HI
H-2
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Connector X15-1 – Air filter switch
84607243 16

(1) 613–5 Relay filter heating HI side (2) 637A Air filter switch
Connector X1G1 – Alternator
84163450 17

(3) 23–2 Alternator sense (4) 300–1 Alternator B+
Connector X1G1-1-B1+ – Alternator
84313704 18

(1) 300–1 Alternator B+
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Connector X1G1-B1+ – Alternator
84159611 19

(1) 301 Alternator B+
Connector X33-20 – Interface cab
87696950 20

(1) 330 Turbine speed sensor (17) 370 Gearshift temp
(2) 332 Engine speed sensor (18) 351–3 Speed sensor
(3) 334 Middle wheel chain speed sensor (19) 353 Speed sensor gear
(4) 335–2 Speed sensors common (20) 354 Speed sensor gear
(5) 315–3 Reverse solenoid (21) 341–11 Parking brake
(6) 373–1 Gear oil temp (22) 23–2 Alternator sense
(7) 314–3 Forward solenoid (23) 355–1 Parking brake
(8) 341–6 Ground (24) 361–1 Parking brake
(9) 362 Gearshift Y1 (25) 1_702–2 Fuel level sensor
(10) 363 Gearshift Y2 (26) 325–3 Fuelling system
(12) 365 Gearshift Y4 (28) 372–1 Oil filter press SW
(15) 368 Gearshift VPS1 (31) 1_709–2 Hydraulic oil temp
(16) 369 Gearshift temp
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Connector X33-30 – Inerface cab floor harness
87700171 21

(1) 397–3 Forward reverse sol (13) 1–704–12 CAN LO
(2) 398–1 Ground (14) 1–703–12 CAN HI
(5) 613–2 Relay filter heating HI side (15) CN42–1 AUX relay
X2
(6) 636–2 Relay filter heating low side (16) 342–1 HVAC
(7) 620 ENG AUX (18) 643–3 Throttle control IVS idle active
(8) 645–11 ENG AUX (20) 660 Throttle control IVS idle active
(9) 637–2 Start control relay (23) 666 Throttle supply +5
(10) 617–2 Start control relay low side (24) 645 Throttle control ground
(11) 640–2 Key switch fused power (27) 646 Throttle control signal
(12) 663–2 -
Connector X33-40 – Inerface cab
87703997 22

(1) 14–6 Power relay B (11) 309–1 Start relay GND
(2) 14–5 Power relay L (12) 600–24 EDC Fused power
(3) 14–7 Key switch relay GND (14) 30 Battery B+
(8) 421–3 Relay filter heating 30 (16) CN42–3 -
(9) 154–6 Start relay signal (17) 422–2 Pre-filter fused
(10) 600–23 EDC Fused power
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Connector X33-50 – Interface cab
84164978 1

(1) 87 Battery unswitched
Connector XA-037 – DENOX control unit
47421681 2

(2) 668 DENOX control unit 2 (9) 650–1 DENOX control unit 9
(3) 607 DENOX control unit 3 (10) 684 DENOX control unit 10
(4) 639–2 Sensor tank level and temp (11) 650–2 DENOX control unit 11
(8) 689 DENOX control unit 8 (12) 685 DENOX control unit 12
Connector XA158 – ECU Connector
84300197 3
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(1) 601 EDC fused power (47) 1_704–12 CAN LO
(3) 603 Ground (49) 649 EDC fused power
(5) 605 Ground (50) 650 DENOX control unit 9
(7) 607 DENOX control unit 3 (52) 652 Ground
(8) 608 Sensor tank level and temp (60) 660 Throttle control IVS idle active
(9) 609 SCR downstream temp (61) 636–2 Relay filter heating low side
(10) 610 Temp sensor ground (63) 663–2 -
(13) 613–4 Water in fuel (66) 666 Throttle supply +5
(15) 615 Humidity temp sensor (68) 668 DENOX control unit 2
(16) 616 DOC upstream temp (69) 669 Key switch fused power
(19) 637–2 Start control relay (71) 671 CAN HI proto only
(20) 620 ENG AUX (72) 672 SCR tank heating valve
(23) 623 UREA dosing valve 2 (73) 673 EDC fused power
(25) 625 EDC fused power (74) 674 Grid heater relay HI
(26) 626 EDC fused power (75) 675 Ground
(27) 613–3 Relay filter heating HI side (76) 676 ECU GND
(28) 628 Ground (79) 646 Throttle control signal
(29) 629 ECU Ground (80) 645 Throttle control ground
(31) 631 Sensor tank level and temp (83) 683 Grid heater relay LO
(32) 632 SCR upstream temp (84) 684 DENOX control unit 10
(37) 637A Air filter switch (85) 685 DENOX control unit 12
(39) 639 Sensor tank level and temp (88) 617–2 Start control relay low side
(40) 640–4 Humidity temp sensor (89) 689 DENOX control unit 8
(43) 643 Humidity temp sensor (90) 690 Humidity temp sensor
(45) 645–11 ENG AUX (95) 695 CAN LO proto only
(46) 1_703–1 CAN HI (96) 696 UREA dosing valve 1
2
Connector XA9 – Gearshift connector
INA 4

(1) 362 Gearshift Y1 (6) 367 Gearshift Y6
(2) 363 Gearshift Y2 (7) 368 Gearshift VPS1
(3) 364 Gearshift Y3 (8) 369 Gearshift temp
(4) 365 Gearshift Y4 (9) 371–2 -
(5) 366 Gearshift Y5
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Connector XB-020 – DEF level / temp
84062580 5

(1) 631 Sensor tank level and temp (3) 608 Sensor tank level and temp
(2) 639–1 Sensor tank level and temp
Connector XB-021 – SCR upstream exhaust gas temp sensor
87709793 6

(1) 632 SRC upstream temp (2) 610–1 Temp sensor ground
Connector XB-022 – SCR downstream exhaust gas temp sensor
87709793 7

(1) 609 SRC downstream temp (2) 610–3 Temp sensor ground
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Connector XB-049 – DOC upstream exhaust gas temp sensor
87709793 8

(1) 616 DOC upstream temp (2) 610–2 Temp sensor ground
Connector XB-050 – DEF quality sensor
84149219 9

(3) CN42–3 AUX relay fuse (5) CAN_O_ CAN LO
4 L-9
(4) CAN_O_ CAN HI (6) 123–45 Ground
H-9
Connector XB-054 – SCR downstream NOX sensor
84190317 10
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(1) 123–31 AUX relay fuse (3) CAN_O_ CAN LO
L-3
(2) 123–41 Ground (4) CAN_O_ CAN HI
H-3
Connector XB-055 – Sensor humidity and temperature
87709809 11

(1) 690 Humidity temp sensor (3) 643–1 Humidity temp sensor
(2) 615 Humidity temp sensor (4) 640–4 Humidity temp sensor
Connector XB-056 – DOC upstream NOX sensor
84190317 12

(1) 123–32 AUX relay fuse (4) CAN_O_ CAN HI
H-5
(2) 123–43 Ground (5) 123–42 Ground
(3) CAN_O_ CAN LO
L-5
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Connector XB-057 – NH3 sensor
84146686 13

(1) CN42–3 AUX relay fuse (3) CAN_O_ CAN LO
3 L-7
(2) CAN_O_ CAN HI (4) 123–44 Ground
H-7
Connector XB1 – Speed sensor engine
84364854 14

(1) 332 Engine speed sensor (2) 333 Engine speed sensor
Connector XB15 – Gear oil temp
84364854 15

(1) 371–1 Gear oil temp (2) 373–1 Gear oil temp
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Connector XB2 – Speed sensor turbine
84364854 16

(1) 330 Turbine speed sensor (2) 331 Turbine speed sensor
Connector XB3 – Speed sensor middle wheel chain
84364854 17

(1) 334 Middle wheel chain speed sensor (2) 335 Middle wheel chain speed sensor
Connector XB4 – Speed sensor gear trans
84062580 18

(1) 354 Speed sensor gear (3x) 351–3 Speed sensor
(2) 353 Speed sensor gear
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Connector XE19B1 – AC pressure switch
47377964 19

(1) 342–1 HVAC (2) 342–2 AC compressor
Connector XE19Y1 – AC Compressor
87687239 20

(1) 342–2 AC compressor
Connector XK1-5 – K1–5 Start relay
87695582 21

(1) 154–6 Start relay signal (2) 309–1 Start relay ground
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Connector XK1-7 – Grid heater
82012083 22

(1) 674 Grid heater relay HI (2) 683 Grid heater relay LO
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Connector XM1 – Starter
84176551 1

(1) 301 Alternator B+
Connector XM1-1 – Starter
84596842 2

(1) 302 Start relay
Connector XM1-2 – Starter
87699700 3

(1) 303 Start signal
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Connector XR-020 – Controller area network
87695580 4

(A) CAN_O_ CAN HI (B) CAN_O_ CAN LO
H-10 L-10
Connector XR14 – Hydraulic oil temp
INA 5

(1) 1_709–2 Hydraulic oil temp (2) 1_709–3 Ground
Connector XR19 – Filter Heater
47373511 6

(A) 421–3 Relay filter heating 30 (B) 421–4 Fuel filter heater GND
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Connector XR19-1 – Heating
87679438 7

(A) 422–2 Pre-filter fused (B) 422–3 Pre-filter fused
Connector XR19-2 – Thermostat
82012083 8

(1) 422–3 Pre-filter fused (2) 422–4 Water seperator SW GND
Connector XR2 – Level sensor
82944117 9

(1) 1_702–2 Fuel level sensor (2) 326–2 Fuel level sensor GND
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Connector XS15-5-1 – Pressure tank switch
87699700 10

(1) 510–1 Fuelling system
Connector XS15-5-2 – Pressure tank switch
87699700 11

Connector XS158-5 – Water in fuel
84806091 12

(1) 613–4 Water in fuel (3) 640–3 Key switch fused power
(2) 643–2 Water in fuel
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Connector XS16-1-1 – Pressure switch parking brake
87699700 13

(1) 355–1 Parking brake
Connector XS16-1-2 – Pressure switch parking brake
87699700 14

(1) 361–1 Parking brake
Connector XS17-9 – Pressure switch oil filter
82012083 15

(1) 371 Oil filter press SW (2) 372–1 Oil filter press SW
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Connector XS67-1 – Level switch
87695525 16

(1) 326–1 Ground (3) 325–3 Fuelling system
Connector XY-007 – UREA Dosing valve
87709798 17

(1) 696 UREA dosing valve 1 (2) 623 UREA dosing valve 2
Connector XY-063 – SCR tank heating valve
84146685 18

(1) 650–3 SCR tank heating valve (3) 672 SCR tank heating valve
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Connector XY16 – Valve parking brake
INA 19

(1) 341–11 Parking brake (2) 341–6 Ground
Connector XY8-5 – Value FWD forward
INA 20

(1) 314–3 Forward solenoid (2) 397–31 Forward solenoid
Connector XY8-6 – Valve FWD reverse
INA 21

(1) 315–3 Reverse solenoid (2) 397–32 Reverse solenoid
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Harnesses and connectors - Component diagram 04 - Cab floor

Connector B12X2 – Gear selector lever
87692802 1

(B) 386 Gear selector (D) 384 Gear selector
(C) 385 Gear selector
Connector B12X3 – Gear selector lever
87692817 2

(A) 352 Gear selector (C) 390 Gear selector
(B) 387 Gear selector (D) 424 Gear selector
Connector S18-1 – Brake pressure
87705127 3

(1) 156–3 Brake pressure
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Connector S18-2 – Brake pressure
87705127 4

(1) 156–1 Brake pressure
Connector X101 – Interface side console
87708534 5

(1) 1_706–1 Ground (26) 388–1 Gear selector
(2) 2_716–1 Fuelling system (27) 409–1 Engager pin
(3) 1_720–1 AIC delay (28) 700–11 Fused hazard warning
(4) 1_714–1 Park brake relay (29) 700–21 Fused flashers
(5) 175–2 Brake lights (30) 325–2 Fuelling system
(6) 341–4 Fused parking brake (31) 343–4 Fuelling system
(7) 2_714–1 AIC fused (32) 510 Fuelling system
(8) 2_721–1 Ignition 15 (33) 510–21 Fuelling system
(9) 143–1 Ignition 15 (34) 527–2 Fuelling system
(10) 2_719–2 Floating position (35) 154–5 Star relay signal
(11) 156–3 Brake pressure (36) 14–4 -
(12) 156–1 Brake pressure (37) 195–5 -
(13) 145–1 Horn relay power (38) 126–12 Radio
(14) 144–121 Headlight relay (39) 126–31 Radio
(15) 144–141 Headlight relay (40) 1_719–1 Camera trigger 2
(16) 186–1 Headlight (41) 174–24 Floating position
(17) 801A Headlight (42) 174–21 Floating position
(18) 192–22 Working lights (43) 317–12 FWD on / off
(19) 191–21 Working lights (44) 397–2 Forward reverse solenoid
(20) 87–2 Reverse light left (45) 802 Switch pad
(21) 149–2 Back up alarm (46) 802–71 Parking plate tail lights
(22) 108–1 Washer front (47) 802–81 Parking marker light
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(23) 86–5 Beacon (48) 358–1 Diagnostic
(24) 316–12 Wheel motor (49) 360–1 Diagnostic
(25) 351–1 Gear selector (50) 1_723–1 Fuelling system
Connector X102 – Interface side console
87708540 6

(1) - - (26) 341–10 Parking brake
(2) 396–2 Trans neutral (27) 97–1 Horn relay HI
(3) 159–1 Domelight fused power (28) 144–4 Fused horn lights
(4) 620–1 ENG AUX (29) 802–2 Switch pad
(5) 391–1 TCU 23–68 (30) 144–32 Parking / head light
(6) 329–3 Auto man (31) 314–2 Forward solenoid
(7) - - (32) 315–2 Reverse solenoid
(8) - - (33) 316–3 Wheel motor
(9) CN42–1 AUX relay (34) 317–3 FWD on / off
X1
(10) 42–2 AUX relay fuse (35) - -
(11) 147 TCU 7 (36) 512–24 HAVC
(12) 645–2 ENG AUX (37) 512–33 HAVC
(13) 1_721–2 Rear defrost (38) 512–43 HAVC
(14) 2_707–1 Rear defrost (39) 408–11 HAVC
(15) 38–11 Defrost (40) 213–14 HAVC
(16) 12–32 WL cab roof rear (41) 213–22 HAVC
(17) 179–1 Ignition 50A (42) 422–1 Pre-filter fused
(18) 23–1 Alternator excite (43) - -
(19) 12–42 WL cab roof front (44) 144–61 Parking light / head light
(20) 421–2 Relay filter heating 30 (45) 1_704–3 CAN LO
(21) 640–1 Key switch fused power (46) 1_703–3 CAN HI
(22) 613–1 Relay filter heating HI side (47) 2_703–6 CAN HI
(23) 636–1 Relay filter heating low side (48) 2_704–6 CAN LO
(24) 637–1 Start control relay (49) 1_703–11 CAN HI
(25) 617–1 Start control relay low side (50) 1_704–11 CAN LO
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Connector X104-2 –
87680386 7

(1) 600–1 EDC fused power
Connector X15A_SP1 – Connecting block side console
84426136 8

(1) 87AA –
Connector X19Connector X19 – Blower heating
INA 9

(A) 512–43 HVAC (E) 342 HVAC
(B) 512–33 HVAC (F) 2_712–1 HVAC
(C) 512–24 HVAC (F) 408–11 HVAC
(D) 512–5 Ground
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Connector X19-1 – Air actuator
87694714 10

(A) 213–14 HVAC (D) 213–22 HVAC
(C) 19–1 Ground
Connector X30-SP1 – Connecting block side console
84426130 11

(1) 30–1 Battery B+
84426130 12

(1) 162–1 Key switch B+
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Connector X31CF1-1 – Cab ground block
84122130 13

(1) 9 Ground
84122130 14

(1) 33–10 Ground (1) 314–20 Ground
84122130 15

(1) 14–8 Ground (1) 337 Ground
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84122130 16

(1) 19–1 Ground (1) 309 Ground
84122130 17

(1) 336 Ground (1) 512–5 Ground
Connector X31CF2-1 – Steering column ground
84122130 18

(1) 9 Ground
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84122130 19

(1) 10 Ground
84122130 20

(1) 8 Ground (1) 68–0 Ground
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Harnesses and connectors - Component diagram 05 - Cab floor

Connector X33-2 – Interface steering column
47589949 1

(1) 2_703–6 CAN HI (9) 12–32 WL cab roof rear
(2) 2_704–6 CAN LO (10) - -
(3) 126–12 Radio (11) 91–2 Interval relay
(4) 126–31 Radio (12) 108–16 Washer front
(5) 12–42 WL cab roof front (13) 108–1 Washer front
(6) 1_721–2 Rear defrost (14) 1_703–1 CAN HI
(7) 700–11 Fused hazard warning (15) 1_704–1 CAN LO
(8) 700–21 Fused flashers
Connector X33-20 – Interface engine / gear harness
87696945 2

(1) 330–1 Turbine speed sensor (17) 370–1 Gearshift temp
(2) 332–1 Engine speed sensor (18) 351–2 Speed sensor
(3) 334–1 Middle wheel chain speed sensor (19) 353–1 Speed sensor gear
(4) 335–1 Speed sensors common (20) 354–1 Speed sensor gear
(5) 315–2 Reverse solenoid (21) 341–10 Parking brake
(6) 373 Gear oil temp (22) 23–1 Alternator excite
(7) 314–2 Forward solenoid (23) 355 Parking brake
(8) 314–20 Ground (24) 361 Parking brake
(9) 362–1 Gearshift Y1 (25) 1_702–1 Fuel level sensor
(10) 363–1 Gearshift Y2 (26) 325–2 Fuelling system
(12) 365–1 Gearshift Y4 (28) 372 Oil filter press SW
(13) 366–1 Gearshift Y5 (29) 510 Fuelling system
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(15) 368–1 Gearshift VPS 1 (31) 1_709–1 Hydraulic oil temp
(16) 369–1 Gearshift temp
47589949 3

(1) 144–61 Parking light / head light (8) 144–32 Parking / head light
(2) 144–121 Headlight relay (9) 174–24 Floating position
(4) 97–1 Horn relay HI (11) 663–1 -
(5) 802 Switch pad (12) - -
(5) 802–2 Switch pad (13) 159–1 Domelight fused power
(6) - - (14) - -
(7) 801 Headlight (15) 144–4 Fused horn lights
Connector X33-30 – Interface engine / gear harness
87426768 4

(1) 397–2 Forward reverse solenoid (16) 342 HVAC
(2) 33–10 Ground (17) - -
(3) - - (18) 643–4 Throttle control IVS idle active
(4) - - (19) - -
(5) 613–1 Relay filter heating HI side (20) 660–1 Throttle control IVS idle active
(6) 636–1 Relay filter heating low side (21) - -
(7) 620–1 ENG AUX (22) - -
(8) 645–2 ENG AUX (23) 666–1 Throttle supply +5
(9) 637-1 Start control relay (24) 645–1 Throttle control ground
(10) 617–1 Start control relay low side (25) - -
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(11) 640–1 Key switch fused power (26) - -
(12) 663–1 - (27) 646–1 Throttle control signal
(13) 1_704–1 CAN LO (28) - -
1
(14) 1_703–1 CAN HI (29) - -
1
(15) CN42–1 AUX relay
X1
47589949 5

(1) 1_723–1 Fuelling system (9) 1_715–1 Brakelights
(2) 1_702–1 Fuel level sensor (9) 1_715–2 Brakelights
(3) - - (10) 86–5 Beacon
(4) 2_707–1 Rear defrost (11) 1_720–1 AIC delay
(5) 1_706–1 Ground (12) 2_716–1 Fuelling system
(6) 1_709–1 Hydraulic oil temp (13) 1_726–1 Fan control
(7) 1_719–1 Camera trigger 2 (14) 1_724–1 Emergency steering
(8) 1_714–1 Park brake relay (15) 38–11 Defrost
Connector X33-40 – Interface engine gear
87696098 6

(1) 195–5 - (10) 600–21 EDC fused power
(2) 14–4 - (11) 309 Ground
(3) 14–8 Ground (12) 600–22 EDC fused power
(4) - - (13) - -
(5) - - (14) 30–1 Battery B+
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(6) - - (15) - -
(7) - - (16) 42–2 AUX relay fuse
(8) 421–2 Relay filter heating 30 (17) 422–1 Pre-filter fused
(9) 154–5 Start relay signal (18) - -
47589949 7

(1) 162–1 Key switch B+ (7) 2_711-1 Steering pressure
(2) 2_705–1 Brake warning (8) 2_712-1 HVAC
(3) 341–4 Fused parking brake (9) - -
(4) 2_719–2 Floating position (10) 2_714-1 AIC fused
(4) 110 Floating position (11) 2_721-1 Ignition 15
(5) 84–1 Left turn HI (12) - -
(5) 84–11 Left turn HI (13) - -
(6) 85–1 Right turn HI (14) 143–1 Ignition 15
(6) 85–11 Right turn HI (15) 179–1 Ignition 50A
Connector X33-50 – Interface engine gear
47539713 8

(1) 87AA –
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Connector X38-8 – Interface rear frame
87708534 9

(1) - - (14) 382–1 Ground
(2) - - (15) 406–2 Ground
(3) - - (16) 91–2 Interval relay
(4) 1_724–1 Emergency steering (17) 108–16 Washer front
(5) - - (18) 340–13 Ground
(6) - - (19) 87–11 Reverse light left
(7) 343–4 Fuelling system (20) 175–22 Brakelights
(8) 343–43 Ground (21) 78–2 Parking plate tail lights
(9) 347 Engager pin (22) 84–1 Left turn HI
(10) 347–3 Ground (23) 340–43 Ground
(11) 348 Rapid working hydraulic (24) 191–13 Working lights
(12) 348–3 Ground (25) 191–11 Working lights
(13) 149–2 Back up alarm
Connector X3-9-1 – WL cab front left power
INA 10

(1) 192–21 Working lights
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Connector X3-9-2 – WL cab front left GND
INA 11

(1) 192–23 Ground
Connector X44 – Brake pressure
87680385 12

(1) 2_705–1 Brake warning (2) 410 Ground
Connector X4-9-1 – WL cab front right power
INA 13

(1) 192–21 Working lights (1) 192–22 Working lights
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Connector X4-9-2 – WL cab front right GND
INA 14

(1) 192–24 Ground
Connector X68-0 – Interface front frame
84364746 15

(1) 84–11 Left turn HI (9) 145–1 Horn relay power
(2) 85–11 Right turn HI (10) - -
(3) 78–3 Parking plate tail lights (11) 145–6 Ground
(4) 79–2 Parking marker light (12) 313 Parking marker light
(5) 186–3 Headlight (13) 110–3 Ground
(6) 186–2 Headlight (14) - -
(7) 187–1 Headlight (15) 110 Floating position
(8) 187–2 Headlight (16) -
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Connector XA1 – Gear control unit
84550089 16

(1) 336 Ground (35) - -
(2) 337 Ground (36) - -
(3) 335–1 Speed sensor common (37) - -
(4) 354–1 Speed sensor gear (38) - -
(5) - - (39) 369–1 Gearshift temp
(6) - - (40) - -
(7) 147 TCU 7 (41) 330–1 Turbine speed sensor
(8) - - (42) 334–1 Middle wheel chain speed sensor
(9) 366–1 Gearshift Y5 (43) 387 Gear selector
(10) 363–1 Gearshift Y2 (44) - -
(11) - - (45) 356 Gear selector
(12) 368–3 Gearshift VPS 1 (46) 370–1 Gearshift temp
(13) 368–2 Gearshift VPS 1 (47) - -
(14) - - (48) - -
(15) 358–1 Diagnostic (49) 373 Gear oil temp
(16) - - (50) - -
(17) 372 Oil filter press SW (51) 367–1 Gearshift Y6
(18) 360–1 Diagnostic (52) - -
(19) 332–1 Engine speed sensor (53) - -
(20) - - (54) - -
(21) 361 Parking brake (55) 365–1 Gearshift Y4
(22) 384 Gear selector (56) 362–1 Gearshift Y1
(23) 391–3 TCU 23 (57) - -
(24) - - (58) - -
(25) 1_703–2 CAN HI (59) - -
(26) 1_704–2 CAN LO (60) - -
(27) - - (61) - -
(28) - - (62) 353–1 Speed sensor gear
(29) 329–3 Auto man (63) 385 Gear selector
(30) - - (64) 390 Gear selector
(31) - - (65) 386 Gear selector
(32) 364–1 Gearshift Y3 (66) 396–2 Trans neutral
(33) - - (67) 388–2 Gear selector
(34) - - (68) 391–2 TCU 68
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Connector XR10 – Throttle control
87699184 17

(A) 646–1 Throttle control signal (D) 660–1 Throttle control IVS idle active
(B) 645–1 Throttle control ground (E) - -
(C) 666–1 Throttle supply +5 (F) 643–4 Throttle control IVS idle active
Connector XS27 + – Footswitch engager pin
87705127 18

(1) 409–1 Engager pin (1) 409–2 Rapid working hydraulic
Connector XS27-A – Footswitch engager pin
87705127 19

(1) 347 Engager pin
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Connector XS28 + – Footswitch rapid working
87705127 20

(1) 409–2 Rapid working hydraulic
Connector XS28-A – Footswitch rapid working
87705127 21

(1) 348 Rapid working hydraulic
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Harnesses and connectors - Component diagram 06 - Cab roof

Connector X_CAM1 – Rear camera
87700107 1

(1) 455–21 Rear cam PWR (3) 455–11 Rear cam GND
(2) 455–31 Rear cam GND (4) 1_719–3 Camera trigger 2
Connector X_CAM2 – Rear camera
87700105 2

(1) 455–21 Rear cam PWR (3) 455–11 Rear cam GND
Connector X14 – Cab roof steering column interface
84364852 3
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(3) 1_707–2 PWM (11) RES_3 Reserve
(4) 159–3 Domelight fused power (12) 12–75 Radio
(6) 38–13 Defrost (13) 12–51 Radio
(7) 86–7 Beacon (14) 14–14 Ground
(8) 108–22 Wiper front (15) 38–7 Ground
(9) 108–21 Wiper front (16) 14–16 Ground
(10) 108–23 Wiper front
Connector X15 – Cab roof steering column interface
84364746 4

(3) RES_3– Reserve rear wiper (8) 7–1 Flasher cab left
1
(5) 36 WL cab roof rear (9) 108–55 Wiper rear
(6) 31 WL cab roof front (10) 108–57 Wiper rear
(7) 8–1 Flasher cab right (11) 108–58 Wiper rear
Connector X3-1-1 – Working light - power front right
87699700 5

(1) 31–1 WL cab roof front
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Connector X3-1-2 – Working light - GND front right
INA 6

(1) 31–2 Ground
Connector X31-G – Defrost GND
87699700 7

(1) 38–6 Ground
Connector X31-P – Defrost power
87699700 8

(1) 38–13 Defrost
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Connector X3-6-1 – Working light - power rear right
87699700 9

(1) 36–1 WL cab roof rear
Connector X3-6-2 – Working light - GND rear right
INA 10

(1) 36–2 Ground
Connector X40 – Beacon light
84015523 11

(1) 86–7 Beacon (2) 86–11 Ground
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Connector X4-1-1 – Working light - power front left
87699700 12

(1) 41–1 WL cab roof front
Connector X4-1-2 – Working light - GND front left
INA 13

(1) 41–2 Ground
Connector X4-6-1 – Working light - power rear left
87699700 14

(1) 46–1 WL cab roof rear
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Connector X4-6-2 – Working light - GND rear left
INA 15

(1) 46–2 Ground
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Harnesses and connectors - Component diagram 07 - Cab roof

Connector X7-1 – LH turn light
INA 1

(1) 7–1 Flasher cab left
Connector X7-2 – LH turn light GND
INA 2

(1) 7–2 Ground
Connector X8-1 – RH turn light
INA 3

(1) 8–1 Flasher cab right
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Connector X8-2 – RH turn light GND
INA 4

(1) 8–2 Ground
Connector X91-1 – Radio connector
87709660 5

(4) 12–71 Radio (7) 12–7 Radio
(4) 12–72 Radio (7) 12–71 Radio
(6) 12–72 Radio (8) 12–5 Radio
Connector X91-2 – Radio speakers connector
87709371 6

(1) LP1–1 Loudspeaker right -1 (7) LP2–1 Loudspeaker left -1
(2) LP1–2 Loudspeaker right -2 (8) LP2–2 Loudspeaker left -2
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Connector X9-1A – Domelight right
INA 7

(1) 159–9 Ground
Connector X9-1C – Domelight right
INA 8

(1) 159–6 Domelight man
Connector X9-1D – Domelight right
INA 9

(1) 159–4 Domelight fused power
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Connector X9-2A – Domelight left
INA 10

(1) 159–8 Ground
Connector X9-2C – Domelight left
INA 11

(1) 159–7 Domelight man
Connector X9-2D – Domelight left
INA 12

(1) 159–5 Domelight fused power
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Connector XLP1 – Speaker connector right
84147089 13

(1) LP1–1 Loudspeaker right -1 (2) LP1–2 Loudspeaker right -2
Connector XLP2 – Speaker connector left
84147089 14

(1) LP2–1 Loudspeaker left -1 (2) LP2–2 Loudspeaker left -2
Connector XM3 – Wiper motor - front
87691943 15

(1) 108–23 Wiper front (4) RES_3 Reserve
(2) 108–21 Wiper front (5) - -
(3) 108–22 Wiper front (6) M3 Ground
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Connector XM3-1 – Wiper motor - rear
87691943 16

(1) 108–58 Wiper rear (4) RES_3–1 Reserve rear wiper
(2) 108–57 Wiper rear (5) - -
(3) 108–55 Wiper rear (6) M3–1 Ground
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Harnesses and connectors - Component diagram 08 - Side console

Connector 1F1K – Fuse / relay box
87312843 1

(A1) 224 AIC fused (B1) 38–1 1K17–30
(A10) 123 After run fused power (B10) 636 Relay filter heating low side
(A2) 600 EDC fused power (B2) 1_721–3 1K17–85
(A3) 640 Key switch fused power (B3) 14–41 Power relay L
(A4) 14–1 Power relays fused (B4) 14–43 S relay L
(A5) 421 Fuel filter heater power (B5) CN42–11 AUX relay 30
A
(A6) 126 Converter power (B6) 645–3 ENG AUX
(A7) 159A Domelight fused power (B7) 154–4 Start relay signal
(A8) 154–0 Neutral relay 87 (B8) 617 Star control relay low side
(A8) 154–1 UCM fused power (B9) 421–1 Relay filter heating hot
(A9) 23 Alternator excite (D1) 1_721–1 1K17–86
(AA1) 1_1 X15A_SP (D10) 421 Fuel filter heater power
(AA10) 1_10 Battery B+ (D2) 38_3 1K17–86
(AA2) 15A_10 X15A_SP (D3) 14–42 S relay H
(AA3) 1_3 Ignition 15 (D4) 14–1A Power relays fused
(AA4) 14 Ignition 15 (D5) 620–2 ENG AUX
(AA5) 1_5 X15A_SP (D6) CN42–1 AUX relay fuse
(AA6) 1_6 X15A_SP (D7) 637 Start control relay
(AA7) 1_7 X15A_SP (D8) 154–3 After run fused power
(AA8) 179–2 Ignition 50A (D9) 613 Relay filter heating HI side
(AA9) 1_9 X15A_SP
87312843 2
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(A1) 341 Fused parking brake (B1) - -
(A10) CN42–1 AUX relay 30 (B10) 1_714–2 Parking brake relay LO
2
(A2) 325 Fused fuelling system (B2) - -
(A3) 213–1 Fused brake light (B3) 145 Horn relay power
(A4) 174–1 Fused floating position (B4) 146 Horn relay LO
(A5) 174 Fused floating position (B5) 175–1 Brake light relay PWR
(A6) 700–1 Fused hazard waring (B6) 156–12 Brake light relay LO
(A7) 700–2 Fused flashers (B7) 184 Float position relay power
(A8) 144–0 Fused horn lights (B8) 174–5 Float position relay LO
(A9) 802–0 Fused lights (B9) 341–7 Parking brake relay PWR
(AA1) 2_11 X15A_SP (D1) - -
(AA10) CN42–11 AUX relay 30 (D10) 341–2 Fused parking brake
(AA2) 2_12 Ignition 15 (D2) - -
(AA3) 2_13 X15A_SP (D3) 97 Horn relay HI
(AA4) 2_14 X15A_SP (D4) 144–1 Fused horn lights
(AA5) 2_15 X15A_SP (D5) 156–11 Brake light relay HI
(AA6) 2_16 Battery B+ (D6) 175 Fused parking brake
(AA7) 2_17 X15A_SP (D7) 174–2 Float position relay HI
(AA8) 2_18 Switched power (D8) 174 Fused floating position
(AA9) 2_19 Switched power (D9) 341–1 Fused parking brake
87312843 3

(A1) 186–0 Fused headlight right (B1) 195–4 After run relay
(A10) 1_12 Telematics fused power (B10) 147–1 Reverse relay
(A2) 187–0 Fused headlight left (B2) 195–3 AIC delay
(A3) 11 Fused rear worklights (B3) 186 Headlight relay
(A4) 189 Fused optional worklights (B4) 144–13 Headlight relay
(A5) 89 Fused reverse relay (B5) 187 Headlight relay
(A6) CN42–1 AUX relay fuse (B6) 144–15 Headlight relay
(A7) 180 Operators seat (B7) - -
(A8) 108 Fused washer PWR (B8) - -
(A9) 86–1 Fused bacon (B9) 87A Reverse relay
(AA1) 3_21 X15A_SP (D1) 195–11 -
(AA10) 3_30 Battery B+ (D10) 89–2 Reverse light relay
(AA2) 3_22 X15A_SP (D2) 195–12 Engine main relay
(AA3) 3_23 X15A_SP (D3) 144–12 Headlight relay
(AA4) 3_24 X15A_SP (D4) 186–0 Fused headlight right
(AA5) 3_25 X15A_SP (D5) 144–14 Headlight relay
(AA6) 3_26 Switched power (D6) 187–0 Fused headlight left
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(AA7) 3_27 X15A_SP (D7) - -
(AA8) 3_28 X15A_SP (D8) - -
(AA9) 3_29 X15A_SP (D9) 89–1 Reverse light relay
87312843 4

(A1) 512 HVAC (B1) 154–3 After run fused power
(A10) 802–8 Rear lights (B10) 802–14 Working lights relay LO
(A2) 391 TCU fused power (B2) 111 Neutral relay LO
(A3) 357 TCU fused power (B3) 507–2 Fuel pump
(A4) 2_2 Telematics key input (B4) 1_723–2 Fuel pump
(A5) 409 Engager pin power (B5) 510–3 Fuel pump relay
(A6) 507–1 Fuel pump relay (B6) 327–1 Fuel pump
(A7) 422 Pre-filter fused (B7) 12 Working lights relay power
(A8) 38 1K17–86 (B8) 802–13 Working lights relay LO
(A9) 802–7 Parking plate tail lights (B9) 190 Working lights
(AA1) 4_31 X15A_SP (C6) 510–22 Fuel pump
(AA10) 802–62 Rear lights (D1) 388 Neutral relay HI
(AA2) 4_32 Switched power (D10) 189 Fused optional worklights
(AA3) 4_33 Ignition 15 (D2) 154–0 Neutral relay 87
(AA4) 4_34 Ignition 15 (D3) 510–3 Fuel pump relay
(AA5) 4_35 Switched power (D4) 507–1 Fuel pump relay
(AA6) 4_36 Switched power (D5) 327 Fuel pump
(AA7) 4_37 Battery B+ (D7) 802–32 Working lights relay HI
(AA8) 4_38 X15A_SP (D8) 11 Fused rear worklights
(AA9) 802–61 Tail plate parking lights (D9) 802–33 Working lights relay HI
Connector CM6-9 – Creep mode
87635073 5
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(7) 155–2 CAN HI creeper (9) 160–13 FWD
(8) 165–4 CAN LO creeper (10) 100–14 UCM ground
Connector E12-P1 – 12V power outlet
87675193 6

(1) 126–4 Power outlet 1
Connector E12-P2 – 12V power outlet
87675193 7

(1) 126–5 Ground
Connector X_CAM2 – Rear camera power / reverse
87696138 8
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(1) 455–2 Rear cam PWR (3) 455–1 Rear cam signal
Connector X_DIAG – Telematics Diagnostic
87694101 9

(1) 3_1–1 Tel GND (3) 6_3 Tel CAN diagnostic
(2) 7_2 Tel CAN diagnostic
Connector X_TEL – Telematics
87700156 10

(1) 3_1–2 Tel GND (6) 6_3 Tel CAN diagnostic
(2) 2_2 Telematics key input (7) 7_2 Tel CAN diagnostic
(3) 2_703–8 CAN HI (12) 1_12 Telematics fused power
(4) 2_704–8 CAN LO
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Connector X_UCM1 – Interface UCM1
84364841 11

(6) 160–13 FWD (12) 314–1 Forward solenoid
(9) 321 UCM (13) 315–1 Reverse solenoid
(10) 14–9 UCM fused power (14) 316–2 Wheel motor
(11) 154–1 UCM fused power (15) 317–2 FWD on / off
Connector X_UCM2 – Interface UCM2
84364841 12

(2) 100_14 UCM ground (8) 1_703–7 CAN HI
(3) 11A X15A_SP (9) 1_704–7 CAN LO
(4) 15_A X15A_SP (13) 316–11 Wheel motor
(5) 155–1 CAN HI creeper (14) 317–11 FWD on / off
(6) 165–3 CAN LO creeper (15) 397–1 Forward reverse solenoid
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Connector X1 – Interface switch board
87708485 13

(1) 174–1 Fused floating position (26) 2_701–2 Rear defrost
(2) 174–25 Floating position (27) 802–0 Fused lights
(3) 802–31 Working lights relay HI (28) - -
(4) 87–1 Back up alarm (29) 802–21 Switch pad
(5) 149–1 Back up alarm (30) 393–1 Auto man
(6) - - (31) 392–2 Auto man
(7) 86–1 Fused beacon (32) - -
(8) 86–4 Beacon (33) - -
(9) 507–3 Fuelling system (34) - -
(10) 508–1 Fuelling system (35) 512–2 HVAC
(11) - - (36) 512–23 HVAC
(12) 2_716–2 Fuelling system (37) 512–32 HVAC
(13) 389 Transmission neutral (38) 512–42 HVAC
(14) 396–1 Transmission neutral (39) 408–1 HVAC
(15) - - (40) 213–12 HVAC
(16) 12 Working lights relay power (41) 213–21 HVAC
(17) 12–41 WL cab roof front (42) - -
(18) 12–31 WL cab roof rear (43) 144–62 Parking light / head light
(19) 190–1 Working lights front (44) 144–31 Parking / head light
(20) 192–1 Working lights (45) - -
(21) 190–2 Working lights rear (46) - -
(22) 191–1 Working lights (47) 04 Cab ground
(23) - - (48) 01 Ground
(24) - - (49) 02 Ground
(25) 38–2 1K17–86 (50) 03 Ground
Connector X101 – Interface side console - cab floor
87708485 14
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(1) 1_706 Ground (26) 388 Neutral relay HI
(2) 2_716–2 Fuelling system (27) 409 Engager pin power
(3) 195–3 AIC delay (28) 700–1 Fused hazard warning
(4) 1_714–2 Parking brake relay LO (29) 700–2 Fused flashers
(5) 175–1 Brake light relay PWR (30) 325–1 Fuelling system
(6) 341–3 Fused parking brake (31) 507–2 Fuel pump
(7) 224 AIC fused (32) 508–1 Fuelling system
(8) 2_721–2 Ignition 15 (33) 510–22 Fuel pump
(9) 143–2 Ignition 15 (34) 327–1 Fuel pump
(10) 184 Float position relay power (35) 154–4 Start relay signal
(11) 321–2 UCM (36) 14–41 Power relay L
(12) 156 Fused parking brake (37) 195–4 After run relay
(13) 145 Horn relay power (38) 126–11 Radio
(14) 144–12 Headlight relay (39) 126–3 Radio
(15) 144–14 Headlight relay (40) 1_719–2 Camera trigger 2
(16) 186 Headlight relay (41) 174–25 Floating position
(17) 187 Headlight relay (42) 174–2 Floating position relay HI
(18) 192–1 Working lights (43) 317–11 FWD on / off
(19) 191–1 Working lights (44) 397–1 Forward reverse solenoid
(20) 87A1 Reverse relay (45) 802–1 Switch pad
(21) 149–1 Back up alarm (46) 802–7 Parking plate tail lights
(22) 108 Fused washer PWR (47) 802–8 Rear lights
(23) 86–4 Beacon (48) 358 Diagnostic
(24) 316–11 Wheel motor (49) 360 Diagnostic
(25) 393–15 Auto man (50) 1_723–2 Fuel pump
Connector X102 – Interface cab floor
87708537 15

(1) - - (26) 341–7 Parking brake relay PWR
(2) 396–1 Transmission neutral (27) 97 Horn relay HI
(3) 159 Domelight fused power (28) 144–2 Fused horn lights
(4) 620–2 ENG AUX (29) 802–21 Switch pad
(5) 391 TCU fused power (30) 144–31 Parking / head light
(6) 392–2 Auto man (31) 314–1 Forward solenoid
(7) - - (32) 315–1 Reverse solenoid
(8) - - (33) 316–2 Wheel motor
(9) CN42–1 AUX relay 30 (34) 317–2 FWD on / off
X
(10) CN42–1 AUX relay 30 (35) - -
2
(11) 147–1 Reverse relay (36) 512–23 HVAC
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(12) 645–3 ENG AUX (37) 512–32 HVAC
(13) 1_721–3 1K17–85 (38) 512–42 HVAC
(14) 2_701–2 Rear defrost (39) 408–1 HVAC
(15) 38–1 1K17–30 (40) 213–11 HVAC
(16) 12–31 WL cab roof rear (41) 213–21 HVAC
(17) 179–2 Ignition 50A (42) 422 Pre-filter fused
(18) 23 Alternator excite (43) - -
(20) 421–1 Relay filter heating hot (45) 1_704–4 CAN LO
(21) 640 Key switch fused power (46) 1_703–4 CAN HI
(22) 613 Relay filter heating HI side (47) 2_703–7 CAN HI
(23) 636 Relay filter heating low side (48) 2_704–7 CAN LO
(24) 637 Start control relay (49) 1_703–10 CAN HI
(25) 617 Start control relay low side (50) 1_704–10 CAN LO
Connector X104-2 – Connecting block side console
87675193 16

(1) 600 EDC fused power
Connector X110 – Operators seat
84015523 17

(1) 180 Operators seat (2) 407 Cab ground
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Connector X123 – Diagnostic plug
87516075 18

(A) 123–3 Ground (D) 1_704–5 CAN LO
(B) 123–1 After run fused power (H) 2_703–10 CAN HI
(C) 1_703–5 CAN HI (J) 2_704–10 CAN LO
84426130 19

(1) 15A_10 X15A_SP
84426130 20

(1) 11A X15A_SP (1) 15_A X15A_SP
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Harnesses and connectors - Component diagram 09 - Side console

84426130 1

(1) 15A-1 X15A_SP (1) 15A-2 X15A_SP
84426130 2

(1) 15A-5 X15A_SP (1) 15A-6 Switched power
84426130 3

(1) 15A-3 X15A_SP (1) 15A-4 X15A_SP
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84426130 4

(1) 15A-7 Switched power
84426130 5

(1) 30–2 Battery B+
Connector X31SC-1 – GND
84426130 6

(1) 40 Cab ground
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84426130 7

(1) 06 Ground (1) 07 Ground
84426130 8

(1) 08 Ground
84426130 9

(1) 01 Ground (1) 02 Ground
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84426130 10

(1) 1_706 Ground (1) 3_1 Tel GND
84426130 11

(1) 126–2 Ground (1) 407 Cab Ground
84426130 12

(1) 03 Ground (1) 04 Cab Ground
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Connector XA5 – ZF Diagnostic plug
84364851 13

(1) 351 Diagnostic (3) 359 Ground
(1) 357 TCU fused power (4) 360 Diagnostic
(2) 358 Diagnostic
Connector XA90 – CNV
87694112 14

(1) 126–7 Converter power 24V (5) 126–1 Radio
(2) 126–10 Converter power ACC (6) 126–9 Converter opt ground
(3) 126–6 Converter ground
Connector XR-021 – Controller area network
87695580 15

(A) 155–3 CAN HI creeper (B) 165–5 CAN LO creeper
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Connector XR-022 –
87695580 16

(A) 2_703–1 CAN HI (B) 2_704–11 CAN LO
1
Connector XV1-1 – Diode
87680382 17

(1) 512–2 HVAC (1) 512–11 HVAC
87680386 18

(1) 512 HVAC (1) 512–1 HVAC
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87680382 19

(1) 512–11 HVAC
87680386 20

(1) 512–1 HVAC
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Harnesses and connectors - Component diagram 10 - Steering

column
Connector IGNITION 15-50A – Ignition switch 15-50A
87714250 1

(6) 2_723 Ignition 15 (8) 2_717–1 Ignition 50A
(6) 143 Ignition 15 (8) 179 Ignition 50A
Connector IGNITION 30 – Ignition switch 30
84599241 2

(1) 162 Key switch B+
Connector V67-3-1 – Diode
87680386 3
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(1) 2_710–2 Right turn HI
87680382 4

(1) 2_710–3 Right turn HI
87680386 5

(1) 2_709–2 Left turn HI
87680382 6

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87680386 7

(1) 2_719 Floating position
87680382 8

(1) 2_719–1 Floating position
Connector X11 – CAN 2
87687244 9

(1) 2_703–4 CAN HI (2) 2_704–4 CAN LO
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Connector X11A – CAN 2
82012083 10

(1) 2_703–5 CAN HI (2) 2_704–5 CAN LO
Connector X14 – Interface cab roof
84364746 11

(3) 1_707–1 PWM (10) 108–19 Wiper interval relay
(4) 159–2 Domelight fused power (12) 126–13 Radio
(6) 38–12 Defrost (13) 126–32 Radio
(7) 86–6 Beacon (14) 15–1 Ground
(8) 108–18 Washer front (15) 15–2 Ground
Connector X15 – Interface cab roof
84364852 12
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(5) 12–33 WL cab roof rear (9) 108–35 Wiper rear
(6) 12–43 WL cab roof front (10) 108–37 Wiper washer rear
(7) 2_710–4 Right turn HI (11) 108–27 Wiper rear
Connector X21 – Steering column switch
84364841 13

(1) 144–6 Parking light / head light (5) 144–34 Headlight relay
(1) 144–21 Fused horn lights (6) 144–35 Headlight relay
(2) 2_709–1 Left turn HI (7) 97–2 Horn relay HI
(3) 2_710–1 Right turn HI (8) 2_709–6 Flasher relay
(4) 144–33 Parking / head light
Connector X31ST-1 – AIC GND
84260521 14

(1) GND-1 Ground
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84260521 15

(1) GND-2 Ground
84260521 16

(1) GND-3 Ground
Connector X33-2 – Interface cab floor
84364841 17

(1) 2_703–5 CAN HI (9) 12–33 WL cab roof rear
(2) 2_704–5 CAN LO (11) 91 Wiper washer rear
(3) 126–13 Radio (11) 91–1 Interval relay
(4) 126–32 Radio (12) 108–14 Washer front
(5) 12–43 WL cab roof front (12) 108–15 Wiper interval relay
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(5) 803 Switch pad (13) 108–2 Washer front
(6) 1_721 Rear defrost (13) 108–3 Washer front
(7) 700–12 Fused hazard warning (14) 1_703 CAN HI
(8) 700–22 Fused flashers (15) 1_704 CAN LO
84364841 18

(1) 144–6 Parking light / head light (8) 144–33 Parking / head light
(4) 97–2 Horn relay HI (11) 663 -
(5) 802–9 Switch pad (13) 159–2 Domelight fused power
(7) 801–1 Switch pad (15) 144–21 Fused horn lights
84364841 19

(1) 1_723 Fuelling system (9) 1_715 Brake light
(2) 1_702 Fuel level sensor (10) 86–6 Beacon
(4) 2_707 Rear defrost (11) 1_720 AIC delay
(5) 1_706–2 Ground (12) 2_716 Fuelling system
(6) 1_709 Hydraulic oil temp (13) 1_726 Fan control
(7) 1_719 Camera trigger 2 (14) 1_724 Emergency steering
(8) 1_714 Park brake relay (15) 38–12 Defrost
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84364841 20

(1) 162 Key switch B+ (7) 2_711 Steering pressure
(2) 2_705 Brake warning (8) 2_712 HVAC
(3) 341–9 Fused parking brake (10) 2_714 AIC fused
(4) 2_719–1 Floating position (10) 2_720 AIC fused
(5) 2_709 Left turn HI (11) 1_701 Ignition 15
(5) 2_709–1 Left turn HI (11) 2_721 Ignition 15
A
(6) 2_710 Right turn HI (14) 143 Ignition 15
(6) 2_710–1 Right turn HI (15) 179 Ignition 50A
A
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Harnesses and connectors - Component diagram 11 - Steering

column
Connector X33-7 – Interface speed limitation
84156860 1

(1) 1_725–2 Switch pad (3) 2_704–1 CAN LO
(2) 2_703–1 CAN HI (4) 810–2 Ground
Connector XCN1 – AIC
82028493 2

(1) 1_701 Ignition 15 (14) 1_714 Park brake relay
(2) 1_702 Fuel level sensor (15) 1_715 Brake light
(3) 1_703 CAN HI (19) 1_719 Camera trigger 2
(4) 1_704 CAN LO (20) 1_720 AIC delay
(6) 1_706–2 Ground (21) 1_721 Rear defrost
(7) 1_707 PWM (23) 1_723 Fuelling system
(9) 1_709 Hydraulic oil temp (24) 1_724 Emergency steering
(12) 1_712 Ground (25) 1_725 Switch pad
(13) 1_713 Buzzer (26) 1_726 Fan control
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Connector XCN2 – AIC
82016219 3

(3) 2_703 CAN HI (14) 2_714 AIC fused
(4) 2_704 CAN LO (15) 2_715 Ground
(5) 2_705 Brake warning (16) 2_716 Fuelling system
(6) 2_706 Parking brake (17) 2_717 AIC HI
(7) 2_707 Rear defrost (19) 2_719 Floating position
(8) 2_708 Parking brake (20) 2_720 AIC fused
(9) 2_709 Left turn HI (21) 2_721 Ignition 15
(10) 2_710 Right turn HI (22) 2_722 Ground
(11) 2_711 Steering pressure (23) 2_723 Ignition 15
(12) 2_712 HVAC
Connector XH1-1 – Buzzer
87705127 4

(1) 1_713 Buzzer
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Connector XH1-2 – Buzzer
87705127 5

(1) 1_713–1 Ground
Connector XK20-1 – Flasher relay
84153826 6

(4) 2_709–5 Ground (8) 2_709–6 Flasher relay
(6) 700–4 Flasher relay (8) 2_710–01 Flasher relay
Connector XK23 – Front wiper washer relay
84153826 7

(2) 108–13 Washer front (8) 108–7 Washer front
(4) 108–15 Wiper interval relay (8) 108–18 Washer front
(5) 108–19 Wiper interval relay
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Connector XK23-1 – Rear washer wiper relay
84153826 8

(1) 108–25 Wiper washer rear (6) 108–9 Ground
(2) 108–36 Wiper washer rear (8) 108–34 Wiper washer rear
(4) 91–1 Interval relay (8) 108–35 Wiper rear
(5) 108–27 Wiper rear
Connector XS16 – Parking brake
87716755 9

(1) 2_706 Parking brake (7) 811 Ground
(2) 341–9 Fused parking brake (7) 812 Parking brake
(3) 2_708 Parking brake (8) 144–01 Parking brake
Connector XS20 – Switch hazard warning
87632725 10
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(1) 700–22 Fused flashers (10) 700–3 Ground
(2) 700–4 Flasher relay (10) 700–31 Hazard warning
(3) 700–12 Fused hazard warning (17) 2_710–3 Right turn HI
(5) 2_710–0 Flasher relay (18) 2_709–3 Left turn HI
1
(8) 100–8 Hazard warning
Connector XS3 – Front windscreen wiper
87632724 11

Connector XS3-2 – Switch rear windscreen wiper
87632724 12

(9) 812 Parking brake (14) 108–37 Wiper washer rear
(11) 108–24 Wiper washer rear
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Connector XS50-1 – Front windscreen wash pump
87716755 13

(2) 108–2 Washer front (7) 700–31 Hazard warning
(3) 108–14 Washer front (8) 108–28 -
Connector XS50-3 – Rear windscreen washer
87716755 14

(2) 108–52 Washer rear (8) 108–31 Washer rear
(3) 91 Wiper washer rear (8) 108–32 Wiper washer rear
(7) 812–1 Wiper washer rear
Connector XS77-5-1 – Slack rope switch
87705127 15

(1) 174–23 Floating position
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87705127 16

(1) 174–22 Floating position
87705127 17

(1) 174–4 Ground
Connector XSWP1 – Switch pad
87635073 18

(1) 801–1 Switch pad (8) 2_704–3 CAN LO
(2) 802–9 Switch pad (9) 1_725–1 Switch pad
(3) 803 Switch pad (10) 810–1 Ground
(7) 2_703–3 CAN HI
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87680382 19

(1) 1_707 PWM
87680386 20

(1) 1_707–1 PWM
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Harnesses and connectors - Component diagram 12 - Front light

Connector X68 – Interface lamp holder front frame
84364852 1

(1) 84–13 Flasher front left (8) 187–22 Headlight
(2) 85–13 Flasher front right (9) 145–3 Horn power
(3) 78–32 Parking plate tail lights (11) BR-13 Flasher GND
(4) 79–22 Parking marker light (12) BR-22 Flasher GND
(5) 186–12 Headlight (13) 313–11 Parking marker light
(7) 187–12 Headlight
Connector XE1-31 – Left HI LO GND
INA 2

(1) BR-11 Flasher GND (1) BR-14 GND
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Connector XE1-56A – Left HI beam
INA 3

Connector XE1-56B – Left LO beam
INA 4

Connector XE1-E2-1 – Parking light left
INA 5

(1) 78–32 Parking plate tail lights
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Connector XE1-E2-2 – Park light left
INA 6

(1) BR-14 GND
Connector XE22-1 – Flasher front left
INA 7

(1) 84–13 Flasher front left
Connector XE22-2 – Flasher front left
INA 8

(1) BR-1 Flasher GND
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Connector XE22-3 – Side marker light left
INA 9

(1) 313–21 Parking marker light
Connector XE22-BR1 – Left
INA 10

(1) BR-1 Flasher GND (1) BR-12 Flasher GND
Connector XE2-31 – Right HI LO GND
INA 11

(1) BR-21 Flasher GND (1) BR-24 GND
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Connector XE23-1 – Flasher front right
INA 12

(1) 85–13 Flasher front right
Connector XE23-2 – Flasher front right
INA 13

Connector XE23-3 – Side marker light right
INA 14

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Connector XE23-BR2 – Right
INA 15

Connector XE2-56A – Right HI beam
INA 16

Connector XE2-56B – Right LO beam
INA 17

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Connector XE2-E2-1 – Parking light right
INA 18

Connector XE2-E2-2 – Park light right
INA 19

(1) BR-24 GND
Connector XH7-1 – Horn
87705127 20

(1) 145–3 Horn power
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Connector XH7-2 – Horn
87705127 21

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Harnesses and connectors - Component diagram 13 - Front frame

Connector X68 – Interface lamp holder front frame
84364746 1

(1) 84–12 Left turn HI (8) 187–21 Headlight
(2) 85–12 Right turn HI (9) 145–2 Horn power
(3) 78–31 Parking plate tail lights (11) 145–51 Flashers front GND
(4) 79–21 Parking marker light (12) 145–52 Flashers front GND
84364852 2

(1) 84–12 Left turn HI (8) 187–21 Headlight
(2) 85–12 Right turn HI (9) 145–2 Horn power
(4) 79–21 Parking marker light (12) 313–1 Parking marker light
(5) 186–11 Headlight (13) 110–4 Ground
(6) 186–21 Headlight (15) 110–1 Floating position
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Connector X68-4 – Floating position
87680380 3

(1) 110–4 Ground (4) 110–1 Floating position
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Harnesses and connectors - Component diagram 14 - Rear frame

Connector E12 – License plate light
84015523 1

(2) 340–32 Ground (2) 340–35 Ground
Connector H81-1 – Back up alarm
84426117 2

(1) 149–3 Back up alarm
Connector H81-2 – Back up alarm
84426117 3

(1) 382 Ground
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Connector X3-8-1 – WL rear frame left
INA 4

(1) 191–12 WL cab rear left
Connector X3-8-2 – WL rear frame left GND
INA 5

(1) 340–35 Ground
Connector X38-8 – Interface cab floor harness
87708485 6

(4) 1_724–2 Emergency steering (24) 191–22 WL cab rear right
(7) 343–41 Fuelling pump (25) 191–12 WL cab rear left
(8) 343–42 Ground (26) 78–11 Parking plate tail lights
(9) 347–1 Engager pin (27) 340–32 Ground
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(10) 347–2 Ground (28) 340–22 Ground
(11) 348–1 Rapid working hydraulic (29) 87–31 Reverse light right
(12) 348–2 Ground (30) 1_715–3 Brake lights
(13) 149–3 Back up alarm (31) 79–11 Parking marker light
(14) 382 Ground (32) 85–2 Right turn HI
(15) 406 Ground (33) 340–52 Ground
(16) 91–3 Interval relay (34) 316–4 Wheel motor
(17) 108–17 Washer front (35) 316–13 Wheel motor
(18) 340–12 Ground (36) 317–4 FWD on / off
(19) 87–21 Reverse light left (37) 317–13 FWD on / off
(20) 175–3 Brake lights (38) 2_711–2 Steering pressure
(21) 78–21 Parking plate tail lights (39) 2_711–3 Ground
(22) 84–2 Left turn HI (40) 1_726–2 Fan control
(23) 340–42 Ground (41) 1_726–3 Ground
Connector X46-1 – Lighting left
84062580 7

(1) 340–12 Ground (3) 87–21 Reverse light left
(2) 84–2 Left turn HI
Connector X46-2 – Lighting right
84062580 8

(1) 340–22 Ground (3) 87–31 Reverse light right
(2) 85–2 Right turn HI
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Connector X46-5 – Brake / tail light left
87680689 9

(1) 340–42 Ground (3) 175–3 Brake lights
(2) 78–21 Parking plate tail lights
Connector X46-6 – Brake / tail light right
87680689 10

(1) 340–52 Ground (3) 1_715–3 Brake lights
Connector X4-8-1 – WL rear frame right
INA 11

(1) 191–22 WL cab rear right
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Connector X4-8-2 – WL rear frame right GND
INA 12

(1) 340–34 Ground
Connector XM4 – Washer front
84015523 13

(2) 406 Ground
Connector XM4-1 – Washer rear
84015523 14

(1) 91–3 Interval relay (2) 406–1 Washer front
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Connector XM67-1 – Fuelling pump
47365222 15

(1) 343–41 Fuelling pump
Connector XM67-2 – Fuelling pump
47361355 16

(1) 343–42 Ground
Connector XS17-6-A – Emergency steering
84578703 17

(1) 1_724–2 Emergency steering
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Connector XS17-6-B – Emergency steering
84578703 18

(1) 1_724–3 Steering press
Connector XS17-A – Steering pressure
84578703 19

(1) 2_711–2 Steering pressure
Connector XS17-B – Steering pressure
84578703 20

(1) 1_724–3 Steering press (1) 2_711–3 Ground
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Connector XY138 – Solenoid fan control
INA 21

(1) 1_726–2 Fan control (2) 1_726–3 Ground
Connector XY27 – Engager pin
INA 22

(1) 347–1 Engager pin (2) 347–2 Ground
Connector XY28 – Rapid working hydraulic
INA 23

(1) 348–1 Rapid working hydraulic (2) 348–2 Ground
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Connector XY8-1 – FWD on / off
INA 24

(1) 317–4 FWD on / off (2) 317–13 FWD on / off
Connector XY8-2 – Wheel motor
INA 25

(1) 316–4 Wheel motor (2) 316–13 Wheel motor
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Harnesses and connectors - Component diagram 15 - License plate

Connector E12 – License plate light
84038366 1

(1) 78–4 License plate light (2) 340–2 License plate light
Connector XE12-1A –
INA 2

Connector XE12-1B –
INA 3

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Connector XE12-2A –
INA 4

(1) 78–5 License plate light
Connector XE12-2B –
INA 5

(1) 340–3 License plate light
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Harnesses and connectors - Component diagram 16 - Floating

position
Connector X68-4 – Interface float position
87709658 1

(1) 110–41 Floating position (4) 110–2 Floating position
Connector XY3-1 – Valve
87711966 2

87711966 3

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87711966 4

87711966 5

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Harnesses and connectors - Component diagram 17 - Switchboard

Connector X1 – Interface side console harness
87708534 1

(1) 174–11 Floating position (25) 38–21 Defrost
(2) 174–26 Floating position (26) 38–3 Rear defrost
(3) 802–3 Parking light / head light (27) 802–01 Fused lights
(4) 87–4 Back up alarm (29) 802–22 Switch pad
(5) 149 Back up alarm (30) 393–2 Auto man
(7) 86–2 Beacon (31) 329–1 Auto man
(8) 86–3 Beacon (35) 512–21 HVAC
(9) 507–31 Fuelling system (36) 512–22 HVAC
(10) 508 Fuelling system (37) 512–31 HVAC
(12) 2_716–3 Fuelling system (38) 512–41 HVAC
(13) 389–1 Transmission neutral (39) 408 HVAC
(14) 396 Transmission neutral (40) 213–13 HVAC
(16) 12–1 Working lights relay power (41) 213–2 HVAC
(18) 12–3 WL cab roof rear (44) 144–3 Parking light / head light
(19) 190–11 Working lights front (47) 04–1 Cab ground
(20) 192 Working lights (48) 01–1 Cab ground
(21) 190–21 Working lights rear (49) 02–1 Cab ground
(22) 191 Working lights (50) 03–1 Cab ground
Connector X213 – Recirculation air
87635077 2

(1) 213–13 HVAC (3) 213 Cab ground
(2) 213–2 HVAC
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Connector X23 – Blower
87713932 3

(1) 512–21 HVAC (4) 512–22 HVAC
(2) 512–5A HVAC (5) 512–31 HVAC
(3) 512–41 HVAC
Connector X38-1 – Activation
87716755 4

(7) 174–6 Cab ground
Connector X72-3 – A/C
87635076 5
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(1) 512–5A HVAC (3) 72–3 Cab ground
(2) 408 HVAC
Connector XS2 – Defrost rear windscreen
87716755 6

(2) 38–21 Defrost (8) 393–7 Working lights cab roof
(3) 38–3 Rear defrost (8) 393–8 Back up alarm
Connector XS26-4 – Transmission neutralization
87716755 7

(2) 389–1 Transmission neutral (8) 393–11 Transmission neutral
(3) 396 Transmission neutral (8) 393–12 Floating position
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Connector XS36 – Beacon
87716755 8

(2) 86–2 Beacon (8) 393–9 Back up alarm
(3) 86–3 Beacon (8) 393–10 Beacon
Connector XS5 – Switch for light
87716755 9

(2) 802–01 Fused lights (6) 144–3 Parking light / head light
(3) 802–3 Parking light / head light (7) 341–5 Cab ground
(3) 802–22 Switch pad (8) 393–13 Floating position
(5) 144–63 Parking light / head light
Connector XS67 – Fuelling system
87716755 10
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(2) 507–31 Fuelling system (7) 405 Cab ground
(2) 508 Fuelling system (8) 393–10 Beacon
(3) 2_716–3 Fuelling system (8) 393–11 Transmission neutral
Connector XS77-1 – Working lights cab front / rear
87716755 11

(2) 12–2 Working lights cab roof (6) 12–3 WL cab roof rear
(3) 12–4 WL cab roof front (7) 12–6 Cab ground
(5) 12–1 Working lights relay power (8) 393–6 Working lights cab roof
(5) 12–2 Working lights cab roof (8) 393–7 Working lights cab roof
Connector XS77-2 – Working lights cab front below
87716755 12

(2) 190–11 Working lights front (8) 393–5 Working light
(3) 192 Working lights (8) 393–6 Working lights cab roof
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Connector XS77-3 – Working lights rear
87716755 13

(2) 190–21 Working lights rear (8) 393–4 Auto man
(3) 191 Working lights (8) 393–5 Working light
Connector XS77-4 – Back-up alarm
87716755 14

(2) 87–4 Back up alarm (8) 393–8 Back up alarm
(3) 149 Back up alarm (8) 393–9 Back up alarm
Connector XS87-8 – Automatic / manual
87716755 15
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(1) 329–1 Auto man (6) 329 Auto man
(2) 393–2 Auto man (7) 393 Cab ground
(2) 393–3 Auto man (8) 393–3 Auto man
(3) 329 Auto man (8) 393–4 Auto man
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Harnesses and connectors - Component diagram 18 - UCM

Connector 5F/5K – UCM fuse box
87312843 1

(A1) 11A_8 UCM supply (AA1) 11A_2 UCM supply
(A2) 11B UCM supply (AA2) 11A_3 UCM supply
(A3) 11C UCM supply (AA3) 11A_4 UCM supply
(A4) 11D UCM supply (AA4) 11A_5 UCM supply
(A5) 11E UCM supply (AA5) 11A_6 UCM supply
(A6) 11F UCM supply (AA6) 11A_7 UCM supply
Connector X_UCM1 – Interface side console
87691027 2

(6) 160 FWD (12) 314 Forward solenoid
(9) 321–1 UCM (13) 315 Reverse solenoid
(10) 14–10 UCM (14) 316 Wheel motor
(11) 154–11 UCM (15) 317 FWD on / off
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Connector X_UCM2 – Interface side console
87691027 3

(1) Reserve Reverse UCM XCN1A-4 (8) 1_703–8 CAN HI
(2) 100_15 UCM ground (9) 1_704–8 CAN LO
(3) 11A_1 UCM power (13) 316–1 Wheel motor
(4) 15_A-1 UCM (14) 317–1 FWD on / off
(5) 155 CAN HI creeper (15) 397 Forward reverse solenoid
(6) 165–2 CAN LO creeper
Connector X31UCM-1 – UCM GND side console
84260521 4

(1) GND-4 Ground
Connector X31UCM-2 – UCM GND side console
84260521 5
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(1) GND-5 UCM ground
Connector X31UCM-3 – UCM GND sense
84426118 6

(1) 100_31 UCM ground
Connector XCN1A – UCM
82016219 7

(1) 100_16 UCM ground (14) 15_A-1 UCM
(4) Reserve Reverse UCM XCN1A-4 (20) 11A_8 UCM supply
(6) 100_2 UCM ground (26) 11B UCM supply
(7) 100_31 UCM ground
Connector XCN1B – UCM
87410946 8
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(1) 100_4 UCM ground (25) 1_704-8 CAN LO
(2) 397–D Forward reverse LO (30) 317–D FWD LO
(9) 100_5 UCM ground (34) 1_703-8 CAN HI
(10) 316–D Wheel motor LO
82028493 9

(5) 314 Forward solenoid (19) 316 Wheel motor
(6) 315 Reverse solenoid (20) 100_6 UCM ground
(7) 11C_1 UCM supply (25) 317 FWD on / off
(13) 11C_2 UCM supply (26) 100_7 UCM ground
82028495 10

(1) 155 CAN HI creeper (18) 165–1 CAN LO creeper
(10) 165 CAN LO creeper (23) 321–1 UCM
(14) 154–11 UCM (26) 100_8 UCM ground
(16) 14–10 UCM (34) 100_9 UCM ground
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84130757 11

(7) 11F_1 UCM supply (20) 100_10 UCM ground
(13) 11F_2 UCM supply (26) 100_11 UCM ground
84130760 12

(2) 11D_1 UCM supply (26) 100_12 UCM ground
(3) 11D_2 UCM supply (27) 160 FWD
(8) 11E_1 UCM supply (34) 100_13 UCM ground
(9) 11E_2 UCM supply
Connector Y8-1-D1 – Diode
87680382 13

(1) 317–D1 FWD LO
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87680386 14

(1) 317–D2 FWD LO
87680382 15

(1) 316–D1 Wheel motor LO
87680386 16

(1) 316–D2 Wheel motor LO
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Connector Y8-5-6-D1 – Diode
87680382 17

(1) 397–D1 Forward reverse LO
Connector Y8-5-6-D2 – Diode
87680386 18

(1) 397–D2 Forward reverse LO
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Harnesses and connectors - Component diagram 19 - Ground

Connector CAB-GND – CAB ground
84138833 1

(1) 8761370 Side console ground
6
Connector E-GND – Engine ground
84278805 2

(1) 3004708 Engine ground
Connector F-GND – Frame ground
84278805 3

(1) 3004708 Engine ground
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Connector UCM-COVER-GND-1 – UCM cover GND
84260521 4

(1) UCM- -
Cover-
Ground-
Cable1
Connector UCM-COVER-GND-2 – UCM cover GND
84260521 5

(1) UCM- -
Cover-
Ground-
Cable2
Connector UCM-X1 – UCM-GND
87680386 6
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(1) UCM- -
Cover-
Ground-
Cable1
Connector UCM-X2 – UCM-GND
87680382 7

(1) UCM- -
Cover-
Ground-
Cable2
Connector X31-CAB-GND – CAB ground
87744835 8

(1) 8761370 Side console ground
6
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Harnesses and connectors - Component diagram 20 - Battery

Connector BAT-GND
INA 1

(1) 8761370 Cable battery negative
2
Connector P54 – Power relay
INA 2

(1) 8763270 Battery power
8
Connector X-563
INA 3
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(1) 8761370 Cable battery negative
2
Connector X-564
INA 4

(1) 2978055 Battery cable
Connector X-566 – Battery positive
INA 5

(1) 8763270 Battery power
8
Connector X-567
INA 6
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(1) 2978055 Battery cable
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Harnesses and connectors - Component diagram 21 - Grid heater

Connector F20-1A – Grid heater fuse
84398003 1

(1) 304–2 Grid heater power cable
Connector F20-2A – Grid heater fuse
84398003 2

Connector X-371 – Grid heater power
87744835 3

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Connector X-572 – Relay grid heater
87744835 4

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Harnesses and connectors - Component diagram 22 - Starter

Connector K10-1-87_CABLE – Power cable relay
INA 1

(1) 4749940 Cable starter - power relay
4
Connector XK1-7-87-CABLE – Relay grid heater
87744835 2

(1) 4756659 Grid heater power cable
8
Connector XM1-CABLE – Power cable starter
INA 3
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(1) 4749940 Cable starter - power relay
4
Connector XM1-GH-CABLE – Starter
84138833 4

(1) 4756659 Grid heater power cable
8
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Harnesses and connectors - Component diagram 23 - Beacon

Connector C40-1 – Beacon
87691967 1

(1) 86–8 Beacon
Connector C40-2 – Beacon
87691967 2

(1) 86–12 Beacon
Connector X40 – Beacon light
84038366 3

(1) 86–8 Beacon (2) 86–12 Beacon
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Harnesses and connectors - Component diagram 24 - Adapter 12V

power outlet
Connector XE12-1P – 12V Power outlet
87699700 1

(1) 126–41 12V Power outlet
Connector XE12-2P – 12V Power outlet GND
87699700 2

(1) 126–51 12V Power outlet GND
Connector XE12-P1 – 12V Power outlet
87680386 3

(1) 126–41 12V Power outlet
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Connector XE12-P2 – 12V Power outlet GND
87680386 4

(1) 126–51 12V Power outlet GND
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Fuse and relay box - Component identification
SS14E225 1

1 CAN diagnosis socket (all controllers CAN1 and 3F/3K Fuse/relay box 3
CAN2)
2 ZF transmission diagnostic interface 4F/4K Fuse/relay box 4
1F/1K Fuse/relay box 1 5F/5K UCM (not shown)
2F/2K Fuse/relay box 2
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Fuse/relay box 1F/1K
SS14J022 2
Fuse/relay Amperes Color code Consumer

designa-
tion
1F1 10 A Red AIC power supply
1F2 30 A Green EDC power supply
1F3 5A Beige Starter switch S1 to EDC
1F4 2A Beige Power Relay K10.1, UCM Ignition ON
1F5 20 A Yellow Filter heater
1F6 15 A Red Voltage transformer, radio, power outlet
1F7 7.5 A Brown Interior cab light, Power supply rear camera
1F8 7.5 A Brown Starter switch S1, starter relay K1.5, Crank signal UCM
1F9 5A Beige Alternator
1F10 5A Beige Diagnosis socket X123, relay 3K116
1K AR IGN After Run Ignition Power
PWR
1KAUX Auxiliary relay EDC
1K17 Relay Defrost
1KCC Relay start control
1K20.3 Relay filter heater
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SS14F039 3

designa-
tion
2F11 5A Beige Parking brake etc.
2F12 2A Power supply, fuel level switch of fuelling system
2F13 10 A Red Relay stop light 2K19, stop light left/right
2F14 5A Beige Relay 2K42 floating position
2F15 10 A Red Floating position solenoid valves
2F16 7.5 A Brown Hazard warning system
2F17 7.5 A Brown Turn signal lights
2F18 10 A Red Horn, low beam, high beam, headlamp flasher
2F19 10 A Sidemarker lights, parking light, tail light
2F20 20 A Violet Sensor SCR system
2Kxx Reserve
2K14 Relay horn
2K19 Relay stop light
2K42 Relay floating position
2K115 Relay parking brake
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SS14E081 4
Fuse/Re- Amperes Color code Consumer

lay desig-
nation
3F21 7.5 A Brown Low beam
3F22 7.5 A Brown High beam (left, right)
3F23 15 A Blue Floodlamp cab roof (front, rear)
3F24 15 A Blue Floodlamp cab floor (bottom front, rear)
3F25 5A Beige Reversing alarm, reversing headlights
3F26 25 A Grey Power supply NOx sensor, Urea quality, Exhaust flap
3F27 10 A Red Connector, operator seat
3F28 15 A Blue Wiper/washer system, rear, front
3F29 7.5 A Brown Rotary beacon
3F30 30 A Green Telematik Modul & Guidance Control - Unswitched power
3K116 Relay AIC power delay
3K117 Relay low beam
3K118 Relay high beam
3Kxx Reserve
3K81.2 Relay reversing
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SS14E082 5

designa-
tion
4F31 15 A Blue Blower for heating air conditioner
4F32 7.5 A Brown Gearbox control system EST37A
4F33 7.5 A Brown Driving switch, speed sensor/gearbox, EST37A, Power supply
4F34 5A Beige Telematik Modul & Guidance Control - Switched power
4F35 5A Beige Arrestor bolts fast gear working hydraulics
4F36 20 A Yellow Refueling system
4F37 15 A Heater pre-fuel filter
4F38 15 A Defrost rear windowscreen
4F39 5A License plate light, tail lamp left, parking light left
4F40 5A Side-marker front, tail lamp right, parking light right
4K111 Relay gear control neutral
4K67 Relay refueling
4K67.1 Relay refueling
4K10 Relay floodlight driver’s cab
4K12 Relay floodlight driver’s cab floor
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SS14F040 6

designa-
tion
5F1 10 A Red UCM – Power supply 1 switched voltage – power delay
5F2 10 A Red UCM – Power supply 2 switched voltage – power delay
5F3 7.5 A Brown UCM – Power supply – VF3
5F4 7.5 A Brown UCM – Power supply – VS1
5F7 Reserve
5F8 Reserve
5F9 Reserve
5F10 Reserve
5k1 Reserve
5k2 Reserve
5k3 Reserve
5k4 Reserve
5k5 Reserve
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Index

Harnesses and connectors - Electrical schematic sheet 02 - Power distribution - Battery/Starter . . 10
Harnesses and connectors - Electrical schematic sheet 03 - Power distribution (Fuse block 1F/1K) 12
Harnesses and connectors - Electrical schematic sheet 06 - Power distribution /Fuse block 4F/4K) 18
Harnesses and connectors - Electrical schematic sheet 08 - Power distribution 1 . . . . . . . . . . . . . . . 22
Harnesses and connectors - Electrical schematic sheet 12 - Engine control unit 1, Grid heater, Filter
heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Harnesses and connectors - Electrical schematic sheet 13 - Engine control unit 2 . . . . . . . . . . . . . . 32
Harnesses and connectors - Electrical schematic sheet 14 - Engine control unit 3 . . . . . . . . . . . . . . 34
Harnesses and connectors - Electrical schematic sheet 15 - ECU - AIC 1 . . . . . . . . . . . . . . . . . . . . . 36
Harnesses and connectors - Electrical schematic sheet 16 - ECU - AIC 2 . . . . . . . . . . . . . . . . . . . . . 38
Harnesses and connectors - Electrical schematic sheet 17 CAN structure . . . . . . . . . . . . . . . . . . . . . 40
Harnesses and connectors - Electrical schematic sheet 18 - Gear control unit 1 . . . . . . . . . . . . . . . . 42
Harnesses and connectors - Electrical schematic sheet 19 - Gear control unit 2 . . . . . . . . . . . . . . . . 44
Harnesses and connectors - Electrical schematic sheet 20 - ECU - UCM power supply . . . . . . . . . . 46
Harnesses and connectors - Electrical schematic sheet 21 ECU - UCM . . . . . . . . . . . . . . . . . . . . . . . 48
Harnesses and connectors - Electrical schematic sheet 22 - Floating position . . . . . . . . . . . . . . . . . . 50
Harnesses and connectors - Electrical schematic sheet 23 - Engager pin, rapid hydraulic, plug op-
erator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Harnesses and connectors - Electrical schematic sheet 24 - Lighting steering column switch, dome-
light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Harnesses and connectors - Electrical schematic sheet 25 - Lighting hazard warning, blinkers . . . 56
Harnesses and connectors - Electrical schematic sheet 26 - Lighting headlight, full beam, tail, park-
ing, side marker light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Harnesses and connectors - Electrical schematic sheet 27 - Lighting back up, reverse light . . . . . . 60
Harnesses and connectors - Electrical schematic sheet 28 - Lighting working lights cab roof, front
and rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Harnesses and connectors - Electrical schematic sheet 29 - Cab wiper/washer front . . . . . . . . . . . . 64
Harnesses and connectors - Electrical schematic sheet 30 - Cab wiper/washer rear . . . . . . . . . . . . 66
Harnesses and connectors - Electrical schematic sheet 31 - Heating blower heater, HVAC . . . . . . 68
Harnesses and connectors - Electrical schematic sheet 32 - Cabin defrost rear windscreen, beacon 70
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Harnesses and connectors - Electrical schematic sheet 33 - Cabin radio loudspeaker 12V power
outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Harnesses and connectors - Electrical schematic sheet 34 - Miscellaneous, Fuel system . . . . . . . . 74
Harnesses and connectors - Electrical schematic sheet 35 - Miscellaneous, Creep mode . . . . . . . . 76
Harnesses and connectors - Electrical schematic sheet 36 - Miscellaneous, Blade control . . . . . . . 78
Harnesses and connectors - Electrical schematic sheet 37 - Miscellaneous, Telematics . . . . . . . . . 80
Harnesses and connectors - Electrical schematic sheet 38 - Miscellaneous, Rear camera . . . . . . . 82
Fuse and relay box - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Harnesses and connectors - Component diagram 01 - Engine / Gear . . . . . . . . . . . . . . . . . . . . . . . . . 90
Harnesses and connectors - Component diagram 04 - Cab floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Harnesses and connectors - Component diagram 05 - Cab floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Harnesses and connectors - Component diagram 06 - Cab roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Harnesses and connectors - Component diagram 07 - Cab roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Harnesses and connectors - Component diagram 08 - Side console . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Harnesses and connectors - Component diagram 09 - Side console . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Harnesses and connectors - Component diagram 10 - Steering column . . . . . . . . . . . . . . . . . . . . . . . 161
Harnesses and connectors - Component diagram 11 - Steering column . . . . . . . . . . . . . . . . . . . . . . . 169
Harnesses and connectors - Component diagram 12 - Front light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Harnesses and connectors - Component diagram 13 - Front frame . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Harnesses and connectors - Component diagram 14 - Rear frame . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Harnesses and connectors - Component diagram 15 - License plate . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Harnesses and connectors - Component diagram 16 - Floating position . . . . . . . . . . . . . . . . . . . . . . . 198
Harnesses and connectors - Component diagram 17 - Switchboard . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Harnesses and connectors - Component diagram 18 - UCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Harnesses and connectors - Component diagram 19 - Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Harnesses and connectors - Component diagram 20 - Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Harnesses and connectors - Component diagram 21 - Grid heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Harnesses and connectors - Component diagram 22 - Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Harnesses and connectors - Component diagram 23 - Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Harnesses and connectors - Component diagram 24 - Adapter 12V power outlet . . . . . . . . . . . . . . . 225
Harnesses and connectors - Component localization - Main connectors . . . . . . . . . . . . . . . . . . . . . . . 85
Harnesses and connectors - Electrical schematic sheet 01 - Diagram Overview . . . . . . . . . . . . . . . . 6
Harnesses and connectors - Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Battery - 302
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
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Contents
Battery - 302
SERVICE
Battery
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Electrical systems - Battery
Battery - Remove
NOTE: before removing the batteries, turn the key switch in OFF position. Wait for completion of purging of DEF/
Adblue. Pay attention of noises coming from pump after turning key OFF.
1. Remove the two hexagon head screws (1) and the bat-
tery cover (2).
SS14H027 1
NOTE: Detach the negative clamps first, then the positive.

2. Disconnect the negative terminal of the battery.
3. Remove the jumper cable between the batteries (3).
4. Disconnect the positive terminal of the battery.
5. Insulate the battery terminals.
6. Unscrew the battery holders and remove the batteries
(3).
SS14H028 2
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Electrical systems - Battery
Battery - Install
NOTE: Connect the positive clamps first, then the negative.
1. Install the batteries (3) and connect the positive termi-
nal of the battery.
2. Install the jumper cable between the batteries (3).
3. Connect the negative terminal of the battery.
SS14H028 1
4. Place the battery cover (2) and fasten it with the two
hexagon head screws (1).
SS14H027 2
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Index
Battery - 302
Battery - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Battery - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Selective Catalytic Reduction (SCR) electrical system - 988
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
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Contents
SERVICE
Diesel Exhaust Fluid (DEF)/AdBlue® supply module

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Filter - Remove - Filler neck screen of the supply tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Filter - Install - Filler neck screen of the supply tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Filter - Remove - Supply line screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Filter - Install - Supply line screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Diesel Exhaust Fluid (DEF)/AdBlue® dosing module
Dosing valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Dosing valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Selective Catalytic Reduction (SCR) humidity sensor
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Selective Catalytic Reduction (SCR) temperature sensors
Remove - Catalyst upstream temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Install - Catalyst upstream temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Remove - Catalyst downstream temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Install - Catalyst downstream temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Nitrogen Oxide (NOx) sensor
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Remove - Catalyst outlet Nitrogen Oxides (NOx) sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Install - Catalyst outlet Nitrogen Oxides (NOx) sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Diesel Exhaust Fluid (DEF)/AdBlue® tank level and temperature sensor
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Ammonia (NH3) sensor
Remove - Catalyst outlet ammonia (NH3) sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Install - Catalyst outlet ammonia (NH3) sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Remove - NH3 Electronic Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Install - NH3 Electronic Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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Electrical systems - Selective Catalytic Reduction (SCR) electrical system
Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Remove

CAUTION
Flying debris!
pressed air.
C0049A

2. Drain engine coolant.
SS14K018 1
3. Mark supply and return line connection locations for

reference during reassembly.
Disconnect the DEF/ADBLUE® supply and return lines
(1) from the supply module.
Disconnect the coolant water supply and return lines
(2) from the supply module.
Disconnect the wiring harness (3) from the supply mod-
ule.
Remove the hexagonal bolts (4) that secure the supply
module to the mounting support bracket.
Remove the supply module from the machine.
NOTE: To disconnect fittings, squirt water into the fitting
connection to lubricate the O-ring. Squeeze the locking
SS14K040 2
tabs together while slightly pushing the fitting ends together
and then pulling them apart. If the fitting will not release,
but is free to rotate, the O-ring is likely stuck and additional
water should be used.
supply and return line connections.
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Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Install

Prior operation:
Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Remove (55.988)
1. Fit the supply module into the mounting support bracket

and secure with hexagonal bolts (4).
Connect the wiring harness (3) to the supply module.
Reconnect the coolant water supply and return lines (2)
to the supply module.
Reconnect the DEF/ADBLUE® supply and return lines
(1) to the supply module.
To connect, push the fitting ends together, until an au-
dible snap is heard.
Refill engine coolant.
NOTE: Test fitting connections to be sure they are secure.
Match supply and return markings to ensure correct con-
nections are made.
SS14K040 1
NOTE: Make sure wire harness and supply lines do not

contact anything that would cause damage.
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Diesel Exhaust Fluid (DEF)/AdBlue® supply module Filter - Remove

CAUTION
Flying debris!
pressed air.
C0049A
1. The Supply Module filter (2) is located on the right-hand

side of the machine directly below the Supply Module
(1).
SS14K041 1
2. Use a suitable container to catch any fluid that is dis-

charged during hose and filter disassembly.
Thoroughly clean the underside of the supply module
using compressed air. Remove the DEF/ADBLUE® fil-
ter cover by turning counterclockwise.
3. Remove the equalizing element from the center of the
filter.
Discard the equalizing element following local environ-
mental and waste regulations.
4. Observe the color of the filter (gray or black).
Insert the corresponding marked end of the filter re-
moval tool until a click is felt or heard, indicating that
the tool is completely inserted. SS14F050 2
5. Pull the filter and the filter removal tool out by hand.
If necessary, insert a tool in the filter removal toll’s slot
for additional leverage.
Discard the filter following local environmental and
waste regulations.
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Diesel Exhaust Fluid (DEF)/AdBlue® supply module Filter - Install

Prior operation:
Diesel Exhaust Fluid (DEF)/AdBlue® supply module Filter - Remove (55.988)
1. Clean the supply module’s thread surfaces and the in-

ternal filter housing surface with water.
NOTE: Never use a filter wrench to install a new filter.

2. Oil the O-rings of the new filter and insert them into the
supply module housing.
Use a mineral oil ISO VG10.
RCPH11WHL690BAU 1
3. Insert the new equalizing element.

4. Clean the filter cover with water and reinstall it.
Tighten by hand till finger tight, then tighten with a
12–corner 27 mm wrench to 15.0 - 25 N·m (11.1 - 18 lb
ft) torque.
SS14K041 2
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- Filler neck screen of the supply tank
CAUTION
Flying debris!
pressed air.
C0049A
SS14K018 1
2. The Diesel Exhaust Fluid (DEF)/AdBlue® tank is lo-

cated on the left side of the machine. The mesh filter
is located within the neck of the Diesel Exhaust Fluid
(DEF)/AdBlue® fill tube.
SS14F045 2
3. Remove the Diesel Exhaust Fluid (DEF)/AdBlue®

cap (1).
SS14F033 3
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4. Remove the filter assembly from the Diesel Exhaust

Fluid (DEF)/AdBlue® tank neck (turn counter clock-
wise and pull out screen).
SS14F054 4
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Diesel Exhaust Fluid (DEF)/AdBlue® supply module Filter - Install -

Filler neck screen of the supply tank
Prior operation:
Diesel Exhaust Fluid (DEF)/AdBlue® supply module Filter - Remove - Filler neck screen of the supply tank
(55.988)
1. Install the filter assembly at the Diesel Exhaust Fluid

(DEF)/AdBlue® tank neck (turn clockwise to lock in
place).
SS14F054 1
2. Install the Diesel Exhaust Fluid (DEF)/AdBlue® cap

(1).
SS14F033 2
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- Supply line screen
CAUTION
Flying debris!
pressed air.
C0049A
SS14K018 1
2. Locate the housing of the supply line filter screen within

supply line between supply tank (1) and supply module
(2) mounted on right hand side of engine.
around screen assembly.
SS14K046 2
3. Open the supply line fitting. To open fitting, push fitting

together, squeeze locking tabs slightly and then pull
apart.
NOTE: Squirt water into the fitting connection to lubricate
O-ring. If the fitting will not release, but is free to rotate, the
O-ring is likely stuck and additional water should be used
to free the connection.
NOTE: Use a suitable container to catch any fluid dis-
charged during hose and filter disassembly.
SS14K047 3
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55.4 [55.988] / 10
4. Remove the filter screen from housing. Rinse filter

screen with water to remove accumulated debris.
NOTE: If filter screen is damaged, replace it.
SS14K048 4
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Diesel Exhaust Fluid (DEF)/AdBlue® supply module Filter - Install -

Supply line screen
1. Install the filter screen into the supply line filter housing.
SS14K048 1
2. Reconnect the supply line coupling.

To connect, push the fitting ends together, until an au-
dible strap is heard.
SS14K047 2
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Diesel Exhaust Fluid (DEF)/AdBlue® dosing module Dosing valve -

Remove
SS14K018 1
2. Clean dirt and debris from the Diesel Oxidation Catalyst

(DOC) connections and DEF/ADBLUE® dosing valve.
NOTE: The dosing valve is located in the Diesel Oxidation
Catalyst (DOC).
SS14K049 2
3. Mark the location of the supply and return lines for ref-
erence during reassembly.
Disconnect the dosing valve wiring harness (1), the
cooling water lines (2) and the inlet DEF/ADBLUE® line
(3).
Cap the lines to prevent entering of debris in the sys-
tem.
Remove the bolts that secure the dosing valve (4) into
Diesel Oxidation Catalyst (DOC).
Remove the dosing valve (4).
Cover opening of the Diesel Oxidation Catalyst (DOC)
to prevent the entering of debris in the exhaust system.
NOTE: To separate connections, squirt water into fittings
SS14K050 3
to lubricate O-rings. Squeeze fitting locking tabs slightly
and push fitting together then pull it apart. If fitting will not
release, but is free to rotate, the O-ring is likely stuck and
additional water should be applied.
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55.4 [55.988] / 13
4. Inspect the dosing valve and service or replace as rec-

ommended.
LEIL13WHL0227AA 4
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Diesel Exhaust Fluid (DEF)/AdBlue® dosing module Dosing valve

- Install
1. Before the installation of the dosing valve, replace the
gasket (1).
Add gasket between Diesel Oxidation Catalyst (DOC)
and dosing module.
LEIL13WHL0227AA 1
2. Remove cover from the Diesel Oxidation Catalyst

(DOC).
NOTE: Use markings made during disassembly to deter-
mined proper positioning.
3. Secure dosing valve to Diesel Oxidation Catalyst
(DOC). Torque screws to 6.5 - 7.5 N·m (4.8 - 5.5 lb ft).
4. Connect the DEF/ADBLUE® line (3), the supply and the
return lines (2) and the wiring harness (1) to the dosing
valve.
NOTE: Use marks made during disassembly to determine
proper positioning.
SS14K050 2
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Selective Catalytic Reduction (SCR) humidity sensor - Remove

SS14K018 1
2. Locate the humidity sensor (1) on air intake pipe be-

tween the air filter housing and turbocharger.
3. Disconnect the wiring harness plug.
SS14K051 2
4. Remove the hexagonal bolts (1).
SS14K052 3
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5. Remove the sensor (1).
SS14K051 4
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Selective Catalytic Reduction (SCR) humidity sensor - Install

1. Remove plug covering hole in intake pipe and insert
sensor (1).
SS14K051 1
2. Secure sensor with hexagonal bolts (1). Sensor torque

15 - 19 N·m (11 - 14 lb ft).
3. Reconnect wiring harness plug (1).
SS14K052 2
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Selective Catalytic Reduction (SCR) temperature sensors - Remove

- Catalyst upstream temperature sensor
SS14K018 1
2. Locate the catalyst upstream temperature sensor (1)

on the exhaust system before the Selective Catalytic
Reduction (SCR).
3. Loosen the hexagonal nut on the sensor (1).
4. Remove the sensor from the exhaust system.
5. Remove wire ties securing wire harness to support
brackets. Unplug sensor from machine wiring harness
(1) and remove it.
SS14K027 2
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Selective Catalytic Reduction (SCR) temperature sensors - Install -

Catalyst upstream temperature sensor
1. Install the catalyst upstream temperature sensor (1)
into exhaust pipe.
2. Secure sensor into exhaust pipe. Sensor torque 40 -
50 N·m (30 - 37 lb ft).
3. Reconnect sensor to wire harness (1) and secure har-
ness to support brackets using new wire ties.
SS14K027 1
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Selective Catalytic Reduction (SCR) temperature sensors - Remove

- Catalyst downstream temperature sensor
SS14K018 1
2. Locate the catalyst downstream temperature sensor (1)

on exhaust system after Selective Catalytic Reduction
(SCR).
3. Loosen the hexagonal nut and remove the sensor (1)
from the exhaust system.
4. Disconnect sensor (1) from wiring harness.
SS14K028 2
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Selective Catalytic Reduction (SCR) temperature sensors - Install -

Catalyst downstream temperature sensor
1. Install the catalyst downstream temperature sensor (1)
into the exhaust system.
2. Secure the sensor by tightening the hexagonal nut with
a torque from 40 - 50 N·m (30 - 37 lb ft).
3. Reconnect the sensor to the machine wiring harness
(1).
SS14K028 1
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Nitrogen Oxide (NOx) sensor - Remove

SS14K018 1
2. Locate NOx sensor on the inlet of the Diesel Oxidation

Catalyst (DOC).
SS14K054 2
3. Loosen the hexagonal nut and remove the NOx sensor

(1).
4. Disconnect NOx sensor module from machine wiring
harness.
SS14K053 3
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Nitrogen Oxide (NOx) sensor - Install

1. Install the NOx sensor (1) into the inlet of the Diesel
Oxidation Catalyst (DOC).
NOTICE: Grease the sensor with WEICON HIGH-TECH AS-
SEMBLY PASTE .
2. Secure the NOx sensor with the hexagonal nut.

Torque to . 40 - 60 N·m (30 - 44 lb ft).
SS14K053 1
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Nitrogen Oxide (NOx) sensor - Remove - Catalyst outlet Nitrogen

Oxides (NOx) sensor
SS14K018 1
2. Loosen the hexagonal nut on NOx sensor (1) and re-

move NOx sensor from Selective Catalytic Reduction
(SCR).
3. Disconnect the machine wiring harness from the NOx
sensor module.
SS14K029 2
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Nitrogen Oxide (NOx) sensor - Install - Catalyst outlet Nitrogen

Oxides (NOx) sensor
1. Install the NOx sensor (1) into the inlet of the Selective
Catalytic Reduction (SCR).
NOTICE: Grease the sensor with WEICON HIGH-TECH AS-
SEMBLY PASTE .
2. Secure the NOx sensor with the hexagonal nut.

Torque to . 40 - 60 N·m (30 - 44 lb ft).
SS14K029 1
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Diesel Exhaust Fluid (DEF)/AdBlue® tank level and temperature

sensor - Remove
CAUTION
Flying debris!
pressed air.
C0049A
Prior operation:
Diesel Exhaust Fluid (DEF)/AdBlue® tank - Remove (10.500)

SS14K018 1
3. Use compressed air or water to clean dirt and debris

from the DEF/ADBLUE® supply tank around filler cap/
neck (1) and level/temperature sensor pickup heater
element (2).
SS14K055 2
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4. Remove the rubber cover from the DEF/ADBLUE®

level/temperature sensor pickup heater wires and
supply/return lines. Mark the position of hose and wire
connection.
5. Unplug the wiring harness. Disconnect the engine
coolant lines and the DEF/ADBLUE® lines. Disconnect
the lines by pushing coupling together all the way to
unlock. Squeeze tabs and pull coupling apart to break
connections.
6. Move wiring harness, engine coolant, and DEF/
ADBLUE® supply/return and purge line harness off to
the side. Plug all lines to prevent debris entry into the
system. SS14K324 3
7. Mark the position of the DEF/ADBLUE® level tempera-

ture sensor pickup heater unit within the tank. Use the
tool 84422467, to avoid damaging the unit. Turn unit
counter clockwise to loosen it from tank.
8. Lift the DEF/ADBLUE® level/temperature sensor pickup
heater unit out of tank. Cover the tank opening to pre-
vent debris entry.
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Diesel Exhaust Fluid (DEF)/AdBlue® tank level and temperature

sensor - Install
1. Insert the DEF/ADBLUE® tank level/temperature sen-
sor pickup heater unit into the supply tank.
2. Twist the DEF/ADBLUE® tank level/temperature sensor
pick up heater unit clockwise to secure it to the tank.
3. Install the tank.
4. Remove the plugs from all lines. Reconnect the DEF/
ADBLUE® purge and supply/return lines. Reconnect
the engine coolant supply/return lines. Reconnect the
liquid level and temperature sensor wiring harness.
NOTE: Test the connections by pushing them together all
the way and then pull back to be sure they are secure.
SS14K324 1
5. Replace the protective rubber cover (2).

6. Refill the engine cooling system.
SS14K055 2
Next operation:
Diesel Exhaust Fluid (DEF)/AdBlue® tank - Install (10.500)
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Ammonia (NH3) sensor - Remove - Catalyst outlet ammonia (NH3)

sensor
SS14K018 1
2. Locate the catalyst outlet ammonia (NH3) sensor (1) on

the exhaust system after Selective Catalytic Reduction
(SCR).
3. Loosen the hexagonal nut (1) and remove the sensor
from the exhaust system.
4. Disconnect the sensor (1) from NH3 Electronic Control
Unit.
5. Remove the sensor and the wiring harness.
SS14K030 2
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Ammonia (NH3) sensor - Install - Catalyst outlet ammonia (NH3)

sensor
1. Install the ammonia (NH3) sensor into the exhaust sys-
tem.
NOTICE: Grease the sensor with LOCTITE® X203 DRY FILM
MOLY ANTI-SEIZE.
2. Secure sensor by tightening hex nut with a torque from
40 - 50 N·m (30 - 37 lb ft).
3. Reconnect the sensor to the machine wiring harness.
SS14K030 1
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Ammonia (NH3) sensor - Remove - NH3 Electronic Control Unit

SS14K018 1
2. Disconnect the batteries.

Locate the NH3 Electronic Control Unit.
Disconnect the vehicle connector and the NH3 connec-
tor sensor from the NH3 Electronic Control Unit
Loosen the screws and remove the NH3 Electronic
Control Unit.
SS14K321 2
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Ammonia (NH3) sensor - Install - NH3 Electronic Control Unit

1. Install the NH3 Electronic Control Unit to the machine
with the screws.
Reconnect the machine harness and the NH3 sensor
to the NH3 Electronic Control Unit .
NH3 Electronic Control Unit torque 10 - 13 N·m (7 -
10 lb ft).
Connect the batteries.
SS14K321 1
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Index

Ammonia (NH3) sensor - Install - Catalyst outlet ammonia (NH3) sensor . . . . . . . . . . . . . . . . . . . . . . 31
Ammonia (NH3) sensor - Install - NH3 Electronic Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Ammonia (NH3) sensor - Remove - Catalyst outlet ammonia (NH3) sensor . . . . . . . . . . . . . . . . . . . . 30
Ammonia (NH3) sensor - Remove - NH3 Electronic Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Diesel Exhaust Fluid (DEF)/AdBlue® dosing module Dosing valve - Install . . . . . . . . . . . . . . . . . . . . . 15
Diesel Exhaust Fluid (DEF)/AdBlue® dosing module Dosing valve - Remove . . . . . . . . . . . . . . . . . . 13
Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Diesel Exhaust Fluid (DEF)/AdBlue® supply module Filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Diesel Exhaust Fluid (DEF)/AdBlue® supply module Filter - Install - Filler neck screen of the supply
tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Diesel Exhaust Fluid (DEF)/AdBlue® supply module Filter - Install - Supply line screen . . . . . . . . . . 12
Diesel Exhaust Fluid (DEF)/AdBlue® supply module Filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . 5
Diesel Exhaust Fluid (DEF)/AdBlue® supply module Filter - Remove - Filler neck screen of the sup-
ply tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Diesel Exhaust Fluid (DEF)/AdBlue® supply module Filter - Remove - Supply line screen . . . . . . . 10
Diesel Exhaust Fluid (DEF)/AdBlue® tank level and temperature sensor - Install . . . . . . . . . . . . . . . 29
Diesel Exhaust Fluid (DEF)/AdBlue® tank level and temperature sensor - Remove . . . . . . . . . . . . . 27
Nitrogen Oxide (NOx) sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Nitrogen Oxide (NOx) sensor - Install - Catalyst outlet Nitrogen Oxides (NOx) sensor . . . . . . . . . . . 26
Nitrogen Oxide (NOx) sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Nitrogen Oxide (NOx) sensor - Remove - Catalyst outlet Nitrogen Oxides (NOx) sensor . . . . . . . . . 25
Selective Catalytic Reduction (SCR) humidity sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Selective Catalytic Reduction (SCR) humidity sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Selective Catalytic Reduction (SCR) temperature sensors - Install - Catalyst downstream tempera-
ture sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Selective Catalytic Reduction (SCR) temperature sensors - Install - Catalyst upstream temperature
sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Selective Catalytic Reduction (SCR) temperature sensors - Remove - Catalyst downstream temper-
ature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Selective Catalytic Reduction (SCR) temperature sensors - Remove - Catalyst upstream tempera-
ture sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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Exhaust Gas Recirculation (EGR) electrical system - 989
836C AWD
836C
856C AWD
856C
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Contents
SERVICE
Exhaust Gas Recirculation (EGR) temperature sensors

Diesel Oxidation Catalyst (DOC) inlet temperature sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Diesel Oxidation Catalyst (DOC) inlet temperature sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system
Exhaust Gas Recirculation (EGR) temperature sensors Diesel

Oxidation Catalyst (DOC) inlet temperature sensor - Remove
SS14K018 1
2. Locate the temperature sensor on inlet Diesel Oxida-

tion Catalyst (DOC) (1).
3. Loosen the hexagonal nut (1) and remove the sensor
from the exhaust system, before the Diesel Oxidation
Catalyst (DOC).
4. Remove any wire ties that secure the sensor wiring
harness to the machine.
Disconnect sensor from wiring harness.
SS14K057 2
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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system
Exhaust Gas Recirculation (EGR) temperature sensors Diesel

Oxidation Catalyst (DOC) inlet temperature sensor - Install
1. Install temperature sensor (1) into exhaust system. Se-
cure sensor by tightening hex nut with a torque from 40
- 50 N·m (30 - 37 lb ft).
2. Reconnect sensor (1) to machine wiring harness.
Install any wire ties that secure the sensor wiring har-
ness to the machine.
SS14K057 1
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Index

Exhaust Gas Recirculation (EGR) temperature sensors Diesel Oxidation Catalyst (DOC) inlet tem-
perature sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Exhaust Gas Recirculation (EGR) temperature sensors Diesel Oxidation Catalyst (DOC) inlet tem-
perature sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Electronic modules - 640
836C AWD
836C
856C AWD
856C
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Contents
FUNCTIONAL DATA
Electronic module
Fault code index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Electrical systems - Electronic modules
Electronic module - Fault code index

NOTE: for the Engine errors - Series 3000 refer to the Engine Service Manual (Engine F4HFE613Y*B003)
Engine errors - Series 3000

Code displayed
FPT code Description
on cluster
Diagnostic fault check of synchronism for double potentiometer and Low Idle
3001 DTC 3AB1
Switch (LIS)
3002 DTC 16B1 Signal range check high for acceleration pedal position device driver Sensor 1
3003 DTC 28B1 Signal range check low for acceleration pedal position device driver sensor 1
3005 DTC 4B84 Air filter clog or circuit failure
3007 DTC 1113 Engine coolant temperature sensor voltage is higher than expected
3008 DTC 2213 Engine coolant temperature sensor voltage is lower than expected
3010 DTC 2474 Intake manifold temperature sensor voltage is lower than expected
3014 DTC 4C84 Air filter clog or circuit failure present for a long time
3015 DTC 1C15 Fuel temperature sensor voltage is higher than expected
3016 DTC 2D15 Fuel temperature sensor voltage is lower than expected
3019 DTC 1D64 Intake manifold pressure sensor voltage is higher than expected
3024 DTC 13C4 ECU internal failure - Ambient pressure sensor voltage is higher than expected
3025 DTC 24C4 ECU internal failure - Ambient pressure sensor voltage is lower than expected
3028 DTC 26D3 Oil pressure is too low
3029 DTC 18D3 Oil pressure sensor voltage is higher than expected
3030 DTC 29D3 Oil pressure sensor voltage is lower than expected
3034 DTC 11E3 Oil temperature sensor voltage is higher than expected
3035 DTC 22E3 Oil temperature sensor voltage is lower than expected
3037 DTC 2E64 Intake manifold pressure sensor voltage is lower than expected
3051 DTC 1161 Battery voltage is higher than expected
3052 DTC 2261 Battery voltage is lower than expected
NEF 4: Short circuit error of injector in cylinder 1
3063 DTC 6226 NEF 6: Short circuit error of injector in cylinder 1 Cursor: Short circuit error of
injector in cylinder 1
3067 DTC 6726
Cursor: Short circuit error of injector in cylinder 5
3071 DTC 6626
3075 DTC 6526 NEF 6: Short circuit error of injector in cylinder 6 Cursor: Short circuit error of
injector in cylinder 6
3079 DTC 6426 NEF 6: Short circuit error of injector in cylinder 3
3083 DTC 6326 NEF 6: Short circuit error of injector in cylinder 5
3088 DTC 4512 Crankshaft speed sensor values are not plausible
3089 DTC 4412 Crankshaft speed sensor pattern is not plausible
3090 DTC 4212 Camshaft speed sensor values are not plausible
3091 DTC 4112 Camshaft speed sensor pattern is not plausible
3093 DTC 3312 Compared camshaft and crankshaft speed sensor values are not plausible
3096 DTC 951B CAN A Bus off failure
3102 DTC 2525 Fuel rail pressure sensor voltage is lower than expected
3104 DTC F445 Fuel pressure relief valve is open
3105 DTC F245 Fuel pressure relief valve is forced to open, perform pressure increase
3106 DTC 1145 Fuel pressure relief valve reached maximum allowed opening count
3107 DTC 6655 Fuel metering unit is shorted to battery voltage at the low side
3108 DTC 7755 Fuel metering unit is shorted to ground at the low side
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Code displayed
on cluster
3110 DTC 1225 Rail pressure sensor value is above maximum offset
3111 DTC 2325 Rail pressure sensor value is below minimum offset
3112 DTC 1425 Fuel rail pressure sensor voltage is higher than expected
3118 DTC E82D Internal supply voltage is too high
3119 DTC E92D Internal supply voltage is too low
3137 DTC 5255 Fuel metering unit has an open load error
3141 DTC 4465 Fuel pump pressure has exceeded desired pressure limits
3146 DTC 4415 Water in fuel detected or water in fuel circuit failure
3154 DTC 6A14 Intake air heater actuator is shorted to battery voltage
3155 DTC 7C14 Intake air heater actuator is shorted to ground
3156 DTC 5614 Intake air heater actuator has an open load error
3160 DTC 6733 Fan clutch solenoid short circuit to battery failure
3161 DTC 7833 Fan clutch solenoid short circuit to ground failure
3162 DTC 5533 Fan clutch solenoid open load failure
3163 DTC 8633 Fan clutch solenoid ECU driver over temperature failure
3164 DTC 1A33 Fan speed above maximum threshold
3165 DTC 2B33 Fan speed below minimum threshold
3166 DTC 63B5 Fuel filter heater actuator is shorted to battery voltage
3167 DTC 74B5 Fuel filter heater actuator is shorted to ground
3168 DTC 51B5 Fuel filter heater actuator has an open load error
3169 DTC 82B5 Fuel filter heater ECU driver has an over temperature error
3170 DTC 38CB NH3 sensor signal is not changing
3172 DTC F523 Engine coolant temperature has exceeded the pre-warning threshold
3173 DTC F623 Engine coolant temperature has exceeded the warning threshold
3175 DTC 4933 Fan speed signal could not be measured for a period
High pressure pump fuel delivery quantity in over run exceeds a maximum
3176 DTC 3B65
threshold
3177 DTC F1A2 Engine over speed condition detected
CAN communication failure between vehicle controller and ECU - BC2ECU2
3179 DTC 956B
message
3180 DTC 9B7B CAN communication error between vehicle controller to ECU
3182 DTC 9741 CAN time-out error from cruise control vehicle speed (CCVS)
CAN communication failure between vehicle controller and ECU controller -
3183 DTC 93CB
TSC1_VR message (Engine brake)
CAN communication failure between vehicle controller and ECU controller -
3184 DTC 94CB
TSC1_VR message (Engine brake)
3185 DTC 978B CAN time-out error from transmission - Transmission fluids (TF) message
NEF 4: Open load error of injector in cylinder 1
3188 DTC 5316 NEF 6: Open load error of injector in cylinder 1
Cursor: Open load error of injector in cylinder 1
3196 DTC 5716
3204 DTC 5816
Injection bank 1 short circuit failure (all injectors of the same bank can be
3210 DTC 7116
affected)
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Code displayed
on cluster
Injection bank 2 short circuit failure (all injectors of the same bank can be
3218 DTC 7216
affected)
3226 DTC 9A98 CAN time-out error from eVGT Actuator
3230 DTC E126 ECU internal failure - Injector CY33x component
3233 DTC E336 ECU internal failure - Internal SPI injector related time-out error
3235 DTC F936 Exceeded the number of injections for a given engine speed
3236 DTC F836 Number of injections is limited by system
3237 DTC 1636 Number of desired injections exceeds threshold
3238 DTC E64D ECU internal failure
3245 DTC E51D ECU internal failure - Query/response communication errors
3252 DTC E61D ECU internal failure - SPI communication error
3253 DTC E41D ECU internal failure - Voltage ratio in ADC monitoring
3255 DTC E31D ECU internal failure - ADC test
3256 DTC E21D ECU internal failure - NTP error in ADC monitoring
3258 DTC 6722 Starter relay high side driver circuit short to battery failure
3259 DTC 7822 Starter relay high side driver circuit short to ground failure
3260 DTC 5922 Starter relay low side driver circuit open failure
3261 DTC 6B22 Starter relay low side driver circuit short to battery failure
3262 DTC 7C22 Starter relay low side driver circuit short to ground failure
3263 DTC 971B CAN C Bus off failure
3265 DTC E4DD Fuel injection requested during overrun
3280 DTC E62D Sensor supply 1 voltage is too high
3281 DTC E72D Sensor supply 1 voltage is too low
3283 DTC E32D ECU internal failure - Sensor 5 Vsupply 2
3285 DTC E42D ECU internal failure - Sensor 5 V supply 3
3293 DTC 2265 Fuel rail pressure has exceeded maximum positive deviation limits
3301 DTC 1565 Fuel rail pressure has exceeded maximum negative deviation limits
3305 DTC 2765 Fuel rail pressure has exceeded minimum limit
3309 DTC 1865 Fuel rail pressure has exceeded maximum limit
CAN communication failure between vehicle controller and ECU controller
3334 DTC 98BB
- TSC1_PE message
CAN communication failure between vehicle controller and ECU controller
3338 DTC 91CB
- TSC1_VE message
3361 DTC E16D ECU internal failure - EEPROM write/read error
3362 DTC E1FD ECU internal failure - Fuel calibration
3368 DTC F6EF Torque limitation caused by performance limiter
3370 DTC F2EF Strong torque limitation from engine protection active
3371 DTC F3EF Strong torque limitation from injection system active
3403 DTC 8A22 Starter relay low side ECU driver circuit over temperature failure
3425 DTC 1438 Under boost failure
Inducement system is locked due to 3 detections in 40 hours.
3436 DTC FBBF The system must be reset using the dealer service tool screen "Engine Restart
Counter Reset".
3438 DTC 7A61 Auxiliary power relay high side driver circuit short to ground failure
3439 DTC 5B61 Auxiliary power relay low side driver circuit open failure
3440 DTC 8322 Auxiliary power relay low side ECU driver circuit over temperature failure
3441 DTC 6422 Auxiliary power relay low side driver circuit short to battery failure
3442 DTC 7522 Auxiliary power relay low side driver circuit short to ground failure
3443 DTC F3A2 Torque limitation due to excessive coolant temperature
3444 DTC F4A2 Torque limitation due to excessive exhaust gas temperature
3445 DTC F5A2 Torque limitation due to excessive fuel temperature
3446 DTC F6A2 Torque limitation due to excessive intake air temperature
3447 DTC F7A2 Torque limitation due to excessive oil temperature
3448 DTC F8A2 Torque limitation due to turbocharger protection after start
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Code displayed
on cluster
3449 DTC E812 ECU internal failure - Calculated engine speed
3450 DTC 3398 eVGT actuator blocked
3452 DTC 19B5 Fuel Filter: Main fuel filter clogged (severe clogging)
3457 DTC 1374 Intake manifold temperature sensor voltage is higher than expected
3458 DTC 15E3 Crankcase pressure too high
3459 DTC 1BD3 Oil temperature too high
3460 DTC 2CD3 Oil temperature too low
3461 DTC E69D ECU internal failure - Time-out in the shut off path test error
3462 DTC E79D ECU internal failure - Over-voltage monitoring error
3475 DTC 9D63 CAN time-out error from coolant water pump actuator
3501 DTC ED1D ECU internal failure - Software resets in DSM 0
3502 DTC EE1D ECU internal failure - Software resets in DSM 1
3507 DTC 4761 Engine cranked for too long or key switch failure
3508 DTC FAEF Torque limitation active
3517 DTC 19C4 Ambient temperature sensor voltage is higher than expected
3518 DTC 2AC4 Ambient temperature sensor voltage is lower than expected
3521 DTC 3BDA NOx estimation model in ECU software is inaccurate due to other failures
3525 DTC E18E Downstream NOx sensor internal failure (Open Circuit Error)
3526 DTC E28E Downstream NOx sensor internal failure (Short Circuit Error)
3528 DTC 319E Downstream NOx sensor values are not plausible
3529 DTC E16E Downstream NOx sensor internal failure (Heater Open Circuit Error)
3530 DTC E26E Downstream NOx sensor internal failure (Heater Short Circuit Error )
Downstream NOx sensor internal failure (Heater Performance Plausibility
3531 DTC A36E
Error)
3533 DTC 9D6E CAN time-out error from downstream NOx sensor
3549 DTC 1C54 Intake air humidity sensor voltage is higher than expected for too long
3557 DTC FB54 Intake air humidity sensor voltage is higher than expected
3565 DTC F11F SCR inducement warning due to distance/time is active - Level 1
3581 DTC FD8F Torque limitation is active
3594 DTC F7EF Torque limitation caused by SCR catalyst protection
3614 DTC E698 eVGT motor effort too high
3616 DTC F1EF Torque limitation caused by turbo charger protection
3617 DTC FB8F SCR inducement warning due to distance/time is active - Level 9
3619 DTC F5AF SCR inducement warning due to distance/time is active - Level 7
Downstream NOx sensor lambda signal deviation - NOx sensor possible
3623 DTC 3CAE
removal detected
3624 DTC 13A3 Crankcase pressure sensor voltage is higher than expected
3625 DTC 24A3 Crankcase pressure sensor voltage is lower than expected
3626 DTC 37B3 Crankcase pressure has exceeded tolerance limit
3628 DTC 22A3 Crankcase pressure too low
3638 DTC F4EF Torque limitation caused by engine brake
3647 DTC 1338 Over boost failure
3652 DTC 911B CAN A Bus off passive failure
3680 DTC E536 Engine speed limitation via fuel injection cut off is active
3686 DTC 3D1C DOC upstream temperature sensor signal drift at cold start
3687 DTC 3E1C SCR upstream temperature sensor signal drift at cold start
3688 DTC 4F15 Water in fuel sensor or sensor circuit failure
3699 DTC E56D ECU EEPROM memory failure - EEPData1 block
3700 DTC 3754 Intake air humidity sensor value is not plausible
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Code displayed
on cluster
The minimum rail pressure value necessary to allow fuel injection has not
3703 DTC 2B36
been reached
3735 DTC 8355 Fuel metering unit has an over-temperature error
3738 DTC E71D ECU internal failure - ROM error
3739 DTC E13D ECU internal failure - Loss of synchronization to MM from CPU
3740 DTC E23D ECU internal failure - ECU shutdown test failure
3741 DTC E33D ECU internal failure - Wrong set response time
3742 DTC E43D ECU internal failure - SPI errors during MoCSOP execution
3743 DTC E53D ECU internal failure - Under-voltage monitoring error
3745 DTC E63D ECU internal failure - WDA is not working correctly
3746 DTC E73D ECU internal failure - Alarm task period error
3758 DTC E3DD Post injection efficiency failure
3747 DTC E83D ECU internal failure - Positive test failed
3749 DTC E5B1 ECU internal failure - Accelerator pedal position sensor
3750 DTC EC36 ECU internal failure - Fuel injection energizing time is not plausible
3751 DTC ED36 ECU internal failure - Fuel injection energizing phase is not plausible
3752 DTC EE36 Fuel injection correction has exceeded a minimum limit
3753 DTC E5DD ECU internal failure - Injection quantity correction
3754 DTC E6DD ECU internal failure - Rail pressure plausibility
3755 DTC E7DD ECU internal failure - Torque request comparison
3757 DTC E2DD ECU internal failure - Post injection shut-off failure
3756 DTC E1DD ECU internal failure - Post injection quantity
ECU internal failure - Torque request due to fuel pressure exceeds maximum
3759 DTC E8DD
torque limit
ECU internal failure - Torque request due to air control exceeds maximum
3760 DTC E9DD
torque limit
3761 DTC EADD ECU internal failure - Torque request exceeds maximum torque limit
3762 DTC EBDD ECU 5 V supply voltage is higher than expected
3763 DTC ECDD ECU 5 V supply voltage is lower than expected
3764 DTC F561 ECU after run power interruption
ECU internal failure - 'WDA active' reported due to errors in query/response
3767 DTC E81D
communication
3768 DTC E91D ECU internal failure - 'ABE active' reported due to under-voltage detection
3769 DTC EA1D ECU internal failure - 'ABE active' reported due to over-voltage detection
3770 DTC EB1D ECU internal failure - 'WDA/ABE active' reported
3799 DTC F345 Fuel pressure relief valve is forced to open, perform pressure shock
3805 DTC 1D85 Maximum rail pressure exceeded
3808 DTC 3C65 High pressure pump fuel delivery quantity at low idle is too high
3810 DTC 4125 Rail pressure sensor value is intermittent
3811 DTC E22D ECU internal failure - Sensor 5 V supply 1
3812 DTC 115D ECU temperature sensor 1 is too high
3813 DTC 235D ECU temperature sensor 1 is too low
3814 DTC E55D ECU temperature sensor error detected
3838 DTC 2999 Upstream oxidation catalyst temperature sensor voltage is lower than expected
3858 DTC 3598 CAN communication error between ECU and eVGT actuator
3861 DTC 3498 eVGT power supply electrical failure
3865 DTC 4898 eVGT system failure
3868 DTC 8998 eVGT actuator over temperature error
CAN communication failure between vehicle controller and ECU - BC2ECU1
3870 DTC 936B
message
3877 DTC 647D Supply UB1 short circuit to battery failure
3881 DTC 757D Supply UB1 short circuit to ground failure
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Code displayed
on cluster
3903 DTC 1A15 Fuel temperature is too high
3905 DTC 8814 Intake air heater ECU driver has an over-temperature error
3910 DTC 4155 Fuel metering unit intermittent electrical connection failure
3911 DTC 6455 Fuel metering unit is shorted to battery voltage at the high side
3912 DTC 7555 Fuel metering unit is shorted to ground at the high side
3916 DTC 1745 Fuel pressure relief valve has reached maximum allowed open time
3930 DTC FC8F SCR inducement warning due to distance/time is active - Level 10
3936 DTC E52D ECU internal: Error Sensor supplies Voltage Tracker
3961 DTC ED2D CAN communication failure - External torque/speed checksum and counter
3962 DTC 49C3 Crankcase pressure too high for too long
3963 DTC 4AC3 Crankcase pressure too high and oil pressure too low - Fuel in oil suspected
3964 DTC 125D ECU temperature sensor 2 is too high
3965 DTC 245D ECU temperature sensor 2 is too low
3966 DTC 165D ECU temperature sensor voltage is higher than expected
3967 DTC 275D ECU temperature sensor voltage is lower than expected
3968 DTC 5171 After run relay high side driver circuit open failure
3969 DTC 8271 After run relay high side ECU driver circuit over temperature failure
3970 DTC 6371 After run relay high side driver circuit short to battery failure
3971 DTC 6471 After run relay high side driver circuit short to ground failure
3973 DTC 8671 After run relay low side ECU driver circuit over temperature failure
3974 DTC 6771 After run relay low side driver circuit short to battery failure
3977 DTC 15E5 Prefilter fuel pressure sensor voltage is higher than expected
3978 DTC 16E5 Prefilter fuel pressure sensor voltage is lower than expected
3981 DTC 5971 After run relay low side driver circuit open or short to ground failure
3985 DTC 1758 Exhaust gas pressure sensor voltage is higher than expected
3986 DTC 2858 Exhaust gas pressure sensor voltage is lower than expected
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NOTE: for the SCR errors - Series 17000 and 19000 refer to the Engine Service Manual (Engine F4HFE613Y*B003)
SCR errors - Series 17000 and 19000

Code displayed
on cluster
17515 DTC FA2F Engine idle shutdown commanded from SCR inducement
SCR Inducement: Level 1 (Torque reduction), triggered by EGR valve blocked
17517 DTC F19F
fault
17518 DTC F29F SCR Inducement: Level 3 (creep mode), triggered by EGR valve blocked fault
17519 DTC F39F SCR Inducement: Warning, triggered by EGR valve blocked fault
17523 DTC 9E8C Hydrocarbon level 2 exceeded
17524 DTC 31E9 Hydrocarbon level 1 exceeded
19001 DTC 1361 Battery voltage is higher than expected
19002 DTC 2461 Battery voltage is lower than expected
19006 DTC 96EE CAN time-out error from NH3 sensor - NH3Fac message
19007 DTC E6DE NH3 sensor open or short in measuring cell circuit
19008 DTC E7DE NH3 sensor open or short in ground circuit
19009 DTC 18DE NH3 sensor short in heater circuit causing overheating
19010 DTC 161A Downstream SCR catalyst temperature sensor voltage is higher than expected
19011 DTC 271A Downstream SCR catalyst temperature sensor voltage is lower than expected
19012 DTC E9DE NH3 sensor open in heater circuit causing under-heating
19013 DTC EADE NH3 sensor open or short in temperature cell circuit
19014 DTC EBDE NH3 sensor open or short in trim resistor circuit
19015 DTC 4CDE NH3 sensor heater control failure
19016 DTC 37EE NH3 sensor heater performance failure
19017 DTC 38EE NH3 sensor signal out of range failure
19018 DTC 4DDE NH3 sensor power supply failure
19019 DTC 1A1A Upstream SCR catalyst temperature sensor voltage is higher than expected
19020 DTC 2B1A Upstream SCR catalyst temperature sensor voltage is lower than expected
19023 DTC 4EDE NH3 sensor controller failure
19024 DTC 92EE CAN time-out error from NH3 sensor - NH3Sens message
19026 DTC 319C Exhaust flap sticking or internal failure
19027 DTC 329C Exhaust flap actuator supply voltage out of range
19030 DTC 439C Exhaust flap increased friction or high mechanical load or flap sticking
19033 DTC 469C Exhaust flap stuck during power up test
19034 DTC 879C Exhaust flap actuator is over temperature
19035 DTC 91BC CAN time-out error from exhaust flap actuator
19036 DTC 3F1C SCR downstream temperature sensor signal drift at cold start
Upstream oxidation catalyst temperature sensor comparison to a calculated
19040 DTC 352C
temperature value failure
Upstream SCR temperature sensor comparison to a calculated temperature
19041 DTC 362C
value failure
Downstream SCR temperature sensor comparison to a calculated temperature
19042 DTC 372C
value failure
19043 DTC 2D54 Intake air humidity sensor voltage is lower than expected
DEF/ADBLUE® supply module pump motor pressure sensor voltage is higher
19047 DTC 195A
than expected
DEF/ADBLUE® supply module pump motor pressure sensor voltage is lower
19048 DTC 2A5A
than expected
19050 DTC 478E Downstream NOx sensor supply voltage is out of range
19051 DTC E46E Upstream NOx sensor internal failure (Heater Open Circuit Error)
19052 DTC 256E Upstream NOx sensor internal failure (Heater Short Circuit Error)
19053 DTC A66E Upstream NOx sensor internal failure (Heater Performance Plausibility Error)
19054 DTC E48E Upstream NOx sensor internal failure (Open Circuit Error)
19055 DTC 476A DEF/ADBLUE® supply module temperature invalid
19059 DTC 258E Upstream NOx sensor internal failure (Short Circuit Error)
19060 DTC 9E6E CAN time-out error from upstream NOx sensor
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Code displayed
on cluster
Upstream NOx sensor lambda signal deviation - NOx sensor possible removal
19061 DTC 32BE
detected
19062 DTC E98E Upstream NOx sensor values are not plausible
19063 DTC 4A8E Upstream NOx sensor supply voltage is out of range
Upstream oxidation catalyst temperature sensor voltage is higher than
19066 DTC 1899
expected
19067 DTC 141A Downstream SCR catalyst temperature is too high
19068 DTC 251A Downstream SCR catalyst temperature is too low
19069 DTC 181A Upstream SCR catalyst temperature too high
19070 DTC 291A Upstream SCR catalyst temperature too low
19071 DTC 2DDA SCR catalyst efficiency lower than first NOx production threshold level
19077 DTC 334A DEF/ADBLUE® pressure stabilization failure
19079 DTC 1A4A DEF/ADBLUE® over pressure failure
19080 DTC 294A DEF/ADBLUE® under pressure failure
19081 DTC 717A DEF/ADBLUE® dosing valve actuator short circuit to ground in high side failure
19082 DTC 6C5A DEF/ADBLUE® reverting valve driver circuit short to battery failure
19083 DTC 7D5A DEF/ADBLUE® reverting valve driver circuit short to ground failure
19084 DTC 5E5A DEF/ADBLUE® reverting valve driver circuit open failure
19085 DTC 857A DEF/ADBLUE® dosing valve ECU driver over-temperature failure
DEF/ADBLUE® pressure line heater failure and DEF/ADBLUE® tank
19086 DTC 3DBA
temperature is too low
19087 DTC 8DAA DEF/ADBLUE® tank temperature is not within acceptable limits
19095 DTC 2F3A DEF/ADBLUE® tank temperature sensor plausibility failure
19096 DTC 436A DEF/ADBLUE® supply module temperature not available
19097 DTC 446A DEF/ADBLUE® supply module temperature outside valid range
19098 DTC 456A DEF/ADBLUE® supply module heater detected a faulty PWM signal
19105 DTC 879A DEF/ADBLUE®tank heater ECU driver over temperature failure
19106 DTC 759A DEF/ADBLUE® tank heater actuator short circuit to ground failure
19107 DTC 515A DEF/ADBLUE® supply module pump motor open load failure
19108 DTC 613A DEF/ADBLUE® supply module pump motor short circuit to battery failure
19111 DTC 723A DEF/ADBLUE® supply module pump motor short circuit to ground failure
19113 DTC 8F5A DEF/ADBLUE® reverting valve ECU driver circuit over temperature failure
19126 DTC FF9F SCR Inducement: Warning, triggered by tampering fault
19140 DTC 4BCA DEF/ADBLUE® concentration is out of range
19141 DTC 4CCA DEF/ADBLUE® quality sensor detects diesel fuel in DEF/ADBLUE® tank
DEF/ADBLUE® quality sensor temperature failure (Different from
19142 DTC 4DCA
DEF/ADBLUE® level temperature)
19144 DTC 9AEA CAN time-out error from DEF/ADBLUE® quality sensor
19145 DTC 647A DEF/ADBLUE® dosing valve actuator short circuit to battery failure
19149 DTC 737A DEF/ADBLUE® dosing valve actuator short circuit to ground failure
19153 DTC 624E DEF/ADBLUE® quality sensor internal failure (Short circuit to battery error)
19154 DTC 325A DEF/ADBLUE® supply module pump temperature is too low to activate pump
19156 DTC 335A DEF/ADBLUE® supply module pump motor severe speed deviation
19158 DTC 734E DEF/ADBLUE® quality sensor internal failure (Short circuit to ground error)
DEF/ADBLUE® quality sensor internal failure (Concentration value is higher
19159 DTC 144E
than expected)
DEF/ADBLUE® quality sensor internal failure (Concentration value is lower
19160 DTC 254E
than expected)
Downstream NOx sensor signal and NH3 sensor signal plausibility check
19161 DTC 3FDE
failure
DEF/ADBLUE® quality sensor internal failure (Temperature sensor circuit
19165 DTC 684E
short to battery)
DEF/ADBLUE® quality sensor internal failure (Temperature sensor circuit
19166 DTC 794E
short to ground)
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Code displayed
on cluster
DEF/ADBLUE® quality sensor internal failure (Temperature sensor value is
19167 DTC 1A4E
higher than expected)
DEF/ADBLUE® quality sensor internal failure (Temperature sensor value is
19168 DTC 1B4E
lower than expected)
19169 DTC 4C4E DEF/ADBLUE® quality sensor internal failure (Temperature sensor failure)
19173 DTC 627A DEF/ADBLUE® dosing valve actuator short circuit to battery in high side failure
19174 DTC 467A DEF/ADBLUE® dosing valve actuator short circuit in high side failure
19179 DTC 1CBE Downstream NOx sensor self-diagnosis result is higher than the limit
19180 DTC 2DBE Downstream NOx sensor self-diagnosis result is lower than the limit
19187 DTC 11CE Upstream NOx sensor self-diagnosis result is higher than the limit
19188 DTC 22CE Upstream NOx sensor self-diagnosis result is lower than the limit
19225 DTC 931B CAN C Bus off passive failure
19262 DTC 649A DEF/ADBLUE® tank heater actuator short circuit to battery failure
19264 DTC 569A DEF/ADBLUE® tank heater actuator open load failure
19323 DTC 94FB External engine shutdown request received
19336 DTC 354A DEF/ADBLUE® general pressure check failure
DEF/ADBLUE® dosing system back-flow line pressure too high plausibility
19337 DTC 344A
failure
19356 DTC 466A Supply module temperature: Temperature signal in failure range
19379 DTC 43CE Downstream NOx sensor signal is stuck at a constant value
19402 DTC 9AAA CAN time-out error - Urea tank level
19409 DTC 2D93 High pressure intercooler outlet pressure sensor plausibility check low failure
19415 DTC FABF Remaining DEF/ADBLUE® is below the empty threshold
19422 DTC 464E DEF/ADBLUE® quality sensor internal failure (Internal fault)
19434 DTC E26D ECU internal failure - EEPROM erase error
19435 DTC E36D ECU internal failure - EEPROM read error
19436 DTC E46D ECU internal failure - EEPROM write error
19496 DTC 184A Monitoring of over pressure
19524 DTC 15AA DEF/ADBLUE® temperature sensor voltage is higher than expected
19525 DTC 26AA DEF/ADBLUE® temperature sensor voltage is lower than expected
19532 DTC 374A DEF/ADBLUE® pressure did not drop when system was evacuated
19550 DTC 4B8A DEF/ADBLUE® system unable to build sufficient pressure for dosing
19559 DTC F18F DEF/ADBLUE® level too low warning is active - Stage 1
19568 DTC F28F DEF/ADBLUE® level too low warning is active - Stage 2
19650 DTC 119A DEF/ADBLUE® tank level sensor voltage too high
19651 DTC 229A DEF/ADBLUE® tank level sensor voltage too low
19708 DTC 3995 Monitoring for pressure loss in the high pressure accumulator (rail test)
DEF/ADBLUE® supply module pump motor ECU driver over temperature
19748 DTC 833A
failure
SCR Inducement: Level 1 (Torque reduction), triggered by DEF/ADBLUE®
19787 DTC F49F
dosing interruption fault
SCR Inducement: Level 3 (creep mode), triggered by DEF/ADBLUE® dosing
19788 DTC F59F
interruption fault
SCR Inducement: Warning, triggered by DEF/ADBLUE® dosing interruption
19789 DTC F69F
fault
19794 DTC F79F
Consumption fault
SCR Inducement: Level 3 (creep mode), triggered by DEF/ADBLUE®
19795 DTC F89F
Consumption fault
19796 DTC F99F SCR Inducement: Warning, triggered by DEF/ADBLUE® Consumption fault
19797 DTC FA9F
quality fault
SCR Inducement: Level 3 (creep mode), triggered by DEF/ADBLUE® quality
19798 DTC FB9F
fault
19799 DTC FC9F SCR Inducement: Warning, triggered by DEF/ADBLUE® quality fault
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Code displayed
on cluster
19800 DTC FD9F SCR Inducement: Level 1 (Torque reduction), triggered by tampering fault
19801 DTC FE9F SCR Inducement: Level 3 (creep mode), triggered by tampering fault
19809 DTC F9BF SCR Inducement: Diagnosis validation is active
19817 DTC 377A DEF/ADBLUE® dosing valve is blocked
19889 DTC 45E1 Vehicle speed CAN message not received
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Index

Electronic module - Fault code index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Cab controls - 512
836C AWD
836C
856C AWD
856C
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Contents
Cab controls - 512
FUNCTIONAL DATA
Instrument cluster
Armrest control panel
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Electrical systems - Cab controls
Instrument cluster - Component identification
SS14D039 1
Pos. Designation Function Symbol

16 Keypad Navigation keys for
multi-function display
31 Switch Windshield wiper, front

window
35 Pushbutton Windshield washer, front

window
39 Switch Windshield wiper, rear window
43 Pushbutton Windshield washer, rear

window
47 Switch Hazard warning system
69 Steering-column lever switch Lighting Turn signal, horn, headlamp

flasher, high beam
87 Switch Parking brake
103 not used
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107 Pull-switch Activation of floating position
function
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Armrest control panel - Component identification
SS14C018 1

30 Switch Lighting Side-marker lamps and low beam
38 Switch Floating position Activate

Option
40 Switch Rotary beacon

Option
42 Switch, 3–step Floodlamps Driver´s cab, front/rear
43 Switch Floodlamps Cab base, in front below

Option
44 Switch Floodlamps Rear

Option
45 Switch Reversing signal

Option
49 Reserve
51 Reserve
53 Reserve
65 Switch Blower Heating
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82 Gearshift lever Selection of the 6 forward and 3
reverse gears
83 Lever Accelerator Forwards/max speed
Backwards/ idling speed
84 Encoder FWD/CM Encoder All-wheel drive / Creep mode
Option
86 Switch Inching Brake-pressure-dependent
Option transmission cutout
88 Switch Transmission Manual/automatic
91 Switch Air conditioning system

Option
92 Switch Refuelling station External

Option
99 Rotary knob Heating Stepless heating adjustment

100 Switch Fresh air/recirculated air Switching from fresh air to recirculated
air
111 Switch Rear window heating
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Index
Cab controls - 512

Armrest control panel - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Instrument cluster - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Camera - 530
836C AWD
836C
856C AWD
856C
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Contents
Camera - 530
SERVICE
Camera
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Electrical systems - Camera
Camera - Remove
1. Remove the mounting bolts (2).
2. Remove the camera (1).
3. Disconnect the camera from the extension cable.
SS14K058 1

5. Remove the monitor (1).
6. Disconnect monitor from the cables.
SS14K059 2
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Electrical systems - Camera
Camera - Install
1. Install the monitor (1) with the screws (2).
2. Connect the monitor to the cables.
SS14K059 1
3. Install the camera (1) to the machine with the screws

(2).
4. Connect the camera to the extension cable.
SS14K058 2
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Index
Camera - 530
Camera - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Camera - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Warning indicators, alarms, and instruments - 408
836C AWD
836C
856C AWD
856C
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Contents
FUNCTIONAL DATA
Warning indicators, alarms, and instruments

Identification - View fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Warning indicators, alarms, and instruments

Service instruction - Clear fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Electrical systems - Warning indicators, alarms, and instruments
Warning indicators, alarms, and instruments - Component

identification
SS11H003 1

1 Brake pressure warning lamp 9 Steering pressure/emergency steering pressure
warning lamp
2 Main beam indicator lamp 10 Parking brake indicator lamp
3 Transmission oil temperature indicator 11 Turn signal monitoring lamp – right
4 Main warning indicator (YELLOW) 12 Fuel gauge
5 Multi-function LCD display 13 Fuel tank warning lamp
6 Main warning indicator STOP (RED) 14 Engine coolant
7 Hydraulic fluid temperature indicator 15 Turn signal monitoring lamp – left
8 Preheating monitoring lamp
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Warning indicators, alarms, and instruments - Identification - View

fault codes
NOTE: The shown values are examples and no constant values.
Diagnosis screen
At any time the operator may press the ESCAPE key (A) to view currently active faults. In the case of multiple faults
the operator may scroll through the lists. By pressing and holding the ESCAPE key (A) and UP arrow key (C) simul-
taneously for more than 2 s the selection menu, see figure 2, will open
SS14D043 1
This example screen shows following:

• 0 active error in Red list
• 0 active error in Yellow
• 0 active error in White
• 2 errors inactive in Memory
SS14C089 2
Red, yellow, and white faults are stored in fault memory when they are no longer active.
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Fault screen
Current/active faults are displayed by pressing “Escape” directly on the main screen. Red faults have priority over
yellow faults and are therefore always shown first.
Red warning indicators

• In the case of active red faults, the warning tone is sounded continuously.
• The driver can confirm this message by pressing the ENTER key (B) (see figure 1).
• After confirming in the main screen, the continuous tone changes to an intermittent signal and another instruction
(e.g. STOP MOTOR) appears on the display.
• The red main warning lamp remains lit. The fault remains in the active list until the list is updated with the new
status (i.e. fault no longer exists).
Yellow warning indicators

• In the case of yellow warnings, the warning tone is sounded every 2 s.
• The driver can confirm this message by pressing the ENTER key (B) (see figure 1).
• The fault message disappears.
• The warning tone is stopped.
• The yellow main warning lamp remains on.
• The fault remains in the active list until the list is updated with new status (i.e. fault no longer exists).
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SS14J038 3

A “Fault” for red faults F Date of last occurrence
”Warning” for yellow faults
B Number of errors in memory list G Fault description
C Operating hours at start of last occurrence H Fault code
D Total time from last reset, in hour I Memory
E Total number of fault occurrences
Fault code classification

1000 - 1999 Vehicle malfunction 5000 - 5999 Electro–hydraulic system malfunction
3000 - 3999 Engine malfunction 9000 - 9999 Internal AIC malfunction
4000 - 4999 Transmission malfunction 19000 - Selective Catalytic Reduction (SCR)
19999 system malfunction
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Warning indicators, alarms, and instruments - Service instruction -

Clear fault memory
1. The system selection screen appears by following pro-
cedure:
Hold the ESCAPE key (A) and perform key OFF – key
ON.
SS14D043 1
2. Scroll to the “Reset errors” menu and confirm with the

ENTER key (B) (see figure 1).
SS14C100 2
3. This screen allows to set to “Reset” errors. Confirm

with ENTER key (B) (see figure 1).
SS14C103 3
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Index

Warning indicators, alarms, and instruments - Component identification . . . . . . . . . . . . . . . . . . . . . . . 3
Warning indicators, alarms, and instruments - Identification - View fault codes . . . . . . . . . . . . . . . . . 4
Warning indicators, alarms, and instruments - Service instruction - Clear fault memory . . . . . . . . . . 7
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FAULT CODES - DTC
836C AWD
836C
856C AWD
856C
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Contents
FAULT CODES - DTC
DIAGNOSTIC
0000-Retrieving fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3001 (DTC 3AB1)-Diagnostic fault check of synchronism for double potentiometer and Low Idle Switch
(LIS) [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3002 (DTC 16B1)-Signal range check high for acceleration pedal position device driver sensor 1 [ECU]20
3005-(DTC 4B84)-Air filter clog or circuit failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3007-(DTC 1113)-Engine coolant temperature sensor voltage is higher than expected [ECU] . . . . . . . . 24
3008 (DTC 2213)-Engine coolant temperature sensor voltage is lower than expected [ECU] . . . . . . . . . 26
3010-(DTC 2474)-Intake manifold temperature sensor voltage is lower than expected [ECU] . . . . . . . . 28
3014-(DTC 4C84)-Air filter clog or circuit failure present for a long time [ECU] . . . . . . . . . . . . . . . . . . . . . 30
3015-(DTC 1C15)-Fuel temperature sensor voltage is higher than expected [ECU] . . . . . . . . . . . . . . . . . 32
3016-(DTC 2D15)-Fuel temperature sensor voltage is lower than expected [ECU] . . . . . . . . . . . . . . . . . . 34
3019-(DTC 1D64)-Intake manifold pressure sensor voltage is higher than expected [ECU] . . . . . . . . . . 36
3024-(DTC 13C4)-ECU internal failure - Ambient pressure sensor voltage is higher than expected [ECU]38
3025-(DTC 24C4)-ECU internal failure - Ambient pressure sensor voltage is lower than expected [ECU]39
3028-(DTC 26D3)-Oil pressure is too low [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3029-(DTC 18D3)-Oil pressure sensor voltage is higher than expected [ECU] . . . . . . . . . . . . . . . . . . . . . 41
3030-(DTC 29D3)-Oil pressure sensor voltage is lower than expected [ECU] . . . . . . . . . . . . . . . . . . . . . . 43
3034-(DTC 11E3)-Oil temperature sensor voltage is higher than expected [ECU] . . . . . . . . . . . . . . . . . . . 45
3035-(DTC 22E3)-Oil temperature sensor voltage is lower than expected [ECU] . . . . . . . . . . . . . . . . . . . 47
3037-(DTC 2E64)-Intake manifold pressure sensor voltage is lower than expected [ECU] . . . . . . . . . . . 49
3051 (DTC 1161)-Battery voltage is higher than expected [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3052 (DTC 2261)-Battery voltage is lower than expected [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3063 (DTC 6226)-Short circuit error of injector in cylinder 1 [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3067-(DTC 6726)-Short circuit error of injector in cylinder 4 [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3083-(DTC 6326)-Short circuit in injector 5 [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3088-(DTC 4512)-Crankshaft speed sensor values are not plausible [ECU]. . . . . . . . . . . . . . . . . . . . . . . . 72
3089-(DTC 4412)-Crankshaft speed sensor pattern is not plausible [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . 74
3090-(DTC 4212)-Camshaft speed sensor values are not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3091-(DTC 4112)-Camshaft speed sensor pattern is not plausible [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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55.10 [55.DTC] / 2
3093-(DTC 3312)-Compared camshaft and crankshaft speed sensor values are not plausible [ECU]. . 80
3096-(DTC 951B)-CAN A Bus off failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3102-(DTC 2525)-Fuel rail pressure sensor voltage is lower than expected [ECU] . . . . . . . . . . . . . . . . . . 83
3104-(DTC F445)-Fuel pressure relief valve is open [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3105-(DTC F245)-Fuel pressure relief valve is forced to open, perform pressure increase [ECU] . . . . . 86
3106-(DTC 1145)-Fuel pressure relief valve reached maximum allowed opening count [ECU] . . . . . . . . 87
3107-(DTC 6655)-Fuel metering unit is shorted to battery voltage at the low side [ECU] . . . . . . . . . . . . . 88
3108-(DTC 7755)-Fuel metering unit is shorted to ground at the low side [ECU] . . . . . . . . . . . . . . . . . . . . 90
3110-(DTC 1225)-Rail pressure sensor value is above maximum offset [ECU] . . . . . . . . . . . . . . . . . . . . . 92
3111-(DTC 2325)-Rail pressure sensor value is below minimum offset [ECU] . . . . . . . . . . . . . . . . . . . . . . 94
3112-(DTC 1425)-Fuel rail pressure sensor voltage is higher than expected [ECU] . . . . . . . . . . . . . . . . . 96
3118 (DTC E82D)-Internal supply voltage is too high [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3119 (DTC E92D)-Internal supply voltage is too low [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3137 (DTC 5255)-Fuel metering unit has an open load error [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3141 (DTC 4465)-Fuel pump pressure has exceeded desired pressure limits [ECU] . . . . . . . . . . . . . . . 102
3146 (DTC 4415)-Water in fuel detected or water in fuel circuit failure [ECU]. . . . . . . . . . . . . . . . . . . . . . 103
3154-(DTC 6A14)-Intake air heater actuator is shorted to battery voltage [ECU] . . . . . . . . . . . . . . . . . . . 106
3155-(DTC 7C14)-Intake air heater actuator is shorted to ground [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . 108
3156-(DTC 5614)-Intake air heater actuator has an open load error [ECU] . . . . . . . . . . . . . . . . . . . . . . . 110
3160 (DTC 6733)-Fan clutch solenoid short circuit to battery failure [ECU]. . . . . . . . . . . . . . . . . . . . . . . . 112
3161 (DTC 7833)-Fan clutch solenoid short circuit to ground failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . 114
3162 (DTC 5533)-Fan clutch solenoid open load failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3163 (DTC 8633)-Fan clutch solenoid ECU driver over temperature failure [ECU] . . . . . . . . . . . . . . . . . 118
3164 (DTC 1A33)-Fan speed above maximum threshold [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3165 (DTC 2B33)-Fan speed below minimum threshold [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3166-(DTC 63B5)-Fuel filter heater actuator is shorted to battery voltage [ECU] . . . . . . . . . . . . . . . . . . . 124
3167-(DTC 74B5)-Fuel filter heater actuator is shorted to ground [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . 126
3168-(DTC 51B5)-Fuel filter heater actuator has an open load error [ECU] . . . . . . . . . . . . . . . . . . . . . . . 128
3169-(DTC 82B5)-Fuel filter heater ECU driver has an over temperature error [ECU] . . . . . . . . . . . . . . 130
3170-(DTC 38CB)-NH3 sensor signal is not changing [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3172-(DTC F523)-Engine coolant temperature has exceeded the pre-warning threshold [ECU] . . . . . 133
3173-(DTC F623)-Engine coolant temperature has exceeded the warning threshold [ECU] . . . . . . . . . 135
3175-(DTC 4933)-Fan speed signal could not be measured for a period [ECU]. . . . . . . . . . . . . . . . . . . . 137
3176-(DTC 3B65)-High pressure pump fuel delivery quantity in over run exceeds a maximum threshold
[ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3177-(DTC F1A2)-Engine over speed condition detected [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3179-(DTC 956B)-CAN communication failure between vehicle controller and ECU - BC2ECU2 message
[ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3180-(DTC 9B7B)-CAN communication error between vehicle controller to ECU [ECU] . . . . . . . . . . . . 144
3182-(DTC 9741)-CAN timeout error from cruise control vehicle speed (CCVS) [ECU] . . . . . . . . . . . . . 146
3183-(DTC 93CB)-CAN communication failure between vehicle controller and ECU controller - TSC1_VR
message (Engine brake) [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3184-(DTC 94CB)-CAN communication failure between vehicle controller and ECU controller - TSC1_VR
message (Engine brake) [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
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3185-(DTC 978B)-Can timeout error from transmission - Transmission fluids (TF) message [ECU] . . 152
3188-(DTC 5316)-Open load error of injector in cylinder 1 [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3196-Open load error of injector in cylinder 2 [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
3204-Open load error of injector in cylinder 4 [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3210-(DTC 7116)-Injection bank 1 short circuit failure (all injectors of the same bank can be affected)
[ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
[ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3226 (DTC 9A98)-CAN timeout error from eVGT Actuator [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
3230-(DTC E126)-ECU internal failure - Injector CY33x component [ECU] . . . . . . . . . . . . . . . . . . . . . . . 176
3233 (DTC E336)-ECU internal failure - Internal SPI injector related timeout error [ECU] . . . . . . . . . . . 177
3235-(DTC F936)-Exceeded the number of injections for a given engine speed [ECU] . . . . . . . . . . . . . 178
3236-(DTC F836)-Number of injections is limited by system [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
3237 (DTC 1636)-Number of desired injections exceeds threshold [ECU] . . . . . . . . . . . . . . . . . . . . . . . . 180
3238-(DTC E64D)-ECU internal failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3245-(DTC E51D)-ECU internal failure - Query/response communication errors [ECU] . . . . . . . . . . . . . 182
3252-(DTC E61D)-ECU internal failure - SPI communication error [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . 183
3253-(DTC E41D)-ECU internal failure - Voltage ratio in ADC monitoring [ECU] . . . . . . . . . . . . . . . . . . . 184
3255-(DTC E31D)-ECU internal failure - ADC test [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
3256-(DTC E21D)-ECU internal failure - NTP error in ADC monitoring [ECU] . . . . . . . . . . . . . . . . . . . . . 186
3258-(DTC 6722)-Starter relay high side driver circuit short to battery failure [ECU] . . . . . . . . . . . . . . . . 187
3259-(DTC 7822)-Starter relay high side driver circuit short to ground failure [ECU]. . . . . . . . . . . . . . . . 189
3260-(DTC 5922)-Starter relay low side driver circuit open failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . 191
3261-(DTC 6B22)-Starter relay low side driver circuit short to battery failure [ECU] . . . . . . . . . . . . . . . . 193
3262-(DTC 7C22)-Starter relay low side driver circuit short to ground failure [ECU] . . . . . . . . . . . . . . . . 195
3263-(DTC 971B)-CAN C Bus off failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3265 (DTC E4DD)-Fuel injection requested during overrun [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
3280 (DTC E62D)-Sensor supply 1 voltage is too high [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
3281 (DTC E72D)-Sensor supply 1 voltage is too low [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
3283-(DTC E32D)-ECU internal failure - Sensor 5 volt supply 2 [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3285-(DTC E42D)-ECU internal failure - Sensor 5 Volt supply 3 [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3293-(DTC 2265)-Fuel rail pressure has exceeded maximum positive deviation limits [ECU] . . . . . . . . 206
3301-(DTC 1565)-Fuel rail pressure has exceeded maximum negative deviation limits [ECU] . . . . . . . 207
3305 (DTC 2765)-Fuel rail pressure has exceeded minimum limit [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . 208
3309-(DTC 1865)-Fuel rail pressure has exceeded maximum limit [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . 209
3334-(DTC 99BB)-CAN communication failure between vehicle controller and ECU controller - TSC1_PE
message [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
3338-(DTC 92CB)-CAN communication failure between vehicle controller and ECU controller - TSC1_VE
message [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
3361-(DTC E16D)-ECU internal failure - EEPROM write/read error [ECU] . . . . . . . . . . . . . . . . . . . . . . . . 215
3362-(DTC E1FD)-ECU internal failure - Fuel calibration [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
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3368-(DTC F6EF)-Torque limitation caused by performance limiter [ECU] . . . . . . . . . . . . . . . . . . . . . . . . 217
3370-(DTC F2EF)-Strong torque limitation from engine protection active [ECU] . . . . . . . . . . . . . . . . . . . 218
3371-(DTC F3EF)-Strong torque limitation from injection system active [ECU] . . . . . . . . . . . . . . . . . . . . 219
3403-(DTC 8A22)-Starter relay low side ECU driver circuit over temperature failure [ECU]. . . . . . . . . . 220
3425 (DTC 1438)-Under boost failure [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
3436-(DTC FBBF)-Inducement system is locked due to 3 detections in 40 hours. The system must be
reset using the dealer service tool screen "Engine Restart Counter Reset" [ECU] . . . . . . . . . . . . . . . . . 224
3438-(DTC 7A61)-Auxiliary power relay high side driver circuit short to ground failure [ECU] . . . . . . . . 225
3439-(DTC 5B61)-Auxiliary power relay low side driver circuit open failure [ECU]. . . . . . . . . . . . . . . . . . 227
3440-(DTC 8322)-Auxiliary power relay low side ECU driver circuit over temperature failure [ECU] . . 229
3441 (DTC 6422)-Auxiliary power relay low side driver circuit short to battery failure [ECU] . . . . . . . . . 231
3442-(DTC 7522)-Auxiliary power relay low side driver circuit short to ground failure [ECU] . . . . . . . . . 233
3443-(DTC F3A2)-Torque limitation due to excessive coolant temperature [ECU]. . . . . . . . . . . . . . . . . . 235
3444-(DTC F4A2)-Torque limitation due to excessive exhaust gas temperature [ECU] . . . . . . . . . . . . . 236
3445-(DTC F5A2)-Torque limitation due to excessive fuel temperature [ECU] . . . . . . . . . . . . . . . . . . . . . 237
3446-(DTC F6A2)-Torque limitation due to excessive intake air temperature [ECU] . . . . . . . . . . . . . . . . 238
3447 (DTC F7A2)-Torque limitation due to excessive oil temperature [ECU] . . . . . . . . . . . . . . . . . . . . . . 239
3448 (DTC F8A2)-Torque limitation due to turbocharger protection after start [ECU] . . . . . . . . . . . . . . . 240
3449-(DTC E812)-ECU internal failure - Calculated engine speed [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . 241
3450 (DTC 3398)-eVGT actuator blocked [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
3457-(DTC 1374)-Intake manifold temperature sensor voltage is higher than expected [ECU]. . . . . . . 244
3458-(DTC 15E3)-Crankcase pressure too high [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
3459-(DTC 1BD3)-Oil temperature too high [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
3460-(DTC 2CD3)-Oil temperature too low [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
3461-(DTC E69D)-ECU internal failure - Timeout in the shut off path test error [ECU] . . . . . . . . . . . . . . 250
3462-(DTC E79D)-ECU internal failure - Overvoltage monitoring error [ECU] . . . . . . . . . . . . . . . . . . . . . 251
3475-(DTC 9D63)-CAN timeout error from coolant water pump actuator [ECU]. . . . . . . . . . . . . . . . . . . . 252
3501-(DTC E1FD)-ECU internal failure - Software resets in DSM 0 [ECU] . . . . . . . . . . . . . . . . . . . . . . . . 254
3502 (DTC EE1D)-ECU internal failure - Software resets in DSM 1 [ECU] . . . . . . . . . . . . . . . . . . . . . . . . 255
3503-(DTC EF1D)-ECU internal failure - software resets in DSM [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . 257
3507-(DTC 4761)-Engine cranked for too long or key switch failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . 258
3508 (DTC FAEF)-Torque limitation active [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
3517-(DTC 19C4)-Ambient temperature sensor voltage is higher than expected [ECU]. . . . . . . . . . . . . 261
3518-(DTC 2AC4)-Ambient temperature sensor voltage is lower than expected [ECU] . . . . . . . . . . . . . 263
3525-(DTC E18E)-Downstream NOx sensor internal failure (Open Circuit Error) [ECU] . . . . . . . . . . . . 265
3526-(DTC E28E)-Downstream Nox sensor internal failure (Short Circuit Error) [ECU] . . . . . . . . . . . . . 266
3528-(DTC 319E)-Downstream NOx sensor values are not plausible [ECU] . . . . . . . . . . . . . . . . . . . . . . 267
3529-(DTC E16E)-Downstream NOx sensor internal failure (Heater Open Circuit Error) [ECU] . . . . . . 268
3530-(DTC E26E)-Downstream NOx sensor internal failure (Heater Short Circuit Error) [ECU] . . . . . . 269
3531-(DTC A36E)-Downstream NOx sensor internal failure (Heater Performance Plausibility Error)
[ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
3533 (DTC 9D6E)-CAN timeout error from downstream NOx sensor [ECU] . . . . . . . . . . . . . . . . . . . . . . . 272
3549 (DTC 1C54)-Intake air humidity sensor voltage is higher than expected for too long [ECU]. . . . . 274
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3557-(DTC FB54)-Intake air humidity sensor voltage is higher than expected [ECU] . . . . . . . . . . . . . . . 276
3565-(DTC F11F)-SCR inducement warning due to distance/time is active - Level 1 [ECU] . . . . . . . . . 277
3581-(DTC FD8F)-Torque limitation is active [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
3594-(DTC F7EF)-Torque limitation caused by SCR catalyst protection [ECU] . . . . . . . . . . . . . . . . . . . . 280
3614 (DTC E698)-eVGT motor effort too high [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
3616-(DTC F1EF)-Torque limitation caused by turbo charger protection [ECU] . . . . . . . . . . . . . . . . . . . . 283
3617-(DTC FB8F)-SCR inducement warning due to distance/time is active - Level 9 [ECU] . . . . . . . . . 284
3619-(DTC F5AF)-SCR inducement warning due to distance/time is active - Level 7 [ECU] . . . . . . . . . 285
3623-(DTC 3CAE)-Downstream NOx sensor lambda signal deviation - NOx sensor possible removal de-
tected [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
3624-(DTC 13A3)-Crankcase pressure sensor voltage is higher than expected [ECU] . . . . . . . . . . . . . 289
3625-(DTC 24A3)-Crankcase pressure sensor voltage is lower than expected [ECU] . . . . . . . . . . . . . . 291
3626-(DTC 37B3)-Crankcase pressure has exceeded tolerance limit [ECU] . . . . . . . . . . . . . . . . . . . . . . 293
3628-(DTC 22A3)-Crankcase pressure too low [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
3638-(DTC F4EF)-Torque limitation caused by engine brake [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
3647 (DTC 1338)-Over boost failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
3652-(DTC 911B)-CAN A Bus off passive failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
3680-(DTC E536)-Engine speed limitation via fuel injection cut off is active [ECU] . . . . . . . . . . . . . . . . . 300
3686 (DTC 3D1C)-DOC upstream temperature sensor signal drift at cold start [ECU] . . . . . . . . . . . . . . 301
3687-(DTC 3E1C)-SCR upstream temperature sensor signal drift at cold start [ECU] . . . . . . . . . . . . . . 303
3688 (DTC 4F15)-Water in fuel sensor or sensor circuit failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
3699 (DTC E56D)-ECU EEPROM memory failure - EEPData1 block [ECU] . . . . . . . . . . . . . . . . . . . . . . 308
3700 (DTC 3754)-Intake air humidity sensor value is not plausible [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . 309
3703 (DTC 2B36)-The minimum rail pressure value necessary to allow fuel injection has not been reached
[ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
3735-(DTC 8355)-Fuel metering unit has an over-temperature error [ECU] . . . . . . . . . . . . . . . . . . . . . . . 311
3738-(DTC E71D)-ECU internal failure - ROM error [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
3739-(DTC E13D)-ECU internal failure - Loss of synchronization to MM from CPU [ECU] . . . . . . . . . . 314
3740-(DTC E23D)-ECU internal failure - ECU shutdown test failure [ECU]. . . . . . . . . . . . . . . . . . . . . . . . 315
3741-(DTC E33D)-ECU internal failure - Wrong set response time [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . 316
3742-(DTC E43D)-ECU internal failure - SPI errors during MoCSOP execution [ECU] . . . . . . . . . . . . . 317
3743-(DTC E53D)-ECU internal failure - Undervoltage monitoring error [ECU] . . . . . . . . . . . . . . . . . . . . 318
3745-(DTC E63D)-ECU internal failure - WDA is not working correctly [ECU] . . . . . . . . . . . . . . . . . . . . . 319
3746-(DTC E73D)-ECU internal failure - Alarm task period error [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . 320
3747-(DTC E83D)-ECU internal failure - Positive test failed [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
3749 (DTC E5B1)-ECU internal failure - Accelerator pedal position sensor [ECU] . . . . . . . . . . . . . . . . . 322
3750-(DTC EC36)-ECU internal failure - Fuel injection energizing time is not plausible [ECU] . . . . . . . 323
3751-(DTC ED36)-ECU internal failure - Fuel injection energizing phase is not plausible [ECU] . . . . . 324
3752 (DTC EE36)-Fuel injection correction has exceeded a minimum limit [ECU] . . . . . . . . . . . . . . . . . 325
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3753-(DTC E5DD)-ECU internal failure - Injection quantity correction [ECU] . . . . . . . . . . . . . . . . . . . . . . 326
3754-(DTC E6DD)-ECU internal failure - Rail pressure plausibility [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . 327
3755-(DTC E7DD)-ECU internal failure - Torque request comparison [ECU] . . . . . . . . . . . . . . . . . . . . . . 328
3756-(DTC E1DD)-ECU internal failure - Post injection quantity [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
3757-(DTC E2DD)-ECU internal failure - Post injection shut-off failure [ECU] . . . . . . . . . . . . . . . . . . . . . 330
3758 (DTC E3DD)-Post injection efficiency failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
3759-(DTC E8DD)-ECU internal failure - Torque request due to fuel pressure exceeds maximum torque
limit [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
3760-(DTC E9DD)- ECU internal failure - Torque request due to rail control exceeds maximum torque limit
[ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
3761-(DTC EADD)-ECU internal failure - Torque request exceeds maximum torque limit [ECU] . . . . . 334
3762 (DTC EBDD)-ECU 5 volt supply voltage is higher than expected [ECU] . . . . . . . . . . . . . . . . . . . . . 335
3763-(DTC ECDD)-ECU 5 volt supply voltage is lower than expected [ECU] . . . . . . . . . . . . . . . . . . . . . . 336
3764-(DTC F561)-ECU after run power interruption [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
3767-(DTC E81D)-ECU internal failure - 'WDA active' reported due to errors in query/response communi-
cation [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
3768-(DTC E91D)-ECU internal failure - 'ABE active' reported due to undervoltage detection [ECU] . 341
3769-(DTC EA1D)-ECU internal failure - 'ABE active' reported due to overvoltage detection [ECU] . . 342
3770-(DTC EB1D)-ECU internal failure - 'WDA/ABE active' reported [ECU] . . . . . . . . . . . . . . . . . . . . . . . 343
3799-(DTC F345)-Fuel pressure relief valve is forced to open, perform pressure shock [ECU] . . . . . . 344
3805-(DTC 1D85)-Maximum rail pressure exceeded [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
3808-(DTC 3C65)-High pressure pump fuel delivery quantity at low idle is too high [ECU] . . . . . . . . . . 346
3810 (DTC 4125)-Rail pressure sensor value is intermittent [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
3811-(DTC E22D)-ECU internal failure - Sensor 5 volt supply 1 [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
3812-(DTC 115D)-ECU temperature sensor 1 is too high [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
3813-(DTC 235D)-ECU temperature sensor 1 is too low [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
3814-(DTC E55D)-ECU temperature sensor error detected [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
3838-(DTC 2999)-Upstream oxidation catalyst temperature sensor voltage is lower than expected
[ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
3858 (DTC 3598)-CAN communication error between ECU and eVGT actuator [ECU] . . . . . . . . . . . . . 356
3861 (DTC 3498)-eVGT power supply electrical failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
3865 (DTC 4898)-eVGT system failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
3868 (DTC 8998)-eVGT actuator over temperature error [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
3870-(DTC 936B)-CAN communication failure between vehicle controller and ECU - BC2ECU1 message
[ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
3877-(DTC 647D)-Supply UB1 short to battery failure [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
3881-(DTC 757D)-Supply UB1 circuit short to ground failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
3882-(DTC 777D)-Supply UB2 short to ground failure [RCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
3883-(DTC 797D)-Supply UB3 short to ground failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
3903-(DTC 1A15)-Fuel temperature is too high [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
3905-(DTC 8814)-Intake air heater ECU driver has an over-temperature [ECU] . . . . . . . . . . . . . . . . . . . 380
3910-(DTC 4155)-Fuel metering unit intermittent electrical connection [ECU] . . . . . . . . . . . . . . . . . . . . . 382
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3911-(DTC 6455)-Fuel metering unit is shorted to battery voltage at the high side [ECU] . . . . . . . . . . . 384
3912-(DTC 7555)-Fuel metering unit is shorted to ground at the high side [ECU] . . . . . . . . . . . . . . . . . . 386
3916-(DTC 1745)-Fuel pressure relief valve has reached maximum allowed open time [ECU]. . . . . . . 388
3930-(DTC FC8F)-SCR inducement warning due to distance/time is active - Level 10 [ECU]. . . . . . . . 390
3936 (DTC E52D)-ECU internal: error sensor supplies voltage tracker [ECU] . . . . . . . . . . . . . . . . . . . . . 391
3961-(DTC ED2D)-CAN communication failure - External torque/speed checksum and counter [ECU]392
3962 (DTC 49C3)-Crankcase pressure too high for too long [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
3963-(DTC 4AC3)-Crankcase pressure too high and oil pressure too low - Fuel in oil suspected [ECU]395
3964-(DTC 125D)-ECU temperature sensor 2 is too high [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
3965-(DTC 245D)-ECU temperature sensor 2 is too low [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
3966-(DTC 165D)-ECU temperature sensor voltage is higher than expected [ECU]. . . . . . . . . . . . . . . . 398
3967-(DTC 275D)-ECU temperature sensor voltage is lower than expected [ECU] . . . . . . . . . . . . . . . . 399
3968-(DTC 5171)-After run relay high side driver circuit open failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . 400
3969-(DTC 8271)-After run relay high side ECU driver circuit over temperature failure [ECU] . . . . . . . 402
3970-(DTC 6371)-After run relay high side driver circuit short to battery [ECU] . . . . . . . . . . . . . . . . . . . . 404
3971-(DTC 6471)-After run relay high side drive circuit short to ground failure [ECU]. . . . . . . . . . . . . . . 406
3973-(DTC 8671)-After run relay low side ECU drive circuit over temperature failure [ECU] . . . . . . . . . 408
3974-After run relay low side driver circuit short to battery failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . 410
3977-(DTC 15E5)-Prefilter fuel pressure sensor voltage is higher than expected [ECU] . . . . . . . . . . . . 412
3978-(DTC 16E5)-Prefilter fuel pressure sensor voltage is lower than expected [ECU] . . . . . . . . . . . . . 414
3981-After run relay low side driver circuit open or short to ground failure [ECU] . . . . . . . . . . . . . . . . . . 416
3985-(DTC 1758)-Exhaust gas pressure sensor voltage is higher than expected [ECU] . . . . . . . . . . . . 418
3986-(DTC 275D)-Exhaust gas pressure sensor voltage is lower than expected [ECU]. . . . . . . . . . . . . 420
4113-Logical error at FNR switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
4114-Logical error at direction select signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
4116-Logical error at park brake status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
4117-Logic error at direction select signal 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
4133-Short circuit to battery voltage or open circuit at transmission sump temperature sensor input . 431
4134-Short circuit to ground at transmission sump temperature sensor input . . . . . . . . . . . . . . . . . . . . . 432
4135-Short circuit to battery voltage or open circuit at retarder/ torque converter temperature sensor input
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
4136-Short circuit to ground at retarder/ torque converter temperature sensor input . . . . . . . . . . . . . . . 434
4137-Short circuit to battery voltage or open circuit at parking brake sensor input . . . . . . . . . . . . . . . . . 435
4145-Short circuit to battery voltage or open circuit at engine speed input . . . . . . . . . . . . . . . . . . . . . . . . 438
4146-Short circuit to ground at engine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
4147-Logical error at engine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
4148-Short circuit to battery voltage or open circuit at turbine speed input . . . . . . . . . . . . . . . . . . . . . . . 444
4149-Short circuit to ground at turbine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
4150-Logical error at turbine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
4151-Short circuit to battery voltage or open circuit at internal speed input . . . . . . . . . . . . . . . . . . . . . . . 450
4152-Short circuit to ground at internal speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
4153-Logical error at internal speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
4154-Short circuit to battery voltage or open circuit at output speed input . . . . . . . . . . . . . . . . . . . . . . . . 456
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4155-Short circuit to ground at output speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
4156-Logical error at output speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
4158-Output speed zero, doesn't fit to other speed signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
4160-Invalid gear range restriction (CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
4186-Invalid park brake status (CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
4209-Short circuit to battery voltage at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
4210-Short circuit to ground at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
4211-Open circuit at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
4228-Short circuit to battery voltage at clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
4229-Short circuit to ground at clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
4230-Open circuit at clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
4231-Short circuit to battery voltage at clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481
4232-Short circuit to ground at clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
4233-Open circuit at clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
4241-Short circuit to ground at backup alarm relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
4242-Short circuit to battery voltage at backup alarm relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
4243-Open circuit at backup alarm relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488
4273-Slippage at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
4277-Slippage at clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
4278-Slippage at clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
4279-Overtemp sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
4281-Engine overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
4282-TCM sensed a voltage at oil filter maintenance switch out of the allowed range (dirty filter) . . . . 500
4284-Overspeed output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
4290-Transmission input torque overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
4291-Overtemp converter output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
4292-Short circuit to ground at joystick status indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
4293-Short circuit to battery voltage at joystick status indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
4294-Open circuit at joystick status indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
4305-Short circuit to battery voltage at power supply for sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
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4306-Short circuit to ground at power supply for sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
4307-Low voltage at battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
4308-High voltage at battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
4309-Error at valve power supply VPS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
4310-Error valve power supply VPS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
4325-VehicleID#1 timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
4326-Illegal ID request via CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
4337-General EEPROM fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
4338-Configuration error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524
4339-Application error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
4341-Clutch failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
4342-Clutch adjustment data lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
5155-UCM Ground disconnection [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528
5159-Error at Fuse 5F2 [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529
5164-Open Circuit at Wheel Motor Valve Y8.2 [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534
5165-Open Circuit or Short Circuit to battery at Wheel Motor Valve Y8.2 [UCM] . . . . . . . . . . . . . . . . . . . 536
5166-Short Circuit to ground at Wheel Motor Valve Y8.2 [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
5167-Short Circuit to power circuit at Wheel Motor Valve Y8.2 [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540
5169-Open Circuit at FWD On/Off Valve Y8.1 [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
5170-Open Circuit or Short Circuit to battery at FWD On/Off Valve Y8.1 [UCM] . . . . . . . . . . . . . . . . . . . 543
5171-Short Circuit to ground at FWD On/Off Valve Y8.1 [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
5172-Short Circuit to power circuit at FWD On/Off Valve Y8.1 [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547
5174-Open Circuit at FWD Forward Pump Valve Y8.5 [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549
5175-Open Circuit or Short Circuit to battery at FWD Forward Pump Valve Y8.5 [UCM] . . . . . . . . . . . . 551
5176-Short Circuit to ground at FWD Forward Pump Valve Y8.5 [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . 553
5177-Short Circuit to power at FWD Forward Pump Valve Y8.5 [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . 555
5179-Open Circuit at FWD Reverse Pump Valve Y8.6 [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557
5180-Open Circuit or Short Circuit to battery at FWD Reverse Pump Valve Y8.6 [UCM] . . . . . . . . . . . . 558
5181-Short Circuit to ground at FWD Reverse Pump Valve Y8.6 [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . 560
5182-Short Circuit to power at FWD Reverse Pump Valve Y8.6 [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . 562
5184-Timeout of cycling message AIC2UCM [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564
5185-Timeout of first cycling message AIC2UCM1 [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566
5186-Timeout of cycling message EEC1 or EEC2 [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568
5187-Timeout of cycling TCU1 or TCU2 CAN messages [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570
5188-Actual tire circumference error [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
5189-Main Model Info Error [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574
5194-Gear Restriction Mismatch [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576
5197-Mismatch AIC CAN message versus brake pressure switch status [UCM] . . . . . . . . . . . . . . . . . . . 579
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5198-Tire circumference out of range error [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581
5199-Timeout of first cycling TCU1 or TCU2 messages [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582
5202-Cranking line short circuit to power error [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585
5203-Cranking line open circuit error [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587
5204-Timeout of first cycling message C6_9_Status [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589
5205-Timeout of cycling message C6_9_Status [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592
5208-Timeout of first message EEC1 or EEC2 [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595
5214-Parking brake error [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597
19002 (DTC 2461)-Battery voltage is lower than expected [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599
19006 (DTC 2461)-CAN timeout error from NH3 sensor - NH3Fac message [ECU] . . . . . . . . . . . . . . . . 601
19007-NH3 sensor open or short in measuring cell circuit [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
19008-NH3 sensor open or short in ground circuit [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
19009 (DTC 18DE)-NH3 sensor short in heater circuit causing overheating [ECU]. . . . . . . . . . . . . . . . . 606
19010-(DTC 161A)-Downstream SCR catalyst temperature sensor voltage is higher than expected
[ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
19011-(DTC 271A)-Downstream SCR catalyst temperature sensor voltage is lower than expected
[ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
19012 (DTC E9DE)-NH3 sensor open in heater circuit causing underheating [ECU] . . . . . . . . . . . . . . . 612
19013-(DTC EADE)-NH3 sensor open or short in temperature cell circuit [ECU]. . . . . . . . . . . . . . . . . . . 614
19014-(DTC EBDE)-NH3 sensor open or short in trim resistor circuit [ECU] . . . . . . . . . . . . . . . . . . . . . . 615
19015-(DTC 4CDE)-NH3 sensor heater control failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
19016-(DTC 37EE)-NH3 sensor heater performance failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
19017-(DTC 38EE)-NH3 sensor signal out of range failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
19018 (DTC 4DDE)-NH3 sensor power supply failure [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
19019-(DTC 1A1A)-Upstream SCR catalyst temperature sensor voltage is higher than expected [ECU]622
19020-(DTC 2B1A)-Upstream SCR catalyst temperature sensor voltage is lower than expected [ECU]624
19023-(DTC 4EDE)-NH3 sensor controller failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626
19024-CAN timeout error from NH3 sensor - NH3Sens message [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . 627
19026-(DTC 319C)-Exhaust flap sticking or internal failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
19027-(DTC 329C)-Exhaust flap actuator supply voltage out of range [ECU]. . . . . . . . . . . . . . . . . . . . . . 631
19030-(DTC 439C)-Exhaust flap increased friction or high mechanical load or flap sticking [ECU] . . . 633
19033-(DTC 469C)-Exhaust flap stuck during power up test [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635
19034-(DTC 879C)-Exhaust flap actuator is over temperature [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 637
19035-(DTC 91BC)-CAN timeout error from exhaust flap actuator [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . 639
19036 (DTC 3F1C)-SCR downstream temperature sensor signal drift at cold start [ECU] . . . . . . . . . . . 641
19040-(DTC 352C)-Upstream oxidation catalyst temperature sensor comparison to a calculated temper-
ature value failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643
19041 (DTC 362C)-Upstream SCR temperature sensor comparison to a calculated temperature value
failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645
19042-(DTC 372C)-Downstream SCR temperature sensor comparison to a calculated temperature value
failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 647
19043-(DTC 2D54)-Intake air humidity sensor voltage is lower than expected [ECU]. . . . . . . . . . . . . . . 649
19047-(DTC 195A)-DEF/AdBlue supply module pump motor pressure sensor voltage is higher than ex-
pected [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651
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19048-(DTC 2A5A)-DEF/AdBlue supply module pump motor pressure sensor voltage is lower than ex-
pected [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 653
19050-(DTC 478E)-Downstream NOx sensor supply voltage is out of range [ECU] . . . . . . . . . . . . . . . . 655
19051-(DTC E46E)-Upstream NOx sensor internal failure (Heater Open Circuit Error) [ECU] . . . . . . . 657
19052-(DTC 256E)-Upstream NOx sensor internal failure (Heater Short Circuit Error) [ECU] . . . . . . . . 658
19053-(DTC A66E)-Upstream NOx sensor internal failure (Heater Performance Plausibility Error)
[ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 659
19054-(DTC E48E)-Upstream NOx sensor internal failure (Open Circuit Error) [ECU] . . . . . . . . . . . . . . 661
19059 (DTC 258E)-Upstream NOx sensor internal failure (short circuit error) [ECU] . . . . . . . . . . . . . . . 662
19060-(DTC 9E6E)-CAN timeout error from upstream NOx sensor [ECU] . . . . . . . . . . . . . . . . . . . . . . . . 663
19061-(DTC 32BE)-Upstream NOx sensor lambda signal deviation - NOx sensor possible removal de-
tected [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 665
19062-(DTC E98E)-Upstream NOx sensor values are not plausible [ECU] . . . . . . . . . . . . . . . . . . . . . . . 666
19063-(DTC 4A8E)-Upstream NOx sensor supply voltage is out of range [ECU] . . . . . . . . . . . . . . . . . . 667
19066-(DTC 1899)-Upstream oxidation catalyst temperature sensor voltage is higher than expected
[ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 669
19067 (DTC 141A)-Downstream SCR catalyst temperature is too high [ECU] . . . . . . . . . . . . . . . . . . . . . 671
19068 (DTC 251A)-Downstream SCR catalyst temperature is too low [ECU]. . . . . . . . . . . . . . . . . . . . . . 673
19069 (DTC 181A)-Upstream SCR catalyst temperature too high [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . 675
19070 (DTC 291A)-Upstream SCR catalyst temperature too low [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . 677
19071-(DTC 2DDA)-SCR catalyst efficiency lower than first Nox production threshold level [ECU] . . . 679
19077-(DTC 334A)-DEF/AdBlue pressure stabilization failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 683
19079-(DTC 1A4A)-DEF/AdBlue over pressure failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 685
19080-(DTC 294A)-DEF/AdBlue under pressure failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 687
19081-(DTC 717A)-DEF/AdBlue dosing valve actuator short circuit to ground in high side failure [ECU]690
19082-(DTC 6C5A)-DEF/AdBlue reverting valve driver circuit short to battery failure [ECU] . . . . . . . . . 692
19083-(DTC 7D5A)-DEF/AdBlue reverting valve driver circuit short to ground failure [ECU] . . . . . . . . . 694
19084-(DTC 5E5A)-DEF/AdBlue reverting valve driver circuit open failure [ECU] . . . . . . . . . . . . . . . . . . 696
19096 (DTC 436A)-DEF/AdBlue supply module temperature not available [ECU]. . . . . . . . . . . . . . . . . . 698
19105-(DTC 879A)-DEF/AdBlue tank heater actuator over temperature [ECU] . . . . . . . . . . . . . . . . . . . . 700
19106-(DTC 759A)-DEF/AdBlue tank heater actuator short circuit to ground failure [ECU] . . . . . . . . . . 702
19107-(DTC 515A)-DEF/AdBlue supply module pump motor open load failure [ECU] . . . . . . . . . . . . . . 704
19108-(DTC 613A)-DEF/AdBlue supply module pump motor short circuit to battery failure [ECU]. . . . 706
19111-(DTC 723A)-DEF/AdBlue supply module pump motor short circuit to ground failure [ECU] . . . . 708
19113-(DTC 8F5A)-DEF/AdBlue reverting driver circuit over temperature failure [ECU]. . . . . . . . . . . . . 710
19126 (DTC FF9F)-SCR Inducement: Warning, triggered by tampering fault [ECU]. . . . . . . . . . . . . . . . 712
19140-(DTC 4BCA)-DEF/AdBlue concentration is out of range [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713
19141-(DTC 4CCA)-DEF/AdBlue quality sensor detects diesel fuel in DEF/AdBlue tank [ECU] . . . . . . 714
19142 (DTC 4DCA)-DEF/AdBlue quality sensor temperature failure (different from DEF/AdBlue level tem-
perature) [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715
19144 (DTC 9AEA)-CAN timeout error from DEF/AdBlue quality sensor [ECU]. . . . . . . . . . . . . . . . . . . . 717
19145-(DTC 647A)-DEF/AdBlue dosing valve actuator short circuit to battery failure [ECU] . . . . . . . . . 719
19149-(DTC 737A)-DEF/AdBlue dosing valve actuator short circuit to ground failure [ECU] . . . . . . . . . 721
19153-(DTC 624E)-DEF/AdBlue quality sensor internal failure (Short circuit to battery error) [ECU] . . 723
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19154-(DTC 325A)-DEF/AdBlue supply module pump temperature is too low to activate pump [ECU]724
19156-(DTC 335A)-DEF/AdBlue supply module pump motor severe speed deviation [ECU] . . . . . . . . 725
19158-(DTC 734E)-DEF/AdBlue quality sensor internal failure (Short circuit to ground error) [ECU] . . 726
19159-(DTC 144E)-DEF/AdBlue quality sensor internal failure (Concentration value is higher than ex-
pected) [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 727
19160-(DTC 254E)-DEF/AdBlue quality sensor internal failure (Concentration value is lower than
expected) [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 728
19161-(DTC 464E)-DEF/AdBlue quality sensor internal failure (Internal fault) [ECU] . . . . . . . . . . . . . . . 729
19165-(DTC 684E)-DEF/AdBlue quality sensor internal failure (Temperature sensor circuit short to battery)
[ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 730
19166-(DTC 794E)-DEF/AdBlue quality sensor internal failure (Temperature sensor circuit short to ground)
[ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 731
19167-(DTC 1A4E)-DEF/AdBlue quality sensor internal failure (Temperature sensor value is higher than
expected) [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 732
19168-(DTC 1B4E)-DEF/AdBlue quality sensor internal failure (Temperature sensor value is lower than
expected) [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 733
19169-(DTC 4C4E)-DEF/AdBlue quality sensor internal failure (Temperature sensor failure) [ECU] . . 734
19173-(DTC 627A)-DEF/AdBlue dosing valve actuator short circuit to battery in high side failure [ECU]735
19174-(DTC 467A)-DEF/AdBlue dosing valve actuator short circuit in high side failure [ECU] . . . . . . . 737
19179-(DTC 1CBE)-Downstream NOx sensor self-diagnosis result is higher than the limit [ECU] . . . . 739
19180-(DTC 2DBE)-Downstream NOx sensor self-diagnosis result is lower than the limit [ECU] . . . . . 740
19187-(DTC 11CE) - Upstream NOx sensor self-diagnosis result is higher than the limit [ECU] . . . . . . 741
19188 (DTC 22CE)-Upstream NOx sensor self-diagnosis result is lower than the limit [ECU]. . . . . . . . 742
19225-(DTC 931B)-CAN C Bus off passive failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 743
19262 (DTC 659A)-DEF/AdBlue tank heater actuator short circuit to battery failure [ECU] . . . . . . . . . . 745
19264-(DTC 569A)-DEF/AdBlue tank heater actuator open load failure [ECU] . . . . . . . . . . . . . . . . . . . . 747
19323-(DTC 94FB)-External engine shutdown request received [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . 749
19336-(DTC 354A)-DEF/AdBlue general pressure check failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . 750
19337-(DTC 344A)-DEF/AdBlue dosing system backflow line pressure too high plausibility failure
[ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 752
19356-(DTC 3FDE)-Downstream NOx sensor signal and NH3 sensor signal plausibility check failure
[ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 754
19409 (DTC 2D93)-High pressure intercooler outlet pressure sensor plausibility check low failure [ECU]755
19415 (DTC FABF)-Remaining DEF/AdBlue is below the empty threshold [ECU] . . . . . . . . . . . . . . . . . . 757
19422-(DTC 43CE)-Downstream NOx sensor signal is stuck at a constant value [ECU] . . . . . . . . . . . . 758
19434 (DTC E26D)-ECU internal failure - EEPROM erase error [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . 759
19435 (DTC E36D)-ECU internal failure - EEPROM read error [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 760
19436 (DTC E46D)-ECU internal failure - EEPROM write error [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . 761
19496 (DTC 184A)-Monitoring of over pressure [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 762
19524-(DTC 15AA)-DEF/AdBlue temperature sensor voltage is higher than expected [ECU]. . . . . . . . 764
19525-(DTC 26AA)-DEF/AdBlue temperature sensor voltage is lower than expected [ECU] . . . . . . . . 766
19532-(DTC 374A)-DEF/AdBlue pressure did not drop when system was evacuated [ECU] . . . . . . . . 768
19550-(DTC 4B8A)-DEF/AdBlue system unable to build sufficient pressure for dosing [ECU] . . . . . . . 770
19559 (DTC F18F)-DEF/AdBlue level too low warning is active - Stage 1 [ECU]. . . . . . . . . . . . . . . . . . . 773
19568 (DTC F28F)-DEF/AdBlue level too low warning is active - Stage 2 [ECU]. . . . . . . . . . . . . . . . . . . 774
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19650-(DTC 119A)-DEF/AdBlue tank level sensor voltage too high [ECU] . . . . . . . . . . . . . . . . . . . . . . . . 775
19651-(DTC 229A)-DEF/AdBlue tank level sensor voltage too low [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . 777
19708 (DTC 3995)-Monitoring for pressure loss in the high pressure accumulator (rail test) [ECU] . . . 779
19748 (DTC 833A)-DEF/AdBlue supply module pump motor over temperature failure [ECU]. . . . . . . . 781
19787 (DTC F49F)-SCR Inducement: Level 1 (torque reduction), triggered by DEF/AdBlue dosing inter-
ruption fault [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 783
19788-(DTC F59F)-SCR Inducement: Level 3 (creep mode), triggered by DEF/AdBlue dosing interruption
fault [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 784
19789 (DTC F69F)-SCR Inducement: Warning, triggered by DEF/AdBlue dosing interruption fault
[ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 785
19797 (DTC FA9F)-SCR Inducement: Level 1 (torque reduction), triggered by DEF/AdBlue quality fault
[ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 786
19798 (DTC FB9F)-SCR Inducement: Level 3 (creep mode), triggered by DEF/AdBlue quality fault
[ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 787
19799 (DTC FC9F)-SCR Inducement: Warning, triggered by DEF/AdBlue quality fault [ECU] . . . . . . . 788
19800 (DTC FD9F)-SCR Inducement: Level 1 (torque reduction), triggered by tampering fault [ECU] 789
19801 (DTC FE9F)-SCR Inducement: Level 3 (creep mode), triggered by tampering fault [ECU] . . . . 790
19817-(DTC 377A)-DEF/AdBlue dosing valve is blocked [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 791
19889-(DTC 45E1)-Vehicle speed CAN message not received [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . 793
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Electrical systems - FAULT CODES
0000-Retrieving fault codes

Context:
General fault code identification, clearing faults from memory.
Solution:
1. Press and hold the escape key (A) and up arrow key (C) for more than 2 seconds to access the fault codes.
BC07F333-01 1
(A) Escape key (C) Up key

(B) Enter key (D) Down key
2. Yellow Faults, buzzer will beep once every 2 seconds:
(A) Operator can acknowledge it by pressing the enter key.

(B) The message will disappear.
(C) Buzzer will not beep anymore.
(D) Yellow lamp will stay ON.
(E) Fault will remain in Yellow list until it is closed.
3. Red Faults, buzzer will be continuous, alternating sounds:
(A) Operator can acknowledge it by pressing the enter key.

(B) Buzzer will change tone, but will remain ON.
(C) Message will remain on display with indication of URGENT STOP.
4. Fault Code Grouping
(1) 1000 to 1999 vehicle errors

(2) 2000 to 2999 Not Used
(3) 3000 to 3999 engine errors
(4) 4000 to 4999 transmission errors
(5) 5000 to 5999 Not Used
(6) 6000 to 6999 Not Used
(7) 7000 to 7999 Not Used
(8) 8000 to 8999 Not Used
(9) 9000 to 9999 internal AIC errors
(10) 19000 to 19999 SCR System errors
5. Removing faults from memory.
(1) Press the ENTER key (B) and hold for two seconds, this will bring you into the internal Advanced Instrument
Cluster (AIC) screens.
(2) Us the UP key (C) or DOWN key (D) and scroll to "CONFIG", then press ENTER.
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(3) Us the UP key (C) or DOWN key (D) and scroll to "SPECIAL", then press ENTER key (B).
(4) Highlight "RESET ERRORS" the press ENTER key (B) twice.
(5) Turn the key switch OFF and wait for 20 seconds.
(6) The next time the machine will be started, the memory field will be empty.
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3001 (DTC 3AB1)-Diagnostic fault check of synchronism for double

potentiometer and Low Idle Switch (LIS)
Control Module : ECU
Context:
The Engine Control Unit (ECU) A158 monitors the throttle control R10 to determine synchronization status. The
idle validation switch (IVS) and the throttle position potentiometer are two separate devices mechanically coupled
and contained within the R10. The analog position sensor signal is compared to the status of the IVS position. If
the analog position signal is less than 0.591 V and the IVS is actuated or the analog position signal is greater than
0.958 V and the IVS is not actuated, this fault will occur.
Cause:
The R10 position signal and IVS signal to the ECU do not agree.
Possible failure modes:
1. Faulty R10 position signal or IVS circuit wiring, grounded.

2. Faulty R10 position signal or IVS circuit wiring, shorted to a high source.
3. Faulty R10, failed internally.
4. Faulty software of the ECU.
Solution:
1. Verify fault is present and active.
Use the Electronic Service Tool (EST) to check the status of this fault.
A. If the fault is present and active, continue with Step 2.
B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active.
Continue with Step 5.
2. Check the R10 position signal circuit wiring for a short to ground or a voltage source condition.
Disconnect the Connector X33-30 .
With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle (VE) harness from:
From To Value
Connector X33-30 , pin 27 chassis ground There should be no continuity
Connector X33-30 , pin 20 chassis ground There should be no continuity
Then with the key switch in the ON position, use a multimeter to check for voltage on the vehicle (VE) harness
from:
From To Value
Connector X33-30 , pin 27 chassis ground There should be no voltage
A. If there is no continuity or voltage, connect the Connector X33-30 and continue with Step 3.
B. If there is continuity or voltage, there is a short to ground or a voltage source condition in the vehicle (VE) har-
ness. Use the appropriate vehicle service manual and electrical schematics to locate and repair the grounded
or shorted voltage source condition.
3. Check the R10 position signal circuit wiring for a short to ground or a voltage source condition.
Disconnect the vheicle (VE) harness from the Connector XR10.
With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle (VE) harness from:
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From To Value
Connector XR10, pin A chassis ground There should be no continuity
Connector XR10, pin D chassis ground There should be no continuity
Then with the key switch in the ON position, use a multimeter to check for voltage on the vehicle (VE) harness
from:
From To Value
Connector XR10, pin A chassis ground There should be no voltage
Connector XR10, pin D chassis ground There should be no voltage
A. If there is no continuity or voltage, leave the Connector XR10 disconnected and continue with Step 4.
B. If there is continuity or voltage, there is a short to ground or a voltage source condition in the vehicle (VE) har-
ness. Use the appropriate vehicle service manual and electrical schematics to locate and repair the grounded
or shorted voltage source condition.
4. Check the R10.
Use a multimeter to measure resistance on the R10 from:
From To Value
Connector XR10, pin A Connector XR10, pin B There should be measurable
resistance
Connector XR10, pin A Connector XR10, pin C There should be measurable
resistance
Connector XR10, pin B Connector XR10, pin C There should be measurable
resistance
NOTE: the measured value in the first two checks when added together should equal the measured value of the
third check.
Then, while operating the R10, use the multimeter to measure resistance from:
From To Value
Connector XR10, pin A Connector XR10, pin B There should be a varying
measurable resistance
Connector XR10, pin A Connector XR10, pin C There should be a varying
measurable resistance
NOTE: both measurements should vary in linearly increasing or decreasing fashion throughout the travel of the
throttle control.
Then, while operating R10, use the multimeter to check continuity from:
From To Value
Connector XR10, pin F Connector XR10, pin D There should be a change from no
continuity to continuity (switching
action)
NOTE: early in the travel of the throttle control, typically 14 - 16 % of full travel, the IVS should change states.
A. If the test results are all acceptable, check the ECU for the appropriate software and re-flash, if necessary.
B. If the test results are not all acceptable, the R10 has failed internally. Replace the unit.
5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals,
or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent
breaks or shorts in the wiring concerned. Operate the machine while you monitor the display.
A. If you find damage or the display indicates other than normal display readings, then repair the damage 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.
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Harnesses and connectors - Electrical schematic sheet 13 (55.100)
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3002 (DTC 16B1)-Signal range check high for acceleration pedal

position device driver sensor 1
Context:
The Engine Control Unit (ECU) A158 provides sensor power and ground reference used by the throttle control R10
and monitors both the Idle Validation Switch (IVS) and the throttle position potentiometer. If the R10 position sensor
signal is greater than 5.20 V, this fault will occur.
Cause:
The R10 position signal to the ECU is greater than 5.20 V.
1. Faulty R10 position signal circuit wiring, shorted to a high source.

Solution:
Continue with Step 4 .
2. Check the R10 position signal circuit wiring for a short to voltage source condition.
With the key switch in the ON position, use a multimeter to check for voltage on the vehicle (VE) harness from:
From To Value
A. If there is no voltage, connect the Connector X33-30 and continue with Step 3.
B. If there is a short to a voltage source condition in the vehicle (VE) harness between the Connector X33-30 ,
pin 27 and the Connector XA158 pin 79, wire 646. Locate and repair the damaged conductors.
3. Check the R10 position signal circuit wiring for a short to voltage source condition.
Disconnect the vheicle (VE) harness from the Connector XR10.
With the key switch in the ON position, use a multimeter to check for voltage on the vehicle (VE) harness from:
From To Value
Connector XR10, pin A chassis ground There should be no voltage
A. If there is no voltage, check the ECU for the appropriate software and re-flash, if necessary.
B. If there is a short to a voltage source condition in the vehicle (VE) harness between the Connector X33-30 ,
pin 27 and the Connector XR10, pin A, wire 646-1. Locate and repair the damaged conductors.
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has been resolved.
operation.
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3005-(DTC 4B84)-Air filter clog or circuit failure

Context:
The Engine Control Unit (ECU) A158 monitors the air filter switch S15-1. 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.
1. Faulty S15-1, clogged.

2. Faulty S15-1 or S15-1 wiring.
Solution:
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 S15-1 circuit for a short circuit condition.
Disconnect the Connector XA158.
Disconnect the Connector X15-1.
They key must be in the OFF position.
Use a multimeter to perform the following continuity check:
From To Value
Connector XA158, pin 37 Connector XA158, pin 27 There should be no continuity
A. If there is continuity, there is a short circuit condition in the S15-1 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 S15-1 circuit for a short to key battery power condition.
The key must be in the ON position.
Use a multimeter to perform the following voltage check:
From To Value
Connector XA158, pin 37 Chassis ground There should be no voltage
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A. If there is voltage, there is a short circuit to key battery power in the S15-1 circuit. Locate and repair the shorted
conductor.
B. If there is no voltage, continue to Step 5.

5. Replace the S15-1.
Use the EST to verify the status of this fault.
A. If the fault has been resolved, return the machine to service.
B. If the fault has not been resolved, check the ECU for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
Harnesses and connectors - Electrical schematic sheet 12 (55.100) Harnesses and connectors - Electrical
schematic sheet 13 (55.100)
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3007-(DTC 1113)-Engine coolant temperature sensor voltage is

higher than expected
NOTE: refer to the Engine Service Manual for more details.
Context:
The Engine Control Unit (ECU) monitors the engine coolant temperature B-9003 circuit for a voltage higher than
expected condition. If the ECU detects a voltage greater than 4.93 V in the B-9003 signal circuit, this fault will occur.
Cause:
The ECU has detected a voltage greater than 4.93 V in the B-9003 signal circuit.
1. Faulty B-9003, wiring.

2. Faulty B-9003, internal failure.
Solution:
2. Check the B-9003 circuit for an open circuit condition.
Disconnect connector X-9002 (refer to the Engine Service Manual).
Disconnect connector X-9006 (refer to the Engine Service Manual).
The key must be in the OFF position.
From To Value
X-9001 pin 39 X-9006 pin 1 There should be continuity.
A. If there is no continuity, there is an open circuit condition in the B-9003 signal circuit, wire EN-014 (refer to the
Engine Service Manual). Locate and repair the broken conductor.
B. If there is continuity, leave both connectors disconnected and continue to Step 3.

3. Check the B-9003 signal circuit for a short circuit condition.
From To Value
X-9001 pin 39 All pins in connector X-9001 There should be no continuity.
A. If there is continuity, there is a short circuit condition in the B-9003 signal circuit, wire EN-014. Locate and
repair the shorted conductor.
B. If there is no continuity, leave both connectors disconnected and continue to Step 4.
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4. Check the B-9003 signal circuit for a short key battery power condition.
From To Value
X-9001 pin 39 Chassis ground There should be no voltage.
A. If there is voltage, there is a short to key battery power condition in the B-9003 signal circuit, wire EN-014.
Locate and repair the shorted conductor.
B. If there is no continuity, continue to Step 5.

5. Replace the B-9003.
Use the EST to verify the status of this fault, DTC 1113 - Engine coolant temperature sensor voltage is higher
than expected.
B. If the fault has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
Wiring harnesses - Electrical schematic sheet 05 (55.100)
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3008 (DTC 2213)-Engine coolant temperature sensor voltage is

lower than expected
Context:
The Engine Control Unit (ECU) A-9000 monitors the analog input value of the Coolant temperature sensor B-9003
at the engine plug connector X-9002 pin 39. The Coolant temperature sensor B-9003 is a Negative Temperature
Coefficient (NTC) thermistor with a resistive range of 332 - 10.149K Ω at -10 - 80 °C (14.0 - 176 °F), conversely. If
the Coolant temperature sensor B-9003 input signal circuit is less than 0.188 V, this fault will occur.
Cause:
The ECU A-9000 is sensing an analog input signal less than 0.188 V in the Coolant temperature sensor B-9003 signal
circuit.
1. Faulty Coolant temperature sensor B-9003, shorted internally.

2. Faulty Coolant temperature sensor B-9003 signal circuit, shorted to ground.
3. Faulty ECU A-9000, ECU software.
Solution:
1. Verify this fault code is still present and in an active state. Use the Electronic Service Tool (EST) to check the
status of the fault.
A. If the fault is still present and active, continue with Step 2.
B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active.
2. Verify the condition of the Coolant temperature sensor B-9003. measure the resistance of the sensor.
Disconnect the engine harness from the Coolant temperature sensor B-9003 at connector X-9006.
Use a multimeter to perform the following test on the component:
From To Value
X-9006 pin 1 X-9006 pin 2 There should be between 332 -
10.149K Ω dependant upon coolant
temperature.
A. If the measured resistance is minimal or zero, the Coolant temperature sensor B-9003 has failed, internally.
Replace the sensor.
B. If the measured resistance is within the specified range, leave the Coolant temperature sensor B-9003 con-
nector X-9006 disconnected and continue with Step 3.
3. Check for a short to ground condition in the Coolant temperature sensor B-9003 signal circuit.
Use a multimeter to perform the following check on the engine harness (EN) side:
To From Value
X-9006 pin 1 Chassis ground There should be no continuity
A. If there is continuity, leave the Coolant temperature sensor B-9003 connector X-9006 disconnected and con-
tinue with Step 4.
B. If there is no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary.
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4. Carefully disconnect the engine harness from the ECU A-9000 at connector X-9002. Use a multimeter to check
for continuity from the engine harness side of connector X-9002 pin 39 to chassis ground. There should be no
continuity.
A. If there is continuity, there is a short to ground condition in the engine harness between the ECU A-9000 en-
gine plug connector X-9002 pin 39 and the Coolant temperature sensor B-9003 connector X-9006 pin 1, wire
EN-014. Locate and repair the grounded conductor.
has been resolved.
operation.
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3010-(DTC 2474)-Intake manifold temperature sensor voltage is

lower than expected
NOTE: because this fault causes inducement, it is necessary to perform the SCR Fault Repair Verification Test once
the fault has been resolved. See Selective Catalytic Reduction (SCR) exhaust treatment - Service instruction -
SCR fault repair verification test (10.500) if necessary.
Context:
The Engine Control Unit (ECU) monitors the intake manifold temperature sensor B-9001 signal circuit. If a voltage
lower than expected condition is detected and this fault occurs, the A-9000 will jump to a fixed temperature replace-
ment value of 29.96 °C (85.93 °F).
Cause:
The A-9000 has detected a voltage less than 208 mV for longer than 500 ms in the B-9001 temperature signal circuit.
1. Faulty B-9001 temperature signal wire, shorted to ground.

3. Faulty A-9000, software.
Solution:
2. Check the B-9001 temperature signal circuit for a short to ground condition.
Disconnect connector X-9003.
Disconnect connector X-9002 from the A-9000.
From To Value
X-9002 pin 37 Chassis ground There should be no continuity.
X-9002 pin 37 All other pins There should be no continuity.
A. If there is continuity, there is short to ground condition in the B-9001 temperature signal circuit, wire EN-005.

Use the EST to verify that DTC 2474 - Intake manifold temperature sensor voltage is lower than expected
has been resolved.
A. If the fault has been resolved, use the EST, see Selective Catalytic Reduction (SCR) exhaust treatment
- Configure - Engine restart counter reset (10.500) if necessary. to perform the Engine Restart Counter
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Reset / Unlock Inducement configuration. Then perform the SCR Fault Repair Verification Test, see Selective
Catalytic Reduction (SCR) exhaust treatment - Service instruction - SCR fault repair verification test
(10.500), if necessary. Then return the machine to service.
B. If the fault has not been resolved, check the A-9000 for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
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3014-(DTC 4C84)-Air filter clog or circuit failure present for a long

time
Context:
The Engine Control Unit (ECU) A158 monitors the air filter switch S15-1. Monitoring is performed in two levels. The
first level warning is detected if the ECU 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 S15-1, clogged.

2. Faulty S15-1 or S15-1 wiring.
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.
B. If the fault is not active, continue to Step 3.

3. 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 4.
4. Check the S15-1 circuit for a short circuit condition.
Disconnect the Connector X15-1.
From To Value
A. If there is continuity, there is a short circuit condition in the S15-1 circuit. Locate and repair the shorted con-
ductor.
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5. Check the S15-1 circuit for a short to key battery power condition.
From To Value
A. If there is voltage, there is a short circuit to key battery power in the S15-1 circuit. Locate and repair the shorted
conductor.

6. Replace the S15-1.
has been resolved.
operation.
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3015-(DTC 1C15)-Fuel temperature sensor voltage is higher than

expected
Context:
The Engine Control Unit (ECU) monitors the fuel temperature sensor B-9002 signal circuit voltage. If the A-9000
determines that there is voltage higher than expected condition in the B-9002 signal circuit, this fault will occur.
Cause:
The A-9000 has detected a value greater than 4.93 V in the B-9002 signal circuit.
1. Faulty B-9002 signal circuit, short to high source condition.

Solution:
A. If the fault is present and active, continue with 2.
2. Check the B-9002 signal circuit for a short to high source condition.
From To Value

3. Check the B-9002 for a short to key power condition.
They key must be in the ON position.
From To Value
A. If there is voltage, there is a short to key power condition in the B-9002 signal circuit, wire EN-012. Locate and
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Use the EST to verify the status of this fault, DTC 1C15 - Fuel temperature sensor voltage is higher than
expected.
has been resolved.
operation.
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3016-(DTC 2D15)-Fuel temperature sensor voltage is lower than

expected
Context:
The Engine Control Unit (ECU) A158 monitors the fuel temperature sensor B-9002 signal circuit voltage. If the A-9000
determines that there is voltage lower than expected condition in the B-9002 signal circuit, this fault will occur.
Cause:
The A-9000 has detected a value less than 188 mV in the B-9002 signal circuit.
1. Faulty B-9002 signal circuit, short to ground condition.

Solution:
2. Check the B-9002 signal circuit for a short to ground condition.
From To Value
A. If there is continuity, there is a short to ground condition in the B-9002 signal circuit, wire EN-012. Locate and

Use the EST to verify the status of this fault, DTC 2D15 - Fuel temperature sensor voltage is lower than ex-
pected.
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has been resolved.
operation.
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3019-(DTC 1D64)-Intake manifold pressure sensor voltage is higher

than expected
Context:
The Engine Control Unit (ECU) A158 monitors the intake manifold pressure sensor B-9001 pressure signal circuit. If
the A-9000 determines that the voltage in the pressure signal circuit is higher than expected, this fault will occur.
Cause:
The A-9000 has detected a voltage greater than 4.91 V for a period greater than 500 ms in the B-9001 pressure signal
circuit.

2. Faulty B-9001 pressure signal circuit, open or short to high source condition.
Solution:
2. Check the B-9001 pressure signal circuit for an open circuit condition.
Disconnect connector X-9002 from the A-9000
From To Value
A. If there is continuity, leave both connectors disconnected and continue to Step 3.
B. If there is no continuity, there is an open circuit condition in the B-9001 pressure signal circuit, wire EN-006.
Locate and repair the broken conductor.
3. Check the B-9001 pressure signal circuit for a short to high source condition.
From To Value
X-9002 pin 86 X-9002 pin 7 There should be no continuity.
A. If there is continuity, there is a short to high source condition in the B-9001 pressure signal circuit, wire EN–006.
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Use the EST to verify that DTC 1D64 - Intake manifold pressure sensor voltage is higher than expected has
been resolved.
A. If the fault has been resolved, use the EST, see Selective Catalytic Reduction (SCR) exhaust treatment
- Configure - Engine restart counter reset (10.500) if necessary. to perform the Engine Restart Counter
has been resolved.
operation.
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3024-(DTC 13C4)-ECU internal failure - Ambient pressure sensor

voltage is higher than expected
Context:
The Engine Control Unit (ECU) A158 monitors ambient pressure by the ambient pressure sensor which is internal to
the ECU. If the ECU detects a voltage greater than 4.88 V for a period greater than 800 ms, this fault will occur. If this
fault occurs, the ECU will be frozen at the last valid ambient pressure value for a preliminary failure and a replacement
ambient pressure of 0.8 bar (11.6 psi) if the failure is validated. As this fault can occur from abnormal altitude, verify
that the machine is not being operating in extreme altitude conditions before diagnosing this fault.
Solution:
1. Check the ECU 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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3025-(DTC 24C4)-ECU internal failure - Ambient pressure sensor

voltage is lower than expected
Context:
The Engine Control Unit (ECU) A158 monitors ambient pressure by the ambient pressure sensor which is internal to
the ECU. If the ECU detects a voltage less than 190.00 mV for a period greater than 800 ms, this fault will occur. If this
fault occurs, the ECU will be frozen at the last valid ambient pressure value for a preliminary failure and a replacement
ambient pressure of 0.8 bar (11.6 psi) if the failure is validated. As this fault can occur from to higher than normal
altitude, verify that the machine is not being operating in extreme altitude conditions before diagnosing this fault.
Solution:
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3028-(DTC 26D3)-Oil pressure is too low

Context:
The Engine Control Unit (ECU) A158 monitors for a low engine oil pressure condition. If the ECU determines that oil
pressure is too low, this fault will occur.
Cause:
The ECU has detected a low engine oil pressure condition.
1. Faulty oil pressure sensor with oil temperature sensor.

2. Faulty engine oil level.
3. Faulty engine oil, fuel contamination.
4. Faulty oil pressure control valve.
5. Faulty oil suction line, damaged or leaking.
6. Faulty oil pump.
7. Faulty main bearings, improper clearance or usage.
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3029-(DTC 18D3)-Oil pressure sensor voltage is higher than

expected
Context:
The Electronic Control Unit (ECU) A-9000 monitors the oil pressure sensor B-9000 signal circuit. If the A-9000 deter-
mines that the voltage in the pressure signal circuit is higher than expected, this fault will occur.
Cause:
circuit.

2. Faulty B-9000 pressure signal circuit, short to high source or open circuit condition.
Solution:
From To Value
From To Value
A. If there is continuity, there is a short to high source condition in the B-9000 pressure signal circuit, wire EN–010.
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Use the EST to verify that DTC 18D3 - Oil pressure sensor voltage is higher than expected has been resolved.
A. If it has been resolved, return the machine to service.
B. If it has not been resolved, check the A-9000 for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
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3030-(DTC 29D3)-Oil pressure sensor voltage is lower than

expected
Context:
The Electronic Control Unit (ECU) A-9000 monitors the oil pressure sensor B-9000 signal circuit. If the A-9000 deter-
mines that the voltage in the pressure signal circuit is lower than expected, this fault will occur.
Cause:
The A-9000 has detected a voltage less than 200 mV for a period greater than 500 ms in the B-9000 pressure signal
circuit.

2. Faulty B-9000 pressure signal circuit, short to ground condition.
Solution:
2. Check the B-9000 pressure signal circuit for a short to ground condition.
From To Value
A. If there is continuity, there is a short to ground in the B-9000 pressure signal circuit, wire EN–010. Locate and

Use the EST to verify that DTC 29D3 - Oil pressure sensor voltage is lower than expected has been resolved.
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has been resolved.
operation.
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3034-(DTC 11E3)-Oil temperature sensor voltage is higher than

expected
Context:
The Electronic Control Unit (ECU) A-9000 monitors the oil temperature sensor B-9000 signal circuit. If the A-9000
determines that the voltage in the temperature signal circuit is higher than expected, this fault will occur.
Cause:
The A-9000 has detected a voltage greater than 4.93 V for a period greater than 500 ms in the B-9000 temperature
signal circuit.

2. Faulty B-9000 temperature signal circuit, short to high source or open circuit condition.
Solution:
2. Check the B-9000 temperature signal circuit for an open circuit condition.
From To Value
B. If there is no continuity, there is an open circuit condition in the B-9000 temperature signal circuit, wire EN-009.
From To Value
A. If there is continuity, there is a short to high source condition in the B-9000 temperature signal circuit, wire
EN–009. Locate and repair the shorted conductor.
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Use the EST to verify that DTC 11E3 - Oil temperature sensor voltage is higher than expected has been
resolved.
has been resolved.
operation.
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3035-(DTC 22E3)-Oil temperature sensor voltage is lower than

expected
Context:
The Electronic Control Unit (ECU) A-9000 monitors the oil temperature sensor B-9000 signal circuit. If the A-9000
determines that the voltage in the temperature signal circuit voltage is lower than expected, this fault will occur.
Cause:
The A-9000 has detected a voltage less than 235 mV for a period greater than 500 ms in the B-9000 temperature
signal circuit.

2. Faulty B-9000 temperature signal circuit, short to ground condition.
Solution:
From To Value
A. If there is continuity, there is a short to ground in the B-9000 temperature signal circuit, wire EN-009. Locate
and repair the shorted conductor.

Use the EST to verify that DTC 22E3 - Oil temperature sensor voltage is lower than expected has been re-
solved.
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has been resolved.
operation.
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3037-(DTC 2E64)-Intake manifold pressure sensor voltage is lower

than expected
Context:
The Electronic Control Unit (ECU) A-9000 monitors the intake manifold pressure sensor B-9001 signal circuit. If the
A-9000 determines that the voltage in the pressure signal circuit is lower than expected, this fault will occur.
Cause:
circuit.

Solution:
From To Value

Use the EST to verify that DTC 2E64 - Intake manifold pressure sensor voltage is lower than expected has
been resolved.
A. If it has been resolved, use the EST, see Selective Catalytic Reduction (SCR) exhaust treatment - Config-
ure - Engine restart counter reset (10.500) if necessary. to perform the Engine Restart Counter Reset / Un-
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lock Inducement configuration. Then perform the SCR Fault Repair Verification Test, see Selective Catalytic
Reduction (SCR) exhaust treatment - Service instruction - SCR fault repair verification test (10.500), if
necessary. Then return the machine to service.
has been resolved.
operation.
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3051 (DTC 1161)-Battery voltage is higher than expected

Context:
The Engine Control Unit (ECU) A158 monitors battery voltage. If the ECU determines that battery voltage has ex-
ceeded 32.3 V , this fault will occur.
Cause:
Battery voltage is greater than 32.3 V.
1. Faulty charging system.

Solution:
2. Check the battery voltage.
The engine must be running.
From To Value
Battery 1 (+) terminal Battery 2 (–) terminal There should be approximately 24 V
NOTE: if there are not 24 V, check for 12 V the battery 1 and the battery 2.
A. If there is not approximately 24 V, continue to Step 3.
B. If there is approximately 24 V, check the ECU 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 for the appropriate software and re-flash, if nec-
essary.
has been resolved.
operation.
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3052 (DTC 2261)-Battery voltage is lower than expected

Context:
The Engine Control Unit (ECU) A158 monitors battery voltage. If the ECU determines that battery is less than 19.2 V,
this fault will occur.
Cause:
Battery voltage is less than 19.2 V.
1. Faulty Battery.
2. Engine cranked for extended period of time.
3. Faulty ECU supply wiring.
Solution:
From To Value
A. If there is not approximately 24 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 24 V, continue to Step 3.

3. Check the voltage supply to the ECU.
The key 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
Connector XA158, pin 73 Chassis ground There should be approximately 24 V
Connector XA158, pin 3 Chassis ground There should be continuity
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From To Value
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 ECU supply wiring. Locate and repair the
failed conductor.
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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3063 (DTC 6226)-Short circuit error of injector in cylinder 1

Context:
Hardware errors in the injectors and their respective Engine Control Unit (ECU) A-9000 power stages are investigated
within the ECU A-9000. The ECU A-9000 diagnostic procedure uses pattern detection to identify specific errors.
When an expected combination of errors is detected, the associated fault occurs.
Cause:
During cylinder 1 injector Y-9001 evaluation, the pattern for short circuit was detected.
1. Faulty cylinder 1 injector Y-9001 solenoid windings, shorted or grounded.

2. Faulty electrical wiring, short high side to either low side or ground (damaged wiring harness).
3. Faulty ECU A-9000, software.
Solution:
1. Verify this fault code is still present and in an active state.
Use the Easy Engine software provided on the Electronic Service Tool (EST) to check the fault status and to
perform the cylinder cut-out test.
2. Check the integrity of the cylinder 1 injector Y-9001 control circuit.
Disconnect the engine harness from the ECU A-9000 at the engine plug connector X-9002.
Use a multimeter to measure the resistance on the EN harness side:
From To Value
X-9002 pin 49 X-9002 pin 73 There should be greater than 0.1 Ω
A. If there is greater than 0.1 Ω, leave the engine plug connector X-9002 disconnected and continue with Step 3.
B. If there is less than 0.1 Ω, continue with Step 6.

NOTE: The measured amount of injector coil resistance is a very small value, typically between 0.2 - 0.5 Ω.
3. Check the cylinder 1 injector Y-9001 high side control circuit for a short to ground condition.
Use a multimeter to check for continuity on the EN harness side:
From To Value
X-9002 pin 49 chassis ground There should be no continuity
A. If there is continuity, continue with Step 4.
B. If there is no continuity, continue with Step 8.

4. Determine location of the short to ground condition.
Disconnect the engine cylinder harness from the injector (valve) cover at connector X-9184-6CYL.
Use a multimeter to check for continuity, on the injector (valve) cover side:
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From To Value
X-9184-6CYL pin 4 chassis ground There should be no continuity
A. If there is continuity to chassis ground, leave connector X-9184-6CYL disconnected and continue with step 5.
B. If there is no continuity, there is a short to ground condition in the engine harness between the valve cover
connector X-9184-6CYL pin 4 and the engine plug connector X-9002 pin 49 , wire EN-017-6CYL. Locate and
repair the grounded conductor.
Remove the injector (valve) cover and disconnect the injector harness from Cylinder 1 injector at connector
X-9188-6CYL .
Use a multimeter to check for continuity, on the injector:
From To Value
A. If there is continuity, Cylinder 1 injector Y-9001 solenoid coil has failed, replace the injector.
B. If there is no continuity, there is a short to ground condition in Cylinder 1 injector circuit, between connector
X-9188-6CYL pin 1 and connector X-9184-6CYL pin 4 , wire EN-576-6CYL. Locate and repair the grounded
conductor.
6. Disconnect the engine cylinder harness from the injector (valve) cover at connector X-9184-6CYL.
Use a multimeter to measure the resistance on the injector cover side of the valve cover:
From To Value
X-9184-6CYL pin 4 X-9184-6CYL pin 3 There should be greater than 0.1 Ω
A. If the resistance is greater than 0.1 Ω, there is a short circuit condition in the engine injector harness between
the valve cover connector X-9184-6CYL and the engine plug connector X-9002, wires EN-017-6CYL and
EN-018-6CYL. Locate and repair the short circuit.
B. If the resistance is less than 0.1 Ω, continue with step 7.

7. Remove the injector (valve) cover and disconnect the injector harness from Cylinder 5 injector at connector
X-9188-6CYL .
From To Value
A. If there is greater than 0.1 Ω, there is a short circuit condition in the injector harness, between connector
X-9184-6CYL and connectors X-9188-6CYL pin 1 and X-9188-6CYL pin 2, wires EN-576-6CYL and EN-577-
6CYL. Locate and repair the shorted conductors.
B. If the resistance is less than 0.1 Ω, the Cylinder 1 injector Y-9001 solenoid coil has failed. Replace the injector.
8. Check the ECU A-9000 supply voltage.
Disconnect the vehicle interface harness (VE) from the ECU A-9000 at the vehicle plug connector X-9001.
Place the key switch S-9103 in the ON position.
Use a multimeter to check for voltage on the vehicle interface (VE) harness side of the vehicle plug:
From To Value
X-9001 pin 1 chassis ground There should be 24 V
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A. If the 24 V is present for all five checks, leave the vehicle plug connector X-9001 disconnected and continue
with Step 9.
B. If the 24 V is not present for one or more of the checks, use the appropriate vehicle electrical schematics to
locate and repair the failure.
9. Check the ECU A-9000 ground circuits.
Place the key switch S-9103 in the OFF position.
Use a multimeter to check for continuity on the vehicle interface (VE) harness side of the vehicle plug:
From To Value
X-9001 pin 3 chassis ground There should be continuity.
A. If there is continuity on all five checks, check the ECU A-9000 for the appropriate software and re-flash, if
necessary.
B. If there is no continuity on one or more of the checks, use the appropriate vehicle electrical schematics to
A. If you find damage or the display indicates other than normal display readings, then repair the damage dis-
covered during the inspection or locate and repair the other than normal display condition and verify that the
error has been resolved.
B. If you do not find damage and the display indicates only normal readings, then erase the fault code and
continue operation.
Wiring harnesses - Electrical schematic sheet 02 (55.100) Wiring harnesses - Electrical schematic sheet
06 (55.100)
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3067-(DTC 6726)-Short circuit error of injector in cylinder 4

Context:
Hardware errors in the injectors and their respective Engine Control Unit (ECU) power stages are investigated within
the ECU. The ECU diagnostic procedure uses pattern detection to identify specific errors. When an expected combi-
nation of errors is detected, the associated fault occurs.
Cause:

Solution:
From To Value

From To Value

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From To Value
connector X-9185-6CYL pin 2 and the engine plug connector X-9002 pin 27, wire EN-024-6CYL. Locate and
Remove the injector (valve) cover and disconnect the injector harness from cylinder 4 injector at connector
X-9191-6CYL.
From To Value
A. If there is continuity, cylinder 4 injector Y-9004 solenoid coil has failed, replace the injector.
B. If there is no continuity, there is a short to ground condition in cylinder 4 injector circuit, between connector
X-9185-6CYL pin 2 and connector X-9191-6CYL pin 1, wire EN-582-6CYL. Locate and repair the grounded
conductor.
From To Value

7. Remove the injector (valve) cover and disconnect the injector harness from cylinder 4 injector at connector
X-9192-6CYL.
From To Value
B. If the resistance is less than 0.1 Ω, the cylinder 4 injector Y-9004 solenoid coil has failed. Replace the injector.
Disconnect the vehicle interface harness (VE) from the ECU A-9000 at the vehicle plug connector X-9001 .
From To Value
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with Step 9.
From To Value
necessary.
continue operation.
06 (55.100)
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Context:
Cause:

Solution:
From To Value

From To Value

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From To Value
X-9189-6CYL.
From To Value
conductor.
From To Value
the valve cover connector X-9184-6CYL and the engine plug connector X-9002 , wires EN-019-6CYL and

7. Remove the injector (valve) cover and disconnect the injector harness from Cylinder 2 injector at connector .
X-9189-6CYL
From To Value
From To Value
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with Step 9.
From To Value
necessary.
continue operation.
06 (55.100)
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Context:
Cause:

Solution:
From To Value

From To Value

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From To Value
X-9193-6CYL.
From To Value
conductor.
From To Value

X-9193-6CYL.
From To Value
X-9187-6CYL and connectors X-9193-6CYL pin 1 and X-9193-6CYL pin 2 , wires EN-586-6CYL and EN-587-
From To Value
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with Step 9.
From To Value
necessary.
continue operation.
06 (55.100)
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Context:
Cause:

Solution:
From To Value

From To Value

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From To Value
X-9190-6CYL.
From To Value
conductor.
From To Value
the valve cover connector X-9185-6CYL and the engine plug connector X-9002 , wires EN-021-6CYL and

X-9190-6CYL.
From To Value
From To Value
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with Step 9.
From To Value
necessary.
continue operation.
06 (55.100)
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3083-(DTC 6326)-Short circuit in injector 5

Context:
Cause:

Solution:
From To Value

From To Value

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From To Value
connector X-9187-6CYL pin 3 and the engine plug connector X-9002 pin 25 , wire EN-026-6CYL. Locate and
Remove the injector (valve) cover and disconnect the injector harness from Cylinder 5 injector at connector
X-9192-6CYL.
From To Value
A. If there is continuity, Cylinder 5 injector Y-9005 solenoid coil has failed, replace the injector.
B. If there is no continuity, there is a short to ground condition in Cylinder 5 injector circuit, between connector
conductor.
From To Value

7. Remove the injector (valve) cover and disconnect the injector harness from Cylinder 5 injector at connector
X-9192-6CYL.
From To Value
B. If the resistance is less than 0.1 Ω, the Cylinder 5 injector Y-9005 solenoid coil has failed. Replace the injector.
From To Value
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with Step 9.
From To Value
necessary.
continue operation.
06 (55.100)
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3088-(DTC 4512)-Crankshaft speed sensor values are not plausible

Context:
The Engine Control Unit (ECU) is responsible for evaluating the signals received from the camshaft and crankshaft
speed sensors. Angle and speed determination, signal plausibility and quality are all evaluated. If ECU tests the
plausibility of the camshaft speed sensor signal and determines it is plausible, and the ECU determines that crankshaft
speed signal is not detected for at least two camshaft revolutions, this fault will occur.
Cause:
The ECU has not detected a crankshaft speed signal for at least two camshaft revolutions.
1. Faulty phonic or tone wheel timing.

2. Faulty crankshaft speed sensor B-9007.
3. Faulty crankshaft speed sensor B-9007, wiring or electrical disturbances due to damaged isolation of wiring har-
ness or special electrical features.
Solution:
2. Check the B-9007 signal circuit for an open circuit condition.
Use a multimeter to perform the following continuity check while shaking the harness to promote an intermittent
connection:
From To Value
A. If there is no continuity when shaking the harness or without shaking the harness there is an open circuit
condition in the B-9007 signal circuit, wire EN-040. Locate and repair the broken conductor.

From To Value
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From To Value
A. If there is voltage, there is short circuit condition in the B-9007 signal circuit, wire EN-040. Locate and repair
the shorted conductor.

5. Check the B-9007 wiring for any electrical interferences in the wiring.
Check if the correct camshaft sensor is installed and is properly secured, the sensor should not be loose or moving.
Check phonic wheel timing on cursor engines and tone wheel timing on NEF engines. Refer to the appropriate
service manual for specifications.
A. If there is any electrical interference, an incorrect sensor is installed or any modification to the sensor/harness,
or the sensor is not mounted correctly, repair as necessary.
B. If there are no issues found, continue to Step 5.

Use the EST to verify the status of this fault, DTC 4412 - Crankshaft speed sensor pattern is not plausible.
has been resolved.
operation.
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3089-(DTC 4412)-Crankshaft speed sensor pattern is not plausible

Context:
The Electronic Control Unit (ECU) A-9000 is responsible for evaluating the signals received from the camshaft and
crankshaft speed sensors. Angle and speed determination, signal plausibility and quality are all evaluated. If A-9000
determines that more than eighty crankshaft signal plausibility errors have occurred, this fault will occur.
Cause:
The A-9000 has detected a crankshaft signal implausibility more than eighty times.
1. Faulty phonic or tone wheel timing.

2. Faulty crankshaft speed sensor B-9007.
3. Faulty crankshaft speed sensor B-9007, wiring or electrical disturbances due to damaged isolation of wiring har-
ness or special electrical features.
Solution:
connection:
From To Value

From To Value
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From To Value

B. If there are no issues found, continue to Step 5.

Use the EST to verify the status of this fault, DTC 4412 - Crankshaft speed sensor pattern is not plausible.
has been resolved.
operation.
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3090-(DTC 4212)-Camshaft speed sensor values are not plausible

Context:
The Engine Control Unit (ECU) is responsible for evaluating the signals received from the camshaft and crankshaft
speed sensors. Angle and speed determination, signal plausibility and quality are all evaluated. If the ECU determines
that the camshaft speed signal shows no errors but no camshaft edge signal has been detected at least four times, this
fault will occur. Different monitoring strategies are used by the ECU during engine start and normal engine running.
If the problem is detected at engine start, a redundant synchronization of the angular system is performed using only
the crankshaft increment signal and test injections to determine engine phase. If this procedure fails, the injection is
aborted and the system waits for a restart.
Cause:
The ECU has monitored a loss in camshaft speed signal at least four times.
1. Faulty camshaft speed sensor B-9008, mounting or internal failure.

2. Faulty camshaft speed sensor B-9008, wiring.
3. Faulty phonic wheel timing (Cursor) or tone wheel timing (NEF).
Solution:
connection:
From To Value
condition in the B-9008 wiring.Locate and repair the broken conductor.

From To Value
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A. If there is continuity, there is a short circuit condition in the B-9008 wiring. Locate and repair the shorted con-
ductor.

From To Value
A. If there is voltage, there is short circuit condition in the B-9008 wiring.Locate and repair the shorted conductor.

A. If there is any electrical interference, the sensor is not mounted correctly, or timing is incorrect, repair as nec-
essary.
B. If there are no issues found, continue to Step 5

Use the EST to verify the status of this fault, DTC 4212 - Camshaft speed sensor values are not plausible.
has been resolved.
operation.
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3091-(DTC 4112)-Camshaft speed sensor pattern is not plausible

Context:
The Electronic Control Unit (ECU) A-9000 is responsible for evaluating the signals received from the camshaft and
crankshaft speed sensors. Angle and speed determination, signal plausibility and quality are all evaluated. If the
A-9000 determines that the camshaft signal does not match the correct pattern (edge distance, level) or not all ex-
pected camshaft edges are detected during engine revolution more than six times, this fault will occur. Different
monitoring strategies are used by the A-9000 during engine start and normal engine running. If the problem is de-
tected at engine start, a redundant synchronization of the angular system is performed using only the crankshaft
increment signal and test injections to determine engine phase. If this procedure fails, the injection is aborted and the
system waits for a restart.
Cause:
The A-9000 has detected a camshaft signal implausibility more than six times.
1. Faulty phonic wheel timing. (Cursor engines)

2. Faulty tone wheel timing. (NEF engines)
3. Faulty camshaft speed sensor B-9008.
4. Faulty camshaft speed sensor B-9008, wiring or electrical disturbances due to damaged isolation of wiring harness
or special electrical features.
Solution:
connection:
From To Value

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From To Value

From To Value

B. If there are no issues found, continue to Step 5

Use the EST to verify the status of this fault, DTC 4112 - Camshaft speed sensor pattern is not plausible.
has been resolved.
operation.
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3093-(DTC 3312)-Compared camshaft and crankshaft speed sensor

values are not plausible
Context:
The Engine Control Unit (ECU) A158 monitors the camshaft position sensor and crankshaft position sensor for angle
and speed determination, signal plausibility and quality. If the ECU determines that the compared values between the
two sensors are implausible, this fault will occur.
1. Faulty camshaft positioning.

2. Faulty camshaft position wheel positioning.
3. Faulty camshaft position sensor positioning.
4. Faulty crankshaft signal wheel positioning.
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3096-(DTC 951B)-CAN A Bus off failure

Context:
The Engine Control Unit (ECU) A158 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. CAN Node A Bus is the main vehicle interface bus. The ECU provides a CAN termination resistor for the
CAN Node A Bus, internal to the ECU. If the ECU senses that CAN Node A Bus is not functioning properly, this fault
will occur.
Cause:
ECU 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, termination resistor or software.
Solution:
1. Verify fault is present and in active state.
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 this fault is also
resolved.
B. If other vehicle CAN faults do not exist, continue with Step 3.

3. Check the ECU supply voltage.
Disconnect the vehicle (VE) harness from the ECU at the Connector XA158.
With the key switch in the “ON” position, use a multimeter to check for voltage on the vehicle (VE) harness side:
From To Value
Connector XA158, pin 1 Chassis ground There should be 24 V
A. If the voltage is present on all of the checks, leave the Connector XA158 disconnected and continue with Step
4.
B. If the voltage is not present for one or more of the checks, refer to the appropriate vehicle service manual and
electrical schematics to locate and restore supply power to the ECU.
4. Check the ECU grounding.
With the key switch in the “OFF” position, use a multimeter to check for continuity on the vehicle (VE) harness side:
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From To Value
A. If there is continuity on all of the checks, leave the Connector XA158 disconnected and continue with Step 5.
B. If there is no continuity for one or more of the checks, refer to the appropriate vehicle service manual and
electrical schematics to locate and restore the grounding circuit to the ECU.
5. Determine the condition of the ECU CAN circuit.
With the key switch in the “OFF” position, use a multimeter to measure the resistance of the CAN connection on
the vehicle (VE) harness side:
From To Value
Connector XA158, pin 46 Connector XA158, pin 47 There should be 120 Ω
Connector XA158, pin 46 Chassis ground There should not be continuity
Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU:
From To Value
A. If the measured resistances are correct and neither conductor is grounded, check the ECU for the appropriate
software and re-flash, if necessary.
B. If the measured resistances are not correct or one or both of the conductors is grounded, refer to the appropriate
vehicle service manual and electrical schematics to locate and restore the termination resistance to the CAN
circuit.
has been resolved.
operation.
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3102-(DTC 2525)-Fuel rail pressure sensor voltage is lower than

expected
Context:
For more information on the high pressure fuel system see HIGH PRESSURE FUEL SYSTEM THEORY OF OPERATIONS . The
Engine Control Unit (ECU) monitors the fuel rail pressure sensor B-9004 signal circuit. If the A-9000 determines that
the voltage in the B-9004 signal circuit is lower than expected, this fault will occur.
Cause:
The A-9000 has detected a value less than 189 mV for period greater than 200 ms.

2. Faulty B-9004 signal circuit, short to ground condition.
Solution:
Disconnect connector X-9026-4CYL.
From To Value
A. If there is continuity, there is a short to ground condition in the B-9004 signal circuit, wire EN-002. Locate and

Use the EST to verify the status of DTC 2525 - Fuel rail pressure sensor voltage is lower than expected.
A. If the fault is resolved, return the machine to service.
B. If the fault is not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary.
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has been resolved.
operation.
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3104-(DTC F445)-Fuel pressure relief valve is open

Context:
A mechanical Pressure Relief Valve (PRV), integral to the fuel rail, will open in the event excessive rail pressure
occurs. The Engine Control Unit (ECU) A158 senses and counts the radical reductions in rail pressure. If a valve
opening is detected, this fault will occur.
Cause:
The ECU has detected that the PRV is open.
1. The ECU has commanded the PRV open by a pressure shock.

2. Faulty fuel injectors.
3. Faulty high pressure pump.
4. Faulty fuel metering unit, wiring or internal failure.
5. Faulty PRV.
6. Faulty rail pressure sensor, implausible signal.
Solution:
1. Other possible fuel system faults that may occur or may have caused this fault:
3105 (DTC F245) - Fuel pressure relief valve is forced to open, perform pressure increase
3799 (DTC F345) - Fuel pressure relief valve is forced to open, perform pressure shock
3104 (DTC F445) - Fuel pressure relief valve is open
3137 (DTC 5255) - Fuel metering unit has an open load error
3910 (DTC 4155) - Fuel metering unit intermittent electrical connection failure
3735 (DTC 8355) - Fuel metering unit has an over-temperature error
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
3293 (DTC 2265) - Fuel rail pressure has exceeded maximum positive deviation limits
3805 (DTC 1D85) - Maximum rail pressure exceeded
3112 (DTC 1425) - Fuel rail pressure sensor voltage is higher than expected
3977 (DTC 15E5) - Prefilter fuel pressure sensor voltage is higher than expected
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3105-(DTC F245)-Fuel pressure relief valve is forced to open,

perform pressure increase
Context:
For more information on the fuel injection system see Injection control - Dynamic description (55.010). To deter-
mine mechanical wear out or to send the system into limp home mode, the Engine Control Unit (ECU) A158 can force
the fuel pressure relief valve open. This action consists of two steps, waiting for the rail pressure to build up and
then performing the pressure shock. If the ECU commands this operation, this fault will occur. Once a rail pressure
sensor failure is detected or maximum rail pressure is exceeded, the system will go into a limp home mode. If this
fault occurs, other fuel related system faults can occur due to the increase in fuel pressure.
Solution:
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3106-(DTC 1145)-Fuel pressure relief valve reached maximum

allowed opening count
Context:
A mechanical Pressure Relief Valve (PRV), integral to the fuel rail, will open in the event excessive rail pressure
occurs. The Engine Control Unit (ECU) A158 senses and counts the sudden reductions in rail pressure due to an
opening of the PRV. If the count of 50 is exceeded, this fault will occur.
Cause:
The PRV opening counter, internal to the ECU, has exceeded 50.
1. Faulty PRV, check tightness and opening pressure.

2. Faulty fuel metering unit, wiring.
3. Faulty fuel metering unit, internal failure.
Solution:
1. Check the status of the following related faults:
3141 (DTC 4465) - Fuel pump pressure has exceeded desired pressure limits
3309 (DTC 1865) - Fuel rail pressure has exceeded maximum limit
3301 (DTC 1565) - Fuel rail pressure has exceeded maximum negative deviation limits
A. If any of the listed faults are active, diagnose them first and then return to this fault.
B. If none of the listed faults are active, continue to Step 2.

2. Replace the PRV.
Use the Electronic Service Tool (EST) to perform the PRV counter reset.
A. Return the machine to service.
B. If the fault is still active, check the ECU for the appropriate software and re-flash, if necessary.
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3107-(DTC 6655)-Fuel metering unit is shorted to battery voltage

at the low side
Context:
For more information on the fuel metering unit Y-9000 refer to Injection control - Dynamic description (55.010).
The power stage of the fuel metering unit Y-9000 at low side is monitored by the Electronic Control Unit (ECU) A-9000
for electric failures. If the A-9000 detects a short to a high source on the power stage of the Y-9000 at low side, this
fault will occur.
Cause:
The ECU A-9000 has detected a short to high source in the Y-9000 low side circuit.
1. Y-9000 internal failure.

2. Short to high source condition in the Y-9000 to ECU A-9000 engine (EN) harness.
Solution:
1. Verify that the fault code is active.
Use the Electronic Service Tool (EST) to verify this fault.
A. If the fault is present and active, continue to Step 2.
Continue to Step 5.
2. Check the Y-9000 for an internal short.
Disconnect the Y-9000 connector X-9007.
Use a multimeter to perform the following resistance check:
From To Value
X-9007 pin 1 X-9007 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-9007 disconnected and continue to Step 3.
B. If the value is not in the specified range, the Y-9000 has failed internally. Replace the Y-9000 then refer to
Pressure regulating valve - Configure - Reset ECU data (10.218) if necessary, to perform the Replacement
of the Rail Pressure Metering Unit - Reset ECU Data.
3. Check the voltage on the Y-9000 circuit, low side.
Disconnect A-9000 connector X-9002.
Use a multimeter to perform the following test:
To From Value
A. If there is voltage, there is a short to high a voltage source in the Y-9000 circuit, low side. Refer to the appro-
priate service manual to locate and repair the shorted conductor.
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B. If there is no voltage, go to Step 4.

4. Check for continuity between all pins in connector X-9002.
From To Value
A. If there is continuity, there is a short to high source in the Y-9000 circuit, low side. Use the appropriate service
manual to locate and repair the shorted conductor.
B. If there is no continuity, check the A-9000 for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
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3108-(DTC 7755)-Fuel metering unit is shorted to ground at the

low side
Context:
For more information no the fuel metering unit Y-9000 refer to Injection control - Dynamic description (55.010). If
the Engine Control Unit (ECU) A-9000 detects a short circuit to ground in the Y-9000 low side, this fault will occur.
Cause:
The A-9000 has detected a short to ground in the Y-9000 circuit, low side.
1. Y-9000 internal short to ground condition.

2. Short to ground condition in the Y-9000 circuit, low side.
Solution:
Connect the Electronic Service Tool (EST) to the diagnostic port.
Continue to Step 4.
2. Check the Y-9000 for an internal short to ground condition.
From To Value
X-9007 pin 1 X-9007 pin 2 There should be between 2.8 - 3.2 Ω
(2.8 - 3.2 Ω).
3. Check for a short to ground condition in the (EN) harness at the A-9000 connector X-9002 .
Disconnect the A-9000 connector X-9002.
The key must be at the OFF position.
From To Value
A. If there is continuity, there is a short to ground condition in the circuit. Use the appropriate service manual to
locate and repair the shorted conductor.
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has been resolved.
operation.
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3110-(DTC 1225)-Rail pressure sensor value is above maximum

offset
Context:
The Engine Control Unit (ECU) A158 monitors fuel rail pressure against offset drift at engine stand still after a waiting
period. This allows rail pressure to drop to ambient pressure, which is approximately 1.00 bar. If the ECU determines
that the rail pressure sensor is above maximum offset, this fault will occur.
Cause:
The ECU has determined that the rail pressure sensor is above maximum offset.
1. Faulty wiring of the rail pressure sensor.

2. Faulty internal failure of the rail pressure sensor. (possibly due to overpressure)
Solution:
3810 (DTC 4125) - Rail pressure sensor value is intermittent

3. Check that the rail pressure sensor is properly mounted and secured.
A. If the sensor is loose or incorrectly mounted, repair as necessary.
B. If the rail pressure sensor is properly mounted and secured, continue to Step 4.
4. Replace the rail pressure sensor.
B. If the fault has not been resolved, check the ECU for the appropriate software and re-flash, as necessary.
has been resolved.
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operation.
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3111-(DTC 2325)-Rail pressure sensor value is below minimum

offset
Context:
The Engine Control Unit (ECU) A158 monitors fuel rail pressure against offset drift at engine stand still after a waiting
period. This allows rail pressure to drop to ambient pressure, which is approximately 1.00 bar. If the ECU determines
that the rail pressure sensor is below minimum offset, this fault will occur.
Cause:
The ECU has determined that the rail pressure sensor is below minimum offset.
1. Faulty wiring of the rail pressure sensor.

2. Faulty internal failure of the rail pressure sensor. (possibly due to overpressure)
Solution:
3102 (DTC 2525) - Fuel rail pressure sensor voltage is lower than expected

3. Check that the rail pressure sensor is properly mounted and secured.
A. If the sensor is loose or incorrectly mounted, repair as necessary.
B. If the rail pressure sensor is properly mounted and secured, continue to Step 4.
has been resolved.
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operation.
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3112-(DTC 1425)-Fuel rail pressure sensor voltage is higher than

expected
Context:
For more information on the high pressure fuel system see HIGH PRESSURE FUEL SYSTEM THEORY OF OPERATIONS .
The Electronic Control Unit (ECU) A-9000 monitors the fuel rail pressure sensor B-9004 signal circuit. If the A-9000
determines that the voltage in the B-9004 signal circuit is higher than expected, this fault will occur.
Cause:
The A-9000 has detected a value greater than 4.9 V for period greater than 200 ms.
1. Faulty B-9004 reference voltage, excessive.

3. Faulty B-9004 signal circuit, short to high source or open circuit condition.
Solution:
DTC E42D - ECU internal failure - Sensor 5 volt supply 3
A. If the fault is active, diagnose it first and then return to this fault, DTC 1425 - Fuel rail pressure sensor voltage
is higher than expected.

From To Value
X-9002 pin 36 X-9026-4CYL pin 2 There should be continuity.
A. If there is continuity, leave the connectors disconnected and continue to Step 4.
B. If there is no continuity, there is an open circuit condition in the B-9004 signal circuit, wire EN-002. Locate and
repair the broken conductor.
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From To Value
A. If there is continuity, there is a short to high source condition in the B-9004 signal circuit, wire EN-002. Locate

5. Check the B-9004 signal circuit for a short to key power condition.
From To Value

Use the EST to verify the status of DTC 1425 - Fuel rail pressure sensor voltage is higher than expected.
has been resolved.
operation.
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3118 (DTC E82D)-Internal supply voltage is too high

Context:
The Engine Control Unit (ECU) A158 monitors internal 24 V supply voltage. If the ECU determines that this value is
higher than expected, this fault will occur.
Solution:
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3119 (DTC E92D)-Internal supply voltage is too low

Context:
The Engine Control Unit (ECU) A158 monitors internal 24 V supply voltage. If the ECU determines that this value is
lower than expected, this fault will occur.
Solution:
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3137 (DTC 5255)-Fuel metering unit has an open load error

Context:
For information on fuel metering unit Y-9000 operation, refer to Injection control - Dynamic description (55.010).
If fuel metering unit Y-9000 is not operating, fuel pressure will be at maximum.
Cause:
The Engine Control Unit (ECU) A-9000 has determined that the fuel metering unit Y-9000 electrical control circuit is
open.
1. Fuel metering unit Y-9000 solenoid coil, defective.

2. Faulty fuel metering unit Y-9000 control circuit, broken wiring.
Solution:
2. Check condition of fuel metering unit Y-9000 solenoid coil.
Disconnect the engine (EN) harness from the fuel metering unit Y-9000 at connector X-9007.
Use a multimeter to measure the resistance of the fuel metering unit Y-9000 solenoid coil:
From To Value
X-9007 pin 1 X-9007 pin 2 There should be between 3.2 Ω.
A. If the measured resistance is as specified, leave connector X-9007 disconnected and continue with Step 3.
B. If the measured result is infinite resistance, the fuel metering unit Y-9000 solenoid coil has failed. Replace the
fuel metering unit Y-9000.
3. Verify the condition of the fuel metering unit Y-9000 control circuit.
Disconnect the engine (EN) harness from the ECU A-9000 at connector X-9002.
Use a multimeter to check for continuity in the engine (EN) harness:
From To Value
X-9007 pin 2 X-9002 pin 83 There should be continuity
A. If there is continuity on both checks, check the ECU A-9000 for the appropriate software and re-flash, if nec-
essary.
B. If there is no continuity on either the high side or the low side control circuit, then there is an open circuit
condition in the engine (EN) harness between X-9007 pin 1 and X-9002 pin 58 , wire EN-015 or between
X-9007 pin 2 and X-9002 pin 83, wire EN-016. Locate and repair the broken conductor.
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has been resolved.
operation.
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3141 (DTC 4465)-Fuel pump pressure has exceeded desired

pressure limits
Context:
For more information on the fuel injection system see Injection control - Dynamic description (55.010). The fuel
metering unit controls the desired fuel flow to the fuel rail. The unit is adjusted by feed back control from the Engine
Control Unit (ECU) A158. If the ECU determines that the desired fuel pressure can not be reached, leakage will be
assumed and this fault will occur.
Cause:
Fuel pressure is unable to reach the desired pressure.
1. Operating in higher than normal ambient pressure conditions.

2. Faulty fuel injectors, excessive return leakage or stuck open.
3. Faulty fuel filter, clogged.
4. Faulty low pressure fuel system, leakage or blockage.
5. Faulty charge gear pump, low efficiency.
6. Faulty fuel pressure sensor, wiring or internal failure.
8. Faulty high pressure pump, feeding efficiency low.
Solution:
1. Use the 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.
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
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3146 (DTC 4415)-Water in fuel detected or water in fuel circuit failure

NOTE: this fault code is for the Water in Fuel sensor with black connector housing. If the connector housing of the
sensor is white take care that the pins 2 and 3 are reversed.
Context:
The Engine Control Unit (ECU) A158 monitors the voltage output from the water in fuel sensor S158-5 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 S158-5 indicates water present.
Cause:
This fault code is displayed to warn the operator that the ECU has detected excess water in the fuel system or a fault
in the S158-5 circuit.
1. Excess water in the fuel supply.

2. Faulty S158-5, wiring or internal (mechanical and/or electrical) failure.
Solution:
Use the Easy Engine software provided on the Electronic Service Tool (EST) to check the fault status.
B. If the fault is no longer present or is in an inactive state, Continue with Step 9.

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 S158-5 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 S158-5.
B. If code remains inactive, return the machine to service.

4. Check for open, short and grounded circuit conditions in the S158-5 circuit.
Disconnect the S158-5 at the Connector XS158-5.
Disconnect the vehicle (VE) harness fron the ECU at Connector XA158.
With the key switch in the OFF position, use a multimeter to perform the following tests, on the vehicle (VE) har-
ness:
From To Value
Connector XS158-5, pin 1 Connector XA158, pin 13 There should be continuity
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From To Value
Connector XS158-5, pin 3 Connector X33-30 , pin 11 There should be continuity
Then use the multimeter to perform the following tests, on the vehicle (VE) harness:
From To Value
Connector XS158-5, pin 1 Connector XS158-5, pin 2 There should be no continuity
From To Value
Connector XS158-5, pin 1 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 wiring. Use the appropriate vehicle service manual and schematics to diagnose and
repair the wiring.
B. If the results are as expected in all of the wiring tests listed above, the wiring is ok. Leave the Connector
XA158 and Connector XS158-5 disconnected, connect the Connector X33-30 and continue with Step 5.
Disconnect the Connector X102.
ness:
From To Value
Connector XS158-5, pin 3 Connector X102, pin 21 There should be continuity
circuit condition in the wiring.Use the appropriate vehicle service manual and schematics to diagnose and
repair the wiring.
XA158 and Connector XS158-5 disconnected, connect the Connector X102 and continue with Step 6.
Disconnect the Connector 1F1K.
ness:
From To Value
Connector XS158-5, pin 3 Connector 1F1K, pin A3 There should be continuity
repair the wiring.
XA158 and Connector XS158-5 disconnected, connect the Connector 1F1K and continue with Step 7.
7. Check for key switch voltage supply to S158-5.
With the key switch in an ON position, use a multimeter to perform the following test, on the vehicle (VE) harness
side:
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From To Value
Connector XS158-5, pin 3 Ground There should be key switch voltage
Connector XS158-5, pin 1 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
8.
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.
8. Replace the S158-5, then check to see if this fault has been resolved.
B. If the fault is not resolved, check the ECU 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.
schematic sheet 12 (55.100) Harnesses and connectors - Electrical schematic sheet 13 (55.100)
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3154-(DTC 6A14)-Intake air heater actuator is shorted to battery

voltage
Context:
The Engine Control Unit (ECU) A158 monitors the grid heater relay K1-7 control circuit for a short to high source
condition. If a short to high source condition is detected, this fault will occur.
Cause:
The ECU has detected a short to high source condition in the K1-7 control circuit.
1. Faulty K1-7, coil.

2. Faulty K1-7, short to high source.
Solution:
2. Check the K1-7 coil for an internal failure.
Remove the K1-7.
Use a multimeter to test the K1-7 coil.
From To Value
K1-7, pin 85 K1-7, pin 86 There should be between 70 - 130 Ω
A. If the value is within the specified range, leave the K1-7 removed and continue to Step 3.
B. If the value is not within the specified range, the K1-7 has failed internally. Replace the K1-7.
3. Check the K1-7 control circuit for a short to high source condition.
The key switch must be in the OFF position.
From To Value
Connector XA158, pin 83 All other pins There should be no continuity
A. If there is continuity, there is a short to high source condition in the K1-7 control circuit, wire 683. See the
appropriate service manual to locate and repair the shorted conductor.
B. If there is no continuity, check the ECU for the appropriate software and re-flash, if necessary.
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has been resolved.
operation.
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3155-(DTC 7C14)-Intake air heater actuator is shorted to ground

Context:
The Engine Control Unit (ECU) A158 monitors the grid heater relay K1-7 control circuit for a short to ground condition.
If a short to ground condition is detected, this fault will occur.
Cause:
The ECU has detected a short to ground condition in the K1-7 control circuit.
1. Faulty K1-7, internal failure.

2. Faulty K1-7 control circuit, short to ground condition.
Solution:
2. Check the K1-7 for an internal failure.
Remove the K1-7.
From To Value
A. If the value is within the specified range, leave the K1-7 disconnected and continue to Step 3.
B. If the value is not within the specified range, the K1-7 has failed internally. Replace the K1-7.
3. Check the K1-7 control circuit for a short to ground condition.
From To Value
Connector XA158, pin 83 Chassis ground There should be no continuity
A. If there is continuity, there is a short to ground condition in the K1-7 control circuit, wire 683. See the appropriate
service manual to locate and repair the shorted conductor.
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has been resolved.
operation.
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3156-(DTC 5614)-Intake air heater actuator has an open load error

Context:
The Engine Control Unit (ECU) A158 monitors the grid heater relay K1-7 control circuit for an open load condition. If
an open load condition is detected, this fault will occur.
Cause:
The ECU has detected an open circuit condition in the K1-7 control circuit.

2. Faulty K1-7, open circuit.
Solution:
Remove the K1-7.
Use a multimeter to test the K1-7 coil.
From To Value
A. If the value is within the specified range, leave the K1-7 removed and continue to Step 3.
B. If the value is infinite, the K1-7 has failed internally. Replace the K1-7.
3. Check the K1-7 for an open circuit condition.
From To Value
Connector XA158, pin 83 Connector XK1-7, pin 2 There should be continuity
A. If there is infinite resistance, there is an open circuit condition in the K1-7 signal circuit, wire 683. See the
appropriate service manual to locate and repair the broken conductor.
B. If there is continuity, check the ECU for the appropriate software and re-flash, if necessary.
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has been resolved.
operation.
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3160 (DTC 6733)-Fan clutch solenoid short circuit to battery failure

Context:
The Electronic Control Unit (ECU) A-9000 monitors the fan clutch solenoid Y-9104 for a short circuit to battery condi-
tion. If the A-9000 detects a short to battery condition in the Y-9104 wiring, fault will occur.
Cause:
The A-9000 has detected a short to battery condition in the Y-9104 wiring.
1. Faulty Y-9104, wiring or internal failure.

Solution:
2. Check the Y-9104 for an internal failure.
From To Value
Y-9104 PIN 3 Y-9104 PIN 4 There should approximately 6 - 12 Ω
A. If the specified value is measured, leave the connector disconnected and continue to Step 3.
B. If the specified value is not measured, the Y-9104 has failed internally. Replace the Y-9104.
3. Check the Y-9104 wiring for a short to battery condition.
From To Value
A. If there is continuity, there is a short circuit condition in the Y-9104 circuit, wire VE-115. Locate and repair the
broken conductor.
B. If there is continuity, leave the connectors disconnected and continue to Step 4.

4. Check the Y-9104 wiring for a short to key battery power condition.
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From To Value
A. If there is voltage, there is a short to key battery power condition in the Y-9104 circuit, wire VE-115. Locate

5. Replace the Y-9104.
Use the EST to verify the status of this fault, DTC 5533 - Fan clutch solenoid open load failure.
has been resolved.
operation.
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3161 (DTC 7833)-Fan clutch solenoid short circuit to ground failure

Context:
The Electronic Control Unit (ECU) A-9000 monitors the fan clutch solenoid Y-9104 circuit for a short to ground condi-
tion. If the A-9000 detects a short to ground condition in the Y-9104 wiring, fault will occur.
Cause:
The A-9000 has detected a short to ground condition in the Y-9104 wiring.

Solution:
From To Value
Y-9104 PIN 3 Y-9104 PIN 4 There should approximately 6 - 12 Ω.
3. Check the Y-9104 wiring for a short to ground condition.
From To Value
A. If there is continuity, there is a short circuit condition in the Y-9104 wiring. Locate and repair the broken con-
ductor.

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has been resolved.
operation.
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3162 (DTC 5533)-Fan clutch solenoid open load failure

Context:
The Electronic Control Unit (ECU) A-9000 monitors the fan clutch solenoid Y-9104 for an open load error. If the
A-9000 detects an open load error in the Y-9104 wiring, fault will occur.
Cause:
The A-9000 has detected an open load error in the Y-9104 wiring.

Solution:
From To Value
3. Check the Y-9104 wiring for an open circuit condition.
From To Value
A. If there is no continuity, there is an open circuit condition in the Y-9104 circuit, wire VE-115. Locate and repair
the broken conductor.
B. If there is continuity, continue to Step 4.

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has been resolved.
operation.
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3163 (DTC 8633)-Fan clutch solenoid ECU driver over temperature

failure
Context:
The Electronic Control Unit (ECU) A-9000 monitors the fan clutch solenoid Y-9104 for an over temperature/current
condition. If the A-9000 detects an over temperature/current condition in the Y-9104 wiring, fault will occur.
Cause:
The A-9000 has detected an over temperature/current condition in the Y-9104 wiring.

Solution:
2. 3Check the Y-9104 for an internal failure.
From To Value
3. Check the Y-9104 wiring for a short to battery condition.
From To Value
A. If there is continuity, there is a short circuit condition in the Y-9104 wiring. Locate and repair the broken con-
ductor.

4. Check the Y-9104 wiring for a short to key battery power condition.
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From To Value
A. If there is voltage, there is a short to key battery power condition in the Y-9104 wiring. Locate and repair the
shorted conductor.

has been resolved.
operation.
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3164 (DTC 1A33)-Fan speed above maximum threshold

Context:
The Electronic Control Unit (ECU) A-9000 monitors the fan speed sensor B-9103 for fan speed. Fan speed is mea-
sured using time interval between pulses. If the A-9000 determines that fan speed is above the maximum threshold
based on engine speed, this fault will occur.
Cause:
The A-9000 has determined that fan speed is above the maximum threshold.
1. Faulty cooling fan operation.

2. Faulty vistronic fan clutch solenoid Y-9104, wiring or internal failure.
3. Faulty B-9103, wiring or internal failure.
Solution:
2. Use the EST to check for the following related faults:
DTC 6733 - Fan clutch solenoid short circuit to battery failure
DTC 8633 - Fan clutch solenoid ECU driver over temperature failure
A. If any of the listed faults are active, diagnose them first and then return to this fault, DTC 1A33 - Fan speed
above maximum threshold.

3. Check the fan clutch for proper operation.
Unplug fan connector X-9103. The fan should go to full lock up.
A. If the fan goes into lock up, leave the connector disconnected and continue to Step 4.
B. If the fan does not lock up, the fan clutch assembly has failed. Replace the fan clutch Y-9103.
Use a jumper wire to provide voltage to the Y-9103.
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From To
Battery + X-9103 pin 4
Battery – X-9103 pin 3
The fan should operate at minimum speed. This may take up to 60.00 s.
A. If the fan does not operate, the fan clutch assembly has failed. Replace the Y-9103.
B. If the fan operates, leave the connector disconnected and continue to Step 5.
5. Check the B-9103 wiring for a short circuit condition.
The key must be in the OFF position for continuity and ON position for voltage.
From To Value
A. If the specified values are not measured, there is a short circuit condition in the B-9103 wiring. Locate and
B. If the specified values are measured, continue to Step 6.

Use the EST to verify that the fault has been resolved.
has been resolved.
operation.
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3165 (DTC 2B33)-Fan speed below minimum threshold

Context:
The Electronic Control Unit (ECU) A-9000 monitors the fan speed sensor B-9103 for fan speed. Fan speed is mea-
sured using time interval between pulses. If the A-9000 determines that fan speed is below the minimum threshold
based on engine speed, this fault will occur.
Cause:
The A-9000 has determined that fan speed is below the minimum threshold.
1. Faulty cooling fan operation, blocked or inoperative.

2. Faulty vistronic fan clutch solenoid Y-9104, wiring or internal failure.
Solution:
DTC 5533 - Fan clutch solenoid open load failure
A. If the listed fault is active, diagnose them first and then return to this fault, DTC 1A33 - Fan speed above
maximum threshold.
B. If the listed fault is not active, continue to Step 3.

Unplug fan connector X-9103. The fan should go to full lock up.
A. If the fan goes into lock up, leave the connector disconnected and continue to Step 4.
B. If the fan does not lock up, the fan clutch assembly has failed. Replace the fan clutch Y-9103.
Use a jumper wire to provide voltage to the Y-9103.
From To
Battery + X-9103 pin 4
Battery – X-9103 pin 3
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The fan should operate at minimum speed. This may take up to 60.00 s.
A. If the fan does not operate, the fan clutch assembly has failed. Replace the Y-9103.
B. If the fan operates, leave the connector disconnected and continue to Step 5.
5. Check the B-9103 wiring for a short circuit condition.
From To Value
A. If the specified values are not measured, there is a short circuit condition in the B-9103 wiring. Locate and

has been resolved.
operation.
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3166-(DTC 63B5)-Fuel filter heater actuator is shorted to battery

voltage
Context:
The Engine Control Unit (ECU) A158 monitors the fuel filter heater relay 1K20-3 signal circuit for a short to battery
condition. If the ECU detects a short to battery condition for a period greater than 200 ms, this fault will occur.
Cause:
The ECU has detected a short to battery condition in the 1K20-3 circuit for a period greater than 200 ms.
1. Faulty 1K20-3, coil.

2. Faulty 1K20-3 signal circuit, short to battery condition.
Solution:
1. Verify that the fault code is present and active.
Continue to Step 4.
2. Check the 1K20-3 coil for an internal failure.
Remove the 1K20-3.
Use a multimeter to perform the following resistance test:
From To Value
1K20-3, pin 85 1K20-3, pin 86 The coil resistance should be
between 70.0 - 130.0 Ω (70.0 -
130.0 Ω)
A. If the value is within the specified range, leave the 1K20-3 disconnected and continue to Step 3.
B. If the value is not within the specified value, the 1K20-3 has failed internally. Replace the 1K20-3.
3. Check the 1K20-3 signal circuit for a short to battery condition.
Disconnect the Connector XA158 from the ECU.
Turn the key to the ON position.
Use a multimeter to perform the following voltage test:
From To Value
Connector XA158, pin 61 All other pins There should be no voltage
A. If there is voltage, there is a short to battery condition in the 1K20-3 signal circuit, wires 636-2, 636-1 and/or
636. Locate and repair the shorted conductor.
B. If there is no voltage, check the ECU for the appropriate software and re-flash, if necessary.
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has been resolved.
operation.
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3167-(DTC 74B5)-Fuel filter heater actuator is shorted to ground

Context:
The Engine Control Unit (ECU) A158 monitors the fuel filter heater relay 1K20-3 signal circuit for a short to ground
condition. If a short to ground condition is detected, this fault will occur.
Cause:
The ECU has detected a short to ground condition in the 1K20-3 signal circuit.

2. Faulty 1K20-3 signal circuit, short to ground condition.
Solution:
Continue to Step 5.
Remove the 1K20-3.
From To Value
between 70.0 - 130.0 Ω (70.0 -
130.0 Ω)
A. If the resistance is within the specified range, leave the 1K20-3 disconnected and continue to Step 3.
B. If the resistance is not within the specified value, the 1K20-3 has failed internally. Replace the 1K20-3.
3. Check the 1K20-3 signal circuit for a short to ground condition.
From To Value
A. If there is continuity , there is a short to ground condition in the 1K20-3 signal circuit, wires 636-2, 636-1 and/or
636. Use the appropriate vehicle schematic to locate and repair the shorted conductor.
B. If there is no continuity, leave the Connector XA158 disconnected and continue to Step 4.
4. Check the 1K20-3 supply side circuit for a short to ground condition.
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From To Value
A. If there is continuity, there is a short to ground in the 1K20-3 supply circuit, wires 613-3, 613-2, 613-1 and/or
has been resolved.
operation.
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3168-(DTC 51B5)-Fuel filter heater actuator has an open load error

Context:
The Engine Control Unit (ECU) A158 monitors the fuel filter heater relay 1K20-3 circuit for an open circuit condition.
If the ECU detects an open circuit condition in the 1K20-3 signal circuit, this fault will occur.
Cause:
The ECU has detected an open circuit condition in the 1K20-3 signal circuit.

2. Faulty 1K20-3 ground or voltage supply circuit, open circuit condition.
Solution:
Continue to Step 6.
Remove the 1K20-3.
From To Value
between 70.0 - 130.0 Ω (70.0 -
130.0 Ω)
B. If the value is infinite, the 1K20-3 has failed internally. Replace the 1K20-3.
3. Check the 1K20-3 ground circuit and voltage supply circuit for an open circuit condition.
Turn the key to the OFF position.
From To Value
Connector XA158, pin 61 Connector X33-30 , pin 6 There should be continuity
A. If there is no continuity, there is an open circuit condition in the 1K20-3 ground or voltage supply circuit, wires
636-2, 613-3 or 613-2. Locate and repair the broken conductor.
B. If there is continuity, leave the Connector XA158 disconnected, connect the Connector X33-30 and continue
with Step 4.
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From To Value
Connector XA158, pin 61 Connector X102, pin 23 There should be continuity
636-1 or 613-1. Locate and repair the broken conductor.
B. If there is continuity, leave the Connector XA158 disconnected, connect the Connector X102 and continue
with Step 5.
From To Value
Connector XA158, pin 61 Connector 1F1K, pin B10 There should be continuity
Connector XA158, pin 27 Connector 1F1K, pin D9 There should be continuity
636 or 613. Locate and repair the broken conductor.
has been resolved.
operation.
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3169-(DTC 82B5)-Fuel filter heater ECU driver has an over

temperature error
Context:
The Engine Control Unit (ECU) A158 monitors the fuel filter heater relay 1K20-3 signal circuit for an over temperature
condition. If the ECU detects an over temperature condition for a period greater than 200 ms, this fault will occur.
Cause:
The ECU has detected an over temperature condition in the 1K20-3 circuit for a period greater than 200 ms.

2. Faulty 1K20-3 signal circuit, short to battery condition.
Solution:
Continue to Step 4.
Remove the 1K20-3.
From To Value
between 70.0 - 130.0 Ω (70.0 -
130.0 Ω)
B. If the value is not within the specified value, the 1K20-3 has failed internally. Replace the 1K20-3.
3. Check the 1K20-3 signal circuit for a short to battery condition.
Turn the key to the ON position.
From To Value
Connector XA158, pin 61 Connector XA158, pin 27 There should be no voltage
A. If there is voltage, there is a short to battery condition in the 1K20-3 signal circuit, wires 636-2, 636-1 and/or
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has been resolved.
operation.
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3170-(DTC 38CB)-NH3 sensor signal is not changing

NOTE: because this fault causes inducement, it is necessary to perform the Engine Restart Counter Reset / Un-
lock Inducement configuration with the Electronic Service Tool (EST) before you return the machine to service. See
Selective Catalytic Reduction (SCR) exhaust treatment - Configure - Engine restart counter reset (10.500) if
necessary.
Context:
For information regarding the functional operation of the NH3 sensor and the NH3 Module B-057 see Ammonia (NH3)
sensor - Dynamic description (55.988). The B-057 is required to report information at regular intervals to the Engine
Control Unit (ECU) via Controller Area Network (CAN). If the signal of the NH3 sensor is not changing over time or
the B-057 is not reporting change, this fault will occur.
Cause:
The B-057 has reported, via CAN, to the ECU that the NH3 sensor signal is not changing over time.
1. Faulty NH3 sensor, damaged or improperly or not installed.

2. Faulty B-057, hardware or software.
Solution:
1. Verify condition of NH3 sensor.
Remove and inspect the NH3 sensor for debris accumulation, sensing tip breakage, or other damage.
There should be no accumulation, breakage or damage.
A. If accumulation, breakage or damage is found, replace the NH3 sensor. Then use the EST, see Selective
Catalytic Reduction (SCR) exhaust treatment - Configure - Engine restart counter reset (10.500) if nec-
essary. to perform the Engine Restart Counter Reset / Unlock Inducement configuration. Then perform the
SCR Fault Repair Verification Test, see Selective Catalytic Reduction (SCR) exhaust treatment - Service
instruction - SCR fault repair verification test (10.500), if necessary. Then return the machine to service.
B. If no accumulation, breakage or damage is found, continue with Step 2.

2. As there is no method for field testing or re-flashing the sensor controller, replace the B-057.
Then use the EST, see Selective Catalytic Reduction (SCR) exhaust treatment - Configure - Engine restart
counter reset (10.500) if necessary. to perform the Engine Restart Counter Reset / Unlock Inducement configu-
ration.
Then perform the SCR Fault Repair Verification Test, see Selective Catalytic Reduction (SCR) exhaust treat-
ment - Service instruction - SCR fault repair verification test (10.500), if necessary.
Then check to see if the fault is resolved.
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3172-(DTC F523)-Engine coolant temperature has exceeded the

pre-warning threshold
Context:
The Engine Control Unit (ECU) monitors the engine coolant temperature. Two engine temperature thresholds are
available to signal high engine temperature. A pre-warning is set if engine temperature coolant exceeds 106.0 °C
(222.7 °F) and a warning is set if engine coolant temperature exceeds 110.0 °C (229.9 °F). If the pre-warning threshold
is exceeded, this fault will occur.
Cause:
The engine coolant temperature pre-warning threshold has been exceeded.
1. Engine temperature too high. (heavy use or high environmental temperature)

2. Faulty engine cooling system, coolant low, thermostat stuck closed, restricted cooling package etc.
3. Faulty B-9003 wiring or internal failure.
Solution:
DTC 1113 - Engine coolant temperature sensor voltage is higher than expected
A. If the fault is active, diagnose it first and then return to this fault, DTC F523 - Engine coolant temperature
has exceeded the pre-warning threshold.
B. Is the fault is not active, continue to Step 3.

3. Check the engine cooling system for an over temperature condition.
Check the cooling system for leakage, damage or blockage.
Check the ambient air temperature using the EST to verify that the machine is not operating in extreme ambient
temperatures.
A. If any failures are found, repair the cooling system as necessary.
B. If no failures are found, continue to Step 4.

4. Check the B-9003 wiring.
The key must be in the OFF position for continuity checks and the ON position for voltage checks.
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From To Value
X-9001 pin 39 All pins in connector There should be no continuity.
A. If the specified values are not measured, there is a short circuit condition in the B-9003 wiring, wire EN-014.

Use the EST to verify the status of this fault, DTC F523 - Engine coolant temperature has exceeded the pre-
warning threshold.
has been resolved.
operation.
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3173-(DTC F623)-Engine coolant temperature has exceeded the

warning threshold
Context:
The Engine Control Unit (ECU) monitors the engine coolant temperature. Two engine temperature thresholds are
available to signal high engine temperature. A pre-warning is set if engine temperature coolant exceeds 106.0 °C
(222.7 °F) and a warning is set if engine coolant temperature exceeds 110.0 °C (229.9 °F). If the warning threshold is
exceeded, this fault will occur.
Cause:
The engine coolant temperature warning threshold has been exceeded.
1. Engine temperature too high. (heavy use or high environmental temperature)

2. Faulty engine cooling system, coolant low, thermostat stuck closed, restricted cooling package etc.
3. Faulty B-9003 wiring or internal failure.
Solution:
DTC 1113 - Engine coolant temperature sensor voltage is higher than expected
DTC F523 - Engine coolant temperature has exceeded the pre-warning threshold
A. If the fault is active, diagnose it first and then return to this fault, DTC F523 - Engine coolant temperature
has exceeded the pre-warning threshold.
B. Is the fault is not active, continue to Step 3.

3. Check the engine cooling system for an over temperature condition.
Check the cooling system for leakage, damage or blockage.
Check the ambient air temperature using the EST to verify that the machine is not operating in extreme ambient
temperatures.

The key must be in the OFF position for continuity checks and the ON position for voltage checks.
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From To Value
X-9001 pin 39 All pins in connector There should be no continuity.
A. If the specified values are not measured, there is a short circuit condition in the B-9003 wiring, wire EN-014.

Use the EST to verify the status of this fault, DTC F623 - Engine coolant temperature has exceeded the warning
threshold.
has been resolved.
operation.
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3175-(DTC 4933)-Fan speed signal could not be measured for a

period
Context:
The Electronic Control Unit (ECU) monitors fan speed by the fan speed sensor B-9103. Speed is measured using
time interval between pulses. If the A-9000 determines that the times interval is too long or has stopped completely,
Cause:
The A-9000 has determined that the fan speed signal could not be measured for an extended period of time.
1. Faulty engine cooling fan assembly.

Solution:
2. Check the B-9103 signal circuit wiring.
From To Value
X-9001 pin 64 Chassis ground (Key ON for voltage) There should be no voltage.
A. If the specified values are not obtained, the is a fault in the B-9103 wiring. Locate and repair the faulty con-
ductor.
B. If the specified values are obtained, continue to Step 3.

3. Inspect the cooling fan for proper operation.
A. If the fan is not properly engaging or functioning correctly, repair the fan assembly as necessary.
B. If the fan assembly is functioning properly, continue to Step 4.
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Use the EST to verify the status of this fault, DTC 4933 - Fan speed signal could not be measured for a period.
has been resolved.
operation.
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3176-(DTC 3B65)-High pressure pump fuel delivery quantity in over

run exceeds a maximum threshold
Context:
For more information on the fuel injection system see Injection control - Dynamic description (55.010). The Engine
Control Unit (ECU) A158 controls fuel delivery by the fuel metering unit. The ECU monitors for high pressure leakage
during over run. If high pressure fuel delivery quantity exceeds a maximum threshold in over run and desired fuel
pressure can not be reached, leakage in the system is assumed and this fault will occur.
Cause:
The ECU has determined that desired fuel rail pressure is lower than expected in over run.
1. Faulty fuel injectors, internal leakage or stuck open.

2. Faulty pressure relief valve, leaking.
3. Faulty fuel metering unit.
6. Faulty low pressure fuel lines, leaking. (air entrance)
7. Faulty low pressure gear pump.
8. Faulty electric lift pump. (if applicable)
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3177-(DTC F1A2)-Engine over speed condition detected

Context:
The Engine Control Unit (ECU) A158 monitors engine speed in case of an overspeed condition. Engine overspeed
can be caused by operating states such as downhill travel. If an engine overspeed condition is detected, this fault will
occur.
Cause:
The ECU has detected that engine speed has exceeded 2600 RPM.
1. Operating error. (downhill travel)

2. Engine runaway condition. Engine continues to accelerate without any operator input. (fuel or oil leakage into
cylinders)
3. Faulty fuel injectors, leakage into cylinders. (Causing engine runaway condition)
4. Faulty camshaft speed sensor wiring or internal failure.
5. Faulty crankshaft speed sensor wiring or internal failure.
Solution:
3093 (DTC 3312) - Compared camshaft and crankshaft speed sensor values are not plausible
3091 (DTC 4112) - Camshaft speed sensor pattern is not plausible
3090 (DTC 4212) - Camshaft speed sensor values are not plausible
3089 (DTC 4412) - Crankshaft speed sensor pattern is not plausible
3088 (DTC 4512) - Crankshaft speed sensor values are not plausible

3. Verify that this fault was not activated by a downhill travel condition or any other operating conditions that may
have caused this fault.
A. If the fault is no longer active, return the machine to service.
B. If the fault is still active, check the ECU for the appropriate software and re-flash, if necessary.
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has been resolved.
operation.
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3179-(DTC 956B)-CAN communication failure between vehicle

controller and ECU - BC2ECU2 message
Context:
of the ECU. CAN Node A Bus is the main vehicle interface bus. The ECU provides a CAN termination resistor for
the CAN Node A Bus, internal to the ECU. The ECU receives and responds to proprietary Body Computer (BC)
information. If the ECU senses a message timeout, this fault will occur.
Cause:
ECU has sensed a BC message timeout.
1. Faulty vehicle system, related CAN fault.

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 that this fault is also resolved.
B. If related vehicle CAN faults do not exist, continue with Step 3.

From To Value
4.
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From To Value
From To Value
From To Value
circuit.
has been resolved.
operation.
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3180-(DTC 9B7B)-CAN communication error between vehicle

controller to ECU
Context:
CAN Node A Bus, internal to the ECU. The ECU receives and responds to proprietary idle speed, intermediate speed
and feedback information. If the ECU senses a message timeout, this fault will occur.
Cause:
ECU has sensed a proprietary speed message timeout.

Solution:

From To Value
4.
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From To Value
From To Value
From To Value
circuit.
has been resolved.
operation.
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3182-(DTC 9741)-CAN timeout error from cruise control vehicle

speed (CCVS)
Context:
CAN Node A Bus, internal to the ECU. The ECU receives and responds to proprietary Cruise Control Vehicle Speed
(CCVS) information. If the ECU senses a message timeout, this fault will occur.
Cause:
ECU has sensed a CCVS message timeout.

Solution:

From To Value
4.
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From To Value
From To Value
From To Value
circuit.
has been resolved.
operation.
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3183-(DTC 93CB)-CAN communication failure between vehicle

controller and ECU controller - TSC1_VR message (Engine brake)
Context:
the CAN Node A Bus, internal to the ECU. The ECU receives and responds to Vehicle Retarder (VR) information at
two different rates (active and passive) dependant upon change request status. If the ECU is not sensing the VR
message at the active rate, this fault will occur.
Cause:
The ECU is not properly sensing the VR message.

Solution:

From To Value
4.
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From To Value
From To Value
From To Value
circuit.
has been resolved.
operation.
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controller and ECU controller - TSC1_VR message (Engine brake)
Context:
the CAN Node A Bus, internal to the ECU. The ECU receives and responds to Vehicle Retarder (VR) information at
two different rates (active and passive) dependant upon change request status. If the ECU is not sensing the VR
message at the passive rate, this fault will occur.
Cause:
The ECU is not properly sensing the VR message.

Solution:

From To Value
4.
47829048B 15/06/2016
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From To Value
From To Value
Connector XA158, pin 46 chassis ground There should not be continuity
From To Value
circuit.
has been resolved.
operation.
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3185-(DTC 978B)-Can timeout error from transmission -

Transmission fluids (TF) message
Context:
the CAN Node A Bus, internal to the ECU. The ECU receives and responds to proprietary Transmission Fluids (TF)
Cause:
ECU has sensed a TF message timeout.

Solution:

From To Value
4.
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From To Value
From To Value
From To Value
circuit.
has been resolved.
operation.
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3188-(DTC 5316)-Open load error of injector in cylinder 1

Context:
Cause:
During cylinder 1 injector Y-9001 evaluation, the pattern for an open circuit was detected.
1. Faulty cylinder 1 injector Y-9001 solenoid windings, open circuit.

2. Faulty electrical wiring, broken or disconnected conductor, high side or low side (damaged wiring harness).
Solution:
Disconnect the engine harness from the ECU A-9000 at the engine plug connector X-9002 X-90NN.
Use a multimeter to measure the resistance on the engine (EN) harness side:
From To Value
X-9002 pin 49 X-9002 pin 73 There should be between 0.2 - 0.5 Ω.
A. If there is greater than 0.5 Ω. leave the engine plug connector X-9002 disconnected and continue with Step 3.
B. If there is between 0.2 - 0.5 Ω, continue with Step 7.

3. Determine the location of the open circuit condition.
Disconnect the engine cylinder harness from the injector (valve) cover at connector X-9184-6CYL .
Use a multimeter to check for continuity on the engine (EN) harness side:
From To Value
X-9002 pin 49 X-9184-6CYL pin 4 There should be continuity
A. If there is continuity, leave both the engine plug connector X-9002 and the injector (valve) cover connector
X-9184-6CYL disconnected, then continue with Step 4.
B. If there is no continuity, there is an open circuit condition in the engine (EN) harness between connector X-9002
pin 49 and connector X-9184-6CYL pin 4, wire EN-017-6CYL. Locate and repair the broken conductor.
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From To Value
X-9184-6CYL pin 3 X-9002 pin 73 There should be continuity
A. If there is continuity, continue with step 5.
B. If there is no continuity, there is an open circuit condition in the engine (EN) harness between the valve cover
Remove the injector (valve) cover and disconnect the injector harness from the cylinder 1 injector at connector
X-9188-6CYL.
Use a multimeter to check for continuity in the injector harness:
From To Value
X-9188-6CYL pin 1 X-9184-6CYL pin 4 There should be continuity
A. If there is continuity, leave the injector harness connector X-9188-6CYL disconnected from cylinder 1 continue
with Step 6.
B. If there is no continuity, there is an open circuit condition in the injector harness, between connector X-9188-
6CYL pin 1 and connector X-9184-6CYL pin 4, wire EN-576–6CYL. Locate and repair the broken conductor.
Use a multimeter to measure the resistance, on the injector:
From To Value
X-9188-6CYL pin 1 X-9188-6CYL pin 2 There should be between 0.2 - 0.5 Ω
A. If there is between 0.2 - 0.5 Ω, there is an open circuit condition in the injector harness between connector
X-9188-6CYL pin 2 and connector X-9184-6CYL pin 3, wire EN-577-6CYL. Locate and repair the broken
conductor.
B. If the resistance is greater than 0.5 Ω, the cylinder 1 injector Y-9001 solenoid coil has failed, replace the injector.
Disconnect the vehicle interface harness (VE) from the ECU A-9000 at the vehicle plug connector X-9001 .
From To Value
with Step 8.
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From To Value
necessary.
B. If there is no continuity on one or more of the checks, use the appropriate vehicle electrical schematics to locate
and repair the failure.
has been resolved.
operation.
06 (55.100)
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Context:
Cause:
During cylinder 3 injector evaluation, the pattern for an open circuit was detected.

Solution:
From To Value

From To Value
pin 50 and connector X-9185-6CYL pin 4 , wire EN-021-6CYL. Locate and repair the broken conductor.
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From To Value
X-9190-6CYL.
From To Value
A. If there is continuity, leave the injector harness connector X-9190-6CYL pin 1 disconnected from cylinder 3
continue with Step 6.
6CYL pin 1 and connector X-9185-6CYL pin 4 , wire EN-580-6CYL. Locate and repair the broken conductor.
From To Value
conductor.
From To Value
with Step 8.
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From To Value
necessary.
has been resolved.
operation.
06 (55.100)
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3196-Open load error of injector in cylinder 2

Context:
Cause:

Solution:
Disconnect the engine harness from the ECU A-9000 at the engine plug connector X-9002 .
From To Value

From To Value
pin 51 and connector X-9184-6CYL pin 1 , wire EN-019. Locate and repair the broken conductor.
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From To Value
connector X-9184-6CYL pin 2 and the engine plug connector X-9002 pin 75, wire EN-020. Locate and repair
X-9189-6CYL.
From To Value
with Step 6.
6CYL pin 1 and connector X-9189-6CYL pin 2, wire EN-579. Locate and repair the broken conductor.
From To Value
X-9189-6CYL pin 1 and connector X-9184-6CYL pin 2, wire EN-578. Locate and repair the broken conductor.
From To Value
with Step 8.
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From To Value
necessary.
has been resolved.
operation.
06 (55.100)
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Context:
Cause:

Solution:
From To Value

From To Value
pin 25 and connector X-9187-6CYL pin 3, wire EN-026. Locate and repair the broken conductor.
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From To Value
connector X-9187-6CYL pin 4 and the engine plug connector X-9002 pin 1 , wire EN-025. Locate and repair
X-9192-6CYL.
From To Value
with Step 6.
6CYL pin 2 and connector X-9187-6CYL pin 3, wire EN-585-6CYL. Locate and repair the broken conductor.
From To Value
conductor.
From To Value
with Step 8.
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From To Value
necessary.
has been resolved.
operation.
06 (55.100)
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3204-Open load error of injector in cylinder 4

Context:
Cause:

Solution:
Disconnect the engine harness from the ECU A-9000 at the engine plug connector X-9002 .
From To Value

From To Value
pin 27 and connector X-9185-6CYL pin 2, wire EN-024. Locate and repair the broken conductor.
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From To Value
connector X-9185-6CYL pin 1 and the engine plug connector X-9002 pin 3, wire EN-023. Locate and repair
X-9191-6CYL .
From To Value
with Step 6.
6CYL pin 1and connector, X-9185-6CYL pin 2 wire EN-582. Locate and repair the broken conductor.
From To Value
X-9191-6CYL pin 2 and connector X-9185-6CYL pin 1, wire EN-583. Locate and repair the broken conductor.
From To Value
with Step 8.
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From To Value
necessary.
has been resolved.
operation.
06 (55.100)
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Context:
Cause:

Solution:
From To Value

From To Value
pin 26 and connector X-9187-6CYL pin 2, wire EN-027-6CYL. Locate and repair the broken conductor.
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From To Value
X-9193-6CYL.
From To Value
with Step 6.
6CYL pin 1 and connector X-9187-6CYL pin 2, wire EN-586-6CYL. Locate and repair the broken conductor.
From To Value
conductor.
From To Value
with Step 8.
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From To Value
necessary.
has been resolved.
operation.
06 (55.100)
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3210-(DTC 7116)-Injection bank 1 short circuit failure (all injectors

of the same bank can be affected)
Context:
Hardware errors in the injectors and their respective Engine Control Unit (ECU) A158 power stages are investigated
within the ECU. The injector control scheme also groups the individual injector control circuits into banks. The ECU
diagnostic procedure uses pattern detection to identify specific injector as well as bank errors. When an expected
combination of errors is detected, the associated fault occurs. If a short circuit failure condition exists in bank 1, this
fault will occur.
Cause:
The ECU has determined that a short circuit condition exists in injector control bank 1.
1. Faulty bank 1 injector circuit wiring, shorted.

2. Faulty bank 1 injector solenoid windings, shorted.
Solution:
1. Check for bank 1 injector fault code.
Use the Electronic Service Tool (EST) to check for the presence of 3063 (DTC 6226) - Short circuit error of
injector in cylinder 1 or 3079 (DTC 6426) - Short circuit error of injector in cylinder 3 or 3071 (DTC 6626) -
Short circuit error of injector in cylinder 2.
A. If either 3063 (DTC 6226) - Short circuit error of injector in cylinder 1 or 3079 (DTC 6426) - Short circuit
error of injector in cylinder 3 or 3071 (DTC 6626) - Short circuit error of injector in cylinder 2 is present,
resolve the relevant fault. Then check that this fault is also resolved.
B. If neither 3063 (DTC 6226) - Short circuit error of injector in cylinder 1 or 3079 (DTC 6426) - Short circuit
check the ECU for the appropriate software and re-flash, if necessary.
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3218-(DTC 7216)-Injection bank 2 short circuit failure (all injectors

of the same bank can be affected)
Context:
Hardware errors in the injectors and their respective Engine Control Unit (ECU) A158 power stages are investigated
within the ECU. The injector control scheme also groups the individual injector control circuits into banks. The ECU
diagnostic procedure uses pattern detection to identify specific injector as well as bank errors. When an expected
combination of errors is detected, the associated fault occurs. If a short circuit failure condition exists in bank 2, this
fault will occur.
Cause:
The ECU has determined that a short circuit condition exists in injector control bank 2.
1. Faulty bank 2 injector circuit wiring, shorted.

2. Faulty bank 2 injector solenoid windings, shorted.
Solution:
1. Check for bank 2 injector fault code.
Use the Electronic Service Tool (EST) to check for the presence of 3083 (DTC 6326) - Short circuit error of
injector in cylinder 5 or 3075 (DTC 6526) - Short circuit error of injector in cylinder 6 or 3067 (DTC 6726) -
Short circuit error of injector in cylinder 4.
A. If either 3083 (DTC 6326) - Short circuit error of injector in cylinder 5 or 3075 (DTC 6526) - Short circuit
resolve the relevant fault. Then check that this fault is also resolved.
B. If neither 3083 (DTC 6326) - Short circuit error of injector in cylinder 5 or 3075 (DTC 6526) - Short circuit
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3226 (DTC 9A98)-CAN timeout error from eVGT Actuator

Context:
For information regarding the functional operation of the eVGT actuator A-9003 refer to eVGT actuator — Functional
description. The eVGT actuator A-9003 controller is required to report information at regular intervals to the Engine
Control Unit (ECU) A-9000 via Controller Area Network (CAN). If this information is not communicated within the
allotted time frame, this ECU A-9000 timeout fault will occur.
Cause:
The ECU A-9000 has reported, via the engine sensor CAN bus, that an eVGT A-9003 actuator controller timeout has
occurred.
1. Faulty supply voltage, out of required range.

2. Faulty CAN wiring, open or short circuit.
3. Faulty eVGT A-9003 actuator controller, hardware or firmware.
Solution:
2. Check for eVGT A-9003 actuator controller supply voltage.
Disconnect the EN harness from the eVGT A-9003 actuator controller at connector X-9012.
Use a multimeter to check for voltage on the EN harness side:
From To Value
X-9012 pin 3 X-9012 pin 1 X-9012 pin 4 X-9012 pin 2 There should be 24 V.
A. If the voltage is present, leave connector X-9012 disconnected and continue with Step 3.
B. If the voltage is not present, continue with Step 4.

3. Determine the condition of the eVGT A-9003 actuator controller CAN circuit.
Use a multimeter to measure the resistance of the CAN connection on the EN harness side:
From To Value
X-9012 pin 1 X-9012 pin 2 There should be 60 Ω.
A. If the measured resistance is correct, continue with Step 5.
B. If the measured resistance is not correct, continue with Step 4.

4. Check for other engine ATS (After Treatment System) CAN faults.
Use EST to determine if other ATS CAN faults exist.
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A. If other faults do exist, refer to BASE-LINE ATS CAN CIRCUIT FAILURE IU(S) — ONCE CREATED to locate and repair
the faulted condition.
B. If no other faults exist, the ATS vehicle or EN harness wiring is damaged between the network harness splice
and the eVGT A-9003 actuator controller connector X-9012 pin 1 and/or X-9012 pin 2, wire EN-049A and/or
EN-050A, for supply power and ground or X-9012 pin 3 and/or X-9012 pin 4, wire EN-048C (High) and/or
EN-047C (Low) for CAN signal. Locate and repair the damage to the ATS CAN circuit wiring.
5. As there is no method for field testing or re-flashing the sensor controller, replace the eVGT Control Unit A-9003.
Check to see that the fault is resolved.
has been resolved.
operation.
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3230-(DTC E126)-ECU internal failure - Injector CY33x component

Context:
The Engine Control Unit (ECU) A158 performs a diagnostic procedure using pattern detections to identify specific
ECU errors and triggers the appropriate substitute reaction. If the ECU determines an expected combination of errors
are detected (measured and reference pattern are matching), this fault will occur.
Solution:
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3233 (DTC E336)-ECU internal failure - Internal SPI injector related

timeout error
Context:
Serial Peripheral Interface (SPI) bus communication is monitored once per every camshaft revolution. If a time out
error in the SPI communication is detected, this fault will occur.
Cause:
The Engine Control Unit (ECU) A158 has detected a time out error is the SPI bus communication.

2. Internal failure of the ECU powerstage.
Solution:
1. Check the ECU for the appropriate software.
A. Check the ECU for the appropriate software. If necessary, re-flash the ECU.
B. If the ECU can not be re-flashed, replace the ECU.
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3235-(DTC F936)-Exceeded the number of injections for a given

engine speed
Context:
For more information on the high pressure fuel injection system refer to (high pressure fuel system theory of opera-
tions). If the number of requested injections is greater than the number of injections injected for the current engine
speed, this fault will occur.
Cause:
The number of requested injections is greater than the number of injections injected for the current engine speed.
1. Time for injection calculation is too short.

2. Faulty software of the Engine Control Unit (ECU) A158.
Solution:
1. Check the ECU for the appropriate software.
A. Check the ECU for the appropriate software. If necessary, re-flash the ECU.
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3236-(DTC F836)-Number of injections is limited by system

Context:
For more information on the high pressure fuel injection system refer to High pressure pump - Overview (10.218).
The Engine Control Unit (ECU) A158 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 five injections, this fault will occur.
Cause:
The number of requested injections has exceeded the number of actual injections by 5 injections.
Solution:
1. Check the ECU.
A. Check the ECU for the appropriate software. Re-flash if necessary.
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3237 (DTC 1636)-Number of desired injections exceeds threshold

Context:
For more information on the fuel injection system refer to Fuel system – Theory of operations. The Engine Control
Unit (ECU) A158 monitors the requested number of fuel injections to the actual number of fuel injections fired. If the
number of requested injections is greater than the number of actual injections, this fault will occur.
Cause:
The ECU has detected a larger number of requested fuel injections than actual injections.
1. Faulty power supply to ECU.

Solution:
1. Check ECU supply voltage.
Disconnect the vehicle interface harness (VE) from the ECU at the Connector XA158.
Place the key switch in the ON position.
From To Value
A. If the 24 V is present for all five checks, leave the vehicle plug the Connector XA158 disconnected and con-
tinue with Step 2.
2. Check the ECU ground circuits.
Place the key switch in the OFF position.
From To Value
A. If there is continuity on all five checks, check the ECU for the appropriate software and re-flash, if necessary.
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3238-(DTC E64D)-ECU internal failure

Context:
The Engine Control Unit (ECU) A158 performs a diagnostic test of the sensor supplies by monitoring the communi-
cation between the processor and the voltage supply device. If the ECU determines that the communication data is
incorrect or data transfer was not successful, this fault will occur.
Solution:
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3245-(DTC E51D)-ECU internal failure - Query/response

communication errors
Context:
The Engine Control Unit (ECU) A158 monitors communication between the ECU and the power stage controller over
Serial Peripheral Interface (SPI) bus. If no response or erroneous response is detected, the ECU will reset and monitor
again seven times. If the error is still detected, this fault will occur.
Solution:
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3252-(DTC E61D)-ECU internal failure - SPI communication error

Context:
The Engine Control Unit (ECU) A158 tests the correct functioning of the fuel injection path shut off procedure. During
this test, each injection path is shortly activated during ECU initialization. If a Serial Peripheral Interface (SPI) com-
munication error is detected during this test, this fault will occur.
Solution:
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3253-(DTC E41D)-ECU internal failure - Voltage ratio in ADC

monitoring
Context:
The Engine Control Unit (ECU) A158 monitors the efficiency of the Analog to Digital Converter (ADC) using a voltage
ratio conversion test. The ECU will count each time the voltage ratio is out of the desired range. If the count exceeds
15 times, this fault will occur.
Solution:
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3255-(DTC E31D)-ECU internal failure - ADC test

Context:
The Engine Control Unit (ECU) A158 monitors the efficiency of the Analog to Digital Converter (ADC). A fixed test
input voltage is sent to and converted by the ADC. The test voltage value must be between 4.73 - 4.83 V. The ECU
monitors this test and counts each time the value is not recorded in the specified range. If the counter exceeds 15
times, this fault will occur.
Solution:
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3256-(DTC E21D)-ECU internal failure - NTP error in ADC monitoring

Context:
The Engine Control Unit (ECU) A158 uses a No-load Test Pulse (NTP) operation to check the efficiency of the Analog
to Digital Converter (ADC). If an error is detected during this test, this fault will occur.
Solution:
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3258-(DTC 6722)-Starter relay high side driver circuit short to

battery failure
Context:
The Engine Control Unit (ECU) A158 controls the voltage to the OK to start 1KCC. The 1KCC controls the voltage to
the starting relay K1-5. The ECU monitors the 1KCC control circuit for a short to battery condition. If the ECU detects
a short to battery in the 1KCC high side control circuit, this fault will occur.
Cause:
The ECU has detected a short to battery condition in the 1KCC control circuit, high side.
1. Faulty 1KCC, coil.

2. Faulty 1KCC high side control circuit, short to battery condition.
Solution:
2. Check the 1KCC high side control circuit for a short to battery condition at the 1KCC pin 86.
Remove the Connector 1F1K.
From To Value
Connector 1F1K, pin D7 Chassis ground There should be no voltage
A. If there is voltage, there is a short to battery in the 1KCC high side control circuit, wires 637, 637-1 and/or
637-2. Locate and repair the shorted conductor.

3. Check the 1KCC high side control circuit for a short to battery condition.
From To Value
Connector XA158, pin 19 All pins There should be no continuity
A. If there is continuity, there is a short to battery in the 1KCC high side control circuit. Locate and repair the
shorted conductor.
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has been resolved.
operation.
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3259-(DTC 7822)-Starter relay high side driver circuit short to

ground failure
Context:
the starting relay K1-5. The ECU monitors the 1KCC high side control circuit for a short to ground condition. If the
ECU detects a short to ground condition in the 1KCC high side control circuit, this fault will occur.
Cause:
The ECU has detected a short to ground condition in the 1KCC control circuit, high side.

2. Faulty 1KCC high side control circuit, short to ground condition.
Solution:
2. Check the 1KCC coil for an internal failure.
Remove the 1KCC.
Use a multimeter to check the 1KCC coil resistance.
From To Value
1KCC, pin 86 1KCC, pin 85 There should be between 70 - 130 Ω
A. If the value is within the specified range, leave the 1KCC disconnected and continue with Step 3.
B. If the value is infinite, the 1KCC has failed internally. Replace the 1KCC.
3. Check the 1KCC high side control circuit for a short to ground condition.
The key must in the OFF position.
From To Value
A. If there is continuity, there is a short to ground condition in the 1KCC high side control circuit, wires 637, 637-1
and/or 637-2. Locate and repair the shorted conductor.
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has been resolved.
operation.
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3260-(DTC 5922)-Starter relay low side driver circuit open failure

Context:
the starting relay K1-5. The ECU monitors the 1KCC control circuit for an open circuit condition. If the ECU detects
an open circuit condition in the 1KCC low side control circuit, this fault will occur.
Cause:
The ECU has detected an open circuit condition in the 1KCC control circuit, low side.

2. Faulty 1KCC low side control circuit, open condition.
Solution:
Remove the 1KCC.
Use a multimeter to test the 1KCC coil.
From To Value
A. If the value is within the specified range, leave 1KCC disconnected and continue to Step 3.
3. Check the 1KCC low side control circuit for an open circuit condition.
From To Value
A. If there is no continuity, there is an open circuit condition in the 1KCC control circuit, low side. Locate and
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has been resolved.
operation.
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3261-(DTC 6B22)-Starter relay low side driver circuit short to

battery failure
Context:
the starting relay K1-5. The ECU monitors the 1KCC control circuit for a short to battery condition. If the ECU detects
a short to battery condition in the 1KCC low side control circuit, this fault will occur.
Cause:
The ECU has detected a short to battery condition in the 1KCC control circuit, low side.

2. Faulty 1KCC low side control circuit, short to battery condition.
Solution:
Remove the 1KCC.
From To Value
3. Check the 1KCC low side control circuit for a short to battery condition.
The key must in the ON position.
From To Value
A. If there is voltage, there is a short to battery condition in the 1KCC low side control circuit, wires 617, 617-1
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has been resolved.
operation.
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3262-(DTC 7C22)-Starter relay low side driver circuit short to

ground failure
Context:
The Engine Control Unit (ECU) A158 controls the voltage to the OK to start 1KCC. The 1KCC controls the voltage
to the starting relay K1-5. The ECU monitors the 1KCC low side control circuit for a short to ground condition. If the
ECU detects a short to ground condition in the 1KCC low side control circuit for a period greater than 90 ms, this fault
will occur.
Cause:
The ECU has detected a short to ground condition for a period greater than 90 ms in the 1KCC control circuit, low
side.
1. Faulty 1KCC low side control circuit, short to ground condition.

Solution:
2. Check the 1KCC low side control circuit for a short to ground condition.
Remove the 1KCC.
From To Value
A. If there is continuity, there is a short to ground condition in the 1KCC low side control circuit, wires 617, 617-1
has been resolved.
operation.
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3263-(DTC 971B)-CAN C Bus off failure

Context:
The Engine Control Unit (ECU) A-9000 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-9000. CAN Node C Bus is the main engine interface bus. The ECU A-9000 provides a CAN
termination resistor for the CAN Node C Bus, internal to the ECU A-9000. If the ECU A-9000 senses that CAN Node
C Bus is not functioning properly, this fault will occur.
Cause:
ECU A-9000 has sensed a “Bus Off” state to be present at CAN Node C.

3. Faulty ECU A-9000, termination resistor or software.
Solution:
Use the EST to determine if other engine CAN faults exist.
A. If other engine CAN faults do exist, resolve the engine CAN faults, then check to see that DTC 971B - CAN C
Bus off failure is also resolved.
B. If other engine CAN faults do not exist, continue with Step 3.

Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9001.
From To Value
X-9001 pin 1 chassis ground There should be 24 V .
A. If the voltage is present on all of the checks, leave connector X-9001 disconnected and continue with Step 4.
electrical schematics to locate and restore supply power to the ECU A-9000.
4. Check the ECU A-9000 grounding.
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From To Value
A. If there is continuity on all of the checks, continue with Step 5.
electrical schematics to locate and restore the grounding circuit to the ECU A-9000.
5. Determine the condition of the ECU A-9000 CAN C circuit.
Disconnect the engine (EN) harness from the ECU A-9000 at connector X-9002.
the engine (EN) harness side:
From To Value
X-9002 pin 17 chassis ground There should not be continuity
Use a multimeter to measure the resistance of the CAN C termination resistor, internal to the ECU A-9000:
From To Value
A. If the measured resistances are correct and neither conductor is grounded, check the ECU A-9000 for the
appropriate software and re-flash, if necessary.
circuit.
has been resolved.
operation.
04 (55.100)
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3265 (DTC E4DD)-Fuel injection requested during overrun

Context:
The Engine Control Unit (ECU) A158 monitors for requested fuel injection during over run. If injections are requested
during over run, this fault will occur.
Cause:
Fuel injection has been requested during over run.
1. Faulty fuel injectors, leakage.

2. Incorrect injection timing.
3. Faulty Pressure Relief Valve (PRV).
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3280 (DTC E62D)-Sensor supply 1 voltage is too high

Context:
The Electronic Control Unit (ECU) A-9000 monitors the A-9000 24 V sensor supplies. If the A-9000 determines that
the sensor supply 1 voltage is too high, this fault will occur. The pin associated with this supply is pin 84 in connector
X-9002.
Cause:
The A-9000 has determined that a sensor supply voltage is too high.
1. Short circuit condition at connector X-9002 pin 84.

Solution:
2. Check for a short circuit condition at connector X-9002 pin 84.
Visually inspect connector X-9002 for corrosion, damage or a burnt condition.
From To Value
A. If there is any corrosion, damage or burning of the connector, repair as necessary. If the specified values are
not measured, there is a short circuit within connector X-9002. Repair as necessary.
B. If there are no faults found within the connector and the specified values are measured, check the ECU A-9000
for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
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3281 (DTC E72D)-Sensor supply 1 voltage is too low

NOTE: pin 84 in engine harness (EN) connector X-9002 may not be populated on some applications.
Context:
The Engine Control Unit (ECU) A-9000 monitors the ECU A-9000 24 V sensor supplies. If the A-9000 determines
that the sensor supply 1 voltage is too low, this fault will occur. The only pin associated with the 24 V sensor supply
1 is pin 84 in the engine harness (EN) connector X-9002.
Cause:
The A-9000 has determined that a sensor supply voltage is too low.
1. Short to ground at connector X-9002 pin 84.

2. Faulty ECU A-9000 engine harness (EN) connector X-9002, damaged or shows signs of corrosion.
Solution:
2. Check for a short to ground condition at the ECU A-9000 engine harness (EN) connector X-9002 pin 84.
Disconnect the engine harness (EN) from the ECU A-9000 at connector X-9002.
Visually inspect the connector X-9002 for corrosion, damage or a burnt condition.
With the key in the OFF position, use a multimeter to perform the following continuity check in the engine harness
(EN) connector X-9002 side:
From To Value
A. If there is any corrosion, damage or burning of the connector, repair as necessary. If there is continuity, there
is a short circuit within connector X-9002. Repair as necessary.
B. If no faults are found within the connector and the specified values are measured, leave connector X-9002
disconnected and continue to Step 3.
3. Check the ECU A-9000 24 V sensor supply 1.
With the key in the ON position, use a multimeter to perform the following voltage check on the ECU A-9000 pin:
From To Value
A-9000 pin 84 Chassis ground There should be approximately 24 V.
A. If there is approximately 24 V, check the ECU A-9000 for the appropriate software and re-flash, if necessary.
B. If there is not approximately 24 V, escalate an ASIST concern.
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has been resolved.
operation.
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3283-(DTC E32D)-ECU internal failure - Sensor 5 volt supply 2

Context:
The Engine Control Unit (ECU) A-9000 provides three independent 5.0 V voltage supplies for sensors. These voltages
are monitored by hardware within the ECU A-9000 to make sure they are within a given range. If sensor supply 2
reference voltage is out of range, this fault will occur.
Cause:
The ECU A-9000 sensor supply 2 reference voltage is out of range.
1. Faulty fuel filter pressure sensor B-9112 or sensor supply wire.

2. Faulty fan speed sensor B-9103 or sensor supply wire. (if equipped)
3. Faulty fuel filter clogging pressure sensor B-9006 or sensor supply wire.
4. Faulty inlet water pump pressure sensor B-9011 or sensor supply wire.
5. Faulty accelerator pedal position sensor B-9011 or sensor supply wire. (if equipped)
6. Faulty exhaust gas absolute pressure sensor B-9005 or sensor supply wire. (if equipped)
Solution:
2. The ECU A-9000 monitors this fault continuously. Disconnect each connector one at a time and use the EST to
monitor the status of DTC E32D - ECU internal failure - Sensor 5 volt supply 2.
- Pre filter pressure sensor B-9112 connector X-9179
- Fan speed sensor B-9103 connector X-9103
- Pre filter clogging pressure sensor B-9006 connector X-9019
- Inlet water pump pressure sensor B-9011 connector X-9027
- Accelerator pedal position sensor B-9011 connector X-9100 (if equipped)
- Exhaust gas absolute pressure sensor B-9005 connector X-9018
A. If DTC E32D - ECU internal failure - Sensor 5 volt supply 2 is eliminated after a connector disconnection,
the relevant component has failed. Replace the relevant component.
B. If DTC E32D - ECU internal failure - Sensor 5 volt supply 2 has not been eliminated after connector discon-
nection, leave all of the connectors disconnected and continue to Step 3.
3. Check the all of the supply 2 circuits for a short circuit condition.
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From To Value
X-9179 pin 1 Chassis ground There should be between 4.5 - 5.5 V.
A. If any of the circuits are not in the specified range, there is a short circuit condition in the relevant circuit. Locate
B. If all of the circuits are within the specified range, check the A-9000 for the appropriate software and re-flash,
if necessary.
has been resolved.
operation.
05 (55.100)
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3285-(DTC E42D)-ECU internal failure - Sensor 5 Volt supply 3

Context:
The Engine Control Unit (ECU) provides three independent 5.0 V voltage supplies for sensors. These voltages are
monitored by hardware within the ECU to make sure they are within a given range. If sensor supply 3 reference
voltage is out of range, this fault will occur.
Cause:
The ECU sensor supply 3 reference voltage is out of range.
1. Faulty humidity and ambient temperature sensor or sensor supply wire.

2. Faulty rail pressure sensor or sensor supply wire.
3. Faulty secondary cooling system outlet intercooler temperature and pressure sensor B-9012 or sensor supply
wire. (if equipped)
Solution:
2. The ECU monitors this fault continuously. Disconnect each connector one at a time and use the EST to monitor
the status of DTC E42D - ECU internal failure - Sensor 5 volt supply 3.
Intake air humidity and ambient temperature sensor B-9105 connector X-9105
Rail pressure sensor connector X-9026
Outlet intercooler temperature and pressure sensor B-9012 connector X-9028
From To Value
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if necessary.
has been resolved.
operation.
05 (55.100)
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3293-(DTC 2265)-Fuel rail pressure has exceeded maximum

positive deviation limits
Context:
For more information on the fuel system see Injection control - Dynamic description (55.010). The Engine Control
Unit (ECU) A158 monitors fuel pressure control. Fuel pressure is controlled by the fuel metering unit. If the ECU
determines that rail pressure is lower than expected based on engine speed dependant threshold, fuel rail pressure
has exceeded maximum positive deviation limits and this fault will occur.
Cause:
The ECU has determined that measured rail pressure is lower than the commanded pressure according to engine
speed dependant threshold.
1. Faulty fuel injectors, leaking.

2. Faulty Pressure Relief Valve (PRV), leaking.
6. Faulty low pressure fuel lines, air entrance, clogged or damaged.
7. Faulty electric fuel pump. (if equipped)
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3301-(DTC 1565)-Fuel rail pressure has exceeded maximum

negative deviation limits
Context:
For more information on the fuel system see Injection control - Dynamic description (55.010). The Engine Control
Unit (ECU) A158 monitors fuel pressure control. Fuel pressure is controlled by the fuel metering unit. If the ECU
determines that desired fuel pressure has been exceeded although the fuel metering unit is fully closed, fuel rail
pressure has exceeded maximum deviation limits and this fault will occur.
Cause:
The ECU has determined that desired fuel pressure has been reached despite the fuel metering unit being closed.

3. Faulty gear pump pressure.
4. Faulty low pressure fuel lines from high pressure pump to tank, clogged or damaged.
Solution:

2. Check the low pressure fuel lines from high pressure pump to tank for damage or clogging. Also check for proper
gear pump pressure.
A. If the lines show damage or signs of clogging, there may be blockage that is not allowing excess fuel to be
returned to the fuel tank. If gear pump pressure is excessive, a fuel rail pressure maximum negative deviation
condition may be present. Repair the fuel system as necessary.
B. If the lines are free of damage, clogging and the gear pump pressure is within the specified range, check the
ECU for the appropriate software and re-flash, if necessary.
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3305 (DTC 2765)-Fuel rail pressure has exceeded minimum limit

Context:
For more information on the fuel injection system, see Injection control - Dynamic description (55.010). The En-
gine Control Unit (ECU) A158 monitors the fuel rail pressure sensor for the appropriate fuel pressure. If the ECU
determines that fuel pressure is less than the necessary pressure needed to perform fuel injection, this fault will oc-
cur.
Cause:
The ECU has detected a fuel pressure less than 200.0 bar (2900.0 psi).
1. Faulty injectors, internal leakage or stuck open.

5. Faulty Pressure Relief Valve (PRV), leaking or stuck open.
6. Faulty electric lift pump. (if equipped)
7. Faulty gear pump pressure, too low.
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3309-(DTC 1865)-Fuel rail pressure has exceeded maximum limit

Context:
For more information on the fuel injection system, see Injection control - Dynamic description (55.010). The Elec-
tronic Control Unit (ECU) A-9000 monitors the fuel rail pressure sensor B-9004 for proper fuel pressure. If the ECU
A-9000 determines that fuel pressure is greater than 2000 bar (29000 psi), this fault will occur.
Cause:
The ECU A-9000 has detected a fuel pressure greater than 2000 bar (29000 psi) for a period greater than 1 s.
1. Faulty Y-9000 wiring, open circuit condition.

2. Faulty Y-9000, internal failure.
3. Faulty fuel return line, damaged or clogged.
Solution:
2. Check for the following possible related fault:
DTC 5255 - Fuel metering unit has an open load error
A. If the fault is active, troubleshoot it first and then return to this fault, DTC 1865 - Fuel rail pressure has ex-
ceeded maximum limit.

From To Value
A. If the value is within the specified range, continue to Step 4.
B. If the value is not within the specified range, the Y-9007 has failed internally. Replace the Y-9007.
4. Inspect the high pressure pump fuel return line for damage or blockage.
A. If there is damage or blockage, repair the fuel line as necessary.
B. If the fuel lines do not have any blockage or damage, check the ECU A-9000 for the appropriate software and
re-flash, if necessary.
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has been resolved.
operation.
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3334-(DTC 99BB)-CAN communication failure between vehicle

controller and ECU controller - TSC1_PE message
Context:
the CAN Node A Bus, internal to the ECU. The ECU receives and responds to Power take-off to Engine controller
(PE) information at two different rates (active and passive) dependant upon change request status. If the ECU is not
sensing the PE message at the passive rate, this fault will occur.
Cause:
The ECU is not properly sensing the PE message.

Solution:

From To Value
4.
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From To Value
From To Value
From To Value
circuit.
has been resolved.
operation.
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controller and ECU controller - TSC1_VE message
Context:
CAN Node A Bus, internal to the ECU. The ECU receives and responds to Torque/Speed Control (TSC) information
at two different rates (active and passive) dependant upon change request status. If the ECU is not sensing the TSC
message at the passive rate, this fault will occur.
Cause:
The ECU is not properly sensing the TSC message.

Solution:

From To Value
4.
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From To Value
Connector XA158, pin 3 Chassis ground There should be continuity.
From To Value
From To Value
circuit.
has been resolved.
operation.
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3361-(DTC E16D)-ECU internal failure - EEPROM write/read error

Context:
The Engine Control Unit (ECU) A158 has the capability of reading and writing values to flash or EEPROM. The ECU
monitors the reading and writing capability of this function. If the ECU determines that calibrated parameters for bad
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

Context:
The Engine Control Unit (ECU) A158 monitors the conversion from fuel quantity to torque for consistency during ECU
initialization. If a calibration error is detected during this test, this fault will occur.
Solution:
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3368-(DTC F6EF)-Torque limitation caused by performance limiter

Context:
This failure path is only for information. There was a performance limitation which was caused by too high NOx
emissions for longer than 60 s. If there is a power reduction greater than 15 % or an engine speed limitation is greater
than 5 % a fault is stored as confirmation that there was an active performance limitation. This failure is a confirmation
of the temporary power limitation. This failure does not ask for any action except, to check if another failure concerning
NOx emission is present in the failure memory. No actions are necessary due to this failure alone. If power reduction
occurred due to an 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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3370-(DTC F2EF)-Strong torque limitation from engine protection

active
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 one of the temperatures exceeds
the dedicated limit established by parameters programmed within the Engine Control Unit (ECU) A158. If a power
reduction is greater than 15.00 % or an engine speed limitation is greater than 5.00 % for more than 120.00 s, a
failure is stored as confirmation that there was an active performance limitation. This is not caused by a 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.
Cause:
One or more of the following failure modes may be the reason for the occurrence of this fault.
1. Oil temperature
2. Coolant temperature
3. Fuel temperature
4. Intake air temperature
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3371-(DTC F3EF)-Strong torque limitation from injection system

active
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 15.00 % or an engine speed limitation greater than 5.00 % for more than
120.00 s, a fault code was stored. This is not caused by a failure of a component or system. This fault code is for
information only and does not require any further action. 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.
Cause:
1. Dirty cooling package

2. Low fuel level
3. High pressure leak
4. Ambient conditions
5. Fuel tank location relative to heat source (overheated hydraulic tank, for example)
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3403-(DTC 8A22)-Starter relay low side ECU driver circuit over

temperature failure
Context:
The Engine Control Unit (ECU) A158 controls the voltage to the OK to start 1KCC. The ECU controls the voltage to
the starting relay K1-5. The ECU monitors the 1KCC low side control circuit for an over temperature/current condition.
If the ECU detects an over temperature/current condition in the 1KCC low side control circuit, this fault will occur.
Cause:
The ECU has detected an over temperature/current condition in the 1KCC low side control circuit.

2. Faulty 1KCC low side control circuit, short to high source condition.
3. Faulty the software of the ECU.
Solution:
3261 (DTC 6B22) - Starter relay low side driver circuit short to battery failure

Remove the 1KCC.
From To Value
B. If the value is not within the specified range, the 1KCC has failed internally. Replace the 1KCC.
4. Check the 1KCC low side control side for an over current condition.
From To Value
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A. If there is continuity, there is a short to high source/over current condition in the 1KCC low side control circuit,
wire BK 0.75. Locate and repair the shorted conductor.
5. Check the 1KCC low side control side for an over current condition.
From To Value
A. If there is voltage, there is a short to high source/over current condition in the 1KCC low side control circuit,
wire BK 0.75. Locate and repair the shorted conductor.
has been resolved.
operation.
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3425 (DTC 1438)-Under boost failure

Context:
The Electronic Control Unit (ECU) A-9000 monitors boost pressure using the intake boost pressure sensor B-9001.
If the A-9000 determines that boost pressure is lower than expected based on engine speed and ambient pressure.
Cause:
Boost pressure is lower than expected.
1. Operating in extreme environmental ambient pressures.

2. Boost leakage.
3. Restricted air filter.
4. Electronic Variable Geometric Turbocharger (EVGT) actuator sticking or blocked. (If equipped)
5. EVGT linkage disconnected or damaged. (If equipped)
6. Faulty turbocharger wastegate or linkage. (If equipped)
Solution:
DTC 1D64 - Intake manifold pressure sensor voltage is higher than expected
A. If the fault is active, diagnose it first and then return to this fault, DTC 1438 - Under boost failure.

3. Visually inspect the Electronic Variable Geometric Turbocharger (EVGT) actuation (If equipped). Verify that the
EVGT mechanism and linkage is properly attached and is not restricted or blocked in any way.
Visually inspect the turbocharger wastegate (If equipped). Verify that the linkage is not damaged or disconnected.
Verify that the machine is not being operated in extreme ambient pressure condition which may have triggered
this fault to occur.
Check for any boost leaks.
Check the air filter and air induction system for any clogging or blockage.
A. If any failures are found, repair as necessary.
B. If there are no failures found, continue to Step 4.

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From To Value
B. If the specified values are not measured, Locate and repair the faulty conductor.
Use the EST to verify the status of this fault, DTC 1438 - Under boost failure.
B. If the fault has not been resolved, continue to Step 6.

6. Replace turbocharger wastegate (if equipped) or replace EVGT (if equipped).
Use the EST to verify the status of this fault, DTC 1438 - Under boost failure.
has been resolved.
operation.
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3436-(DTC FBBF)-Inducement system is locked due to 3 detections

in 40 hours. The system must be reset using the dealer service tool
screen "Engine Restart Counter Reset"
NOTE: since this fault is part of the inducement strategy and has resulted in an inducement lock condition, it may be
necessary to perform the Engine Restart Counter Reset / Unlock Inducement configuration and/or SCR Fault Repair
Verification Test with the Electronic Service Tool (EST) before you return the machine to service, unless these were
both accomplished as part of the resolution of the fault causing this fault. See Selective Catalytic Reduction (SCR)
exhaust treatment - Configure - Engine restart counter reset (10.500) and/or Selective Catalytic Reduction
(SCR) exhaust treatment - Service instruction - SCR fault repair verification test (10.500) , if necessary.
Context:
This failure path is only for information. One or more of the inducement blocks has been detected as active at least
three times in the last 40 h by the Engine Control Unit (ECU) A158 which has caused the inducement system to lock.
The failure causing the inducement must be located, resolved and reset prior to reset of this fault. The EST is required
to release inducement.
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3438-(DTC 7A61)-Auxiliary power relay high side driver circuit short

to ground failure
Context:
The Engine Control Unit (ECU) A158 controls the voltage to the aux 1KAUX. The ECU monitors the 1KAUX high side
circuit for a short to ground condition. If the ECU detects a short to ground condition in the 1KAUX high side circuit,
Cause:
The ECU has detected a short to ground condition in the 1KAUX control circuit, high side.
1. Faulty 1KAUX coil.

2. Faulty 1KAUX high side control circuit, short to ground condition.
Solution:
2. Check the 1KAUX coil for an internal failure.
Remove the 1KAUX.
Use a multimeter to check the 1KAUX coil resistance.
From To Value
1KAUX, pin 85 1KAUX, pin 86 There should be between 70 - 130 Ω
A. If the value is within the specified range, leave the 1KAUX disconnected and continue with Step 3.
B. If the value is not within the specified range, the 1KAUX has failed internally. Replace the 1KAUX.
3. Check the 1KAUX high side control circuit for a short to ground condition.
From To Value
A. If there is continuity, there is a short to ground condition in the 1KAUX high side control circuit, wire WH 0.75.
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has been resolved.
operation.
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3439-(DTC 5B61)-Auxiliary power relay low side driver circuit open

failure
Context:
The Engine Control Unit (ECU) A158 controls the voltage to the aux 1KAUX. The ECU monitors the 1KAUX low side
circuit for an open circuit condition. If the ECU detects an open circuit condition in the 1KAUX low side circuit, this
fault will occur.
Cause:
The ECU has detected an open circuit condition in the 1KAUX control circuit, low side.

2. Faulty 1KAUX low side control circuit, open circuit condition.
Solution:
Remove the 1KAUX.
Use a multimeter to test the 1KAUX coil.
From To Value
A. If the value is within the specified range, leave 1KAUX disconnected and continue to Step 3.
B. If the value is infinite, the 1KAUX has failed internally. Replace the 1KAUX.
3. Check the 1KAUX low side control circuit for an open circuit condition.
From To Value
A. If there is no continuity, there is an open circuit condition in the 1KAUX low side control circuit, wire BK 0.75.
B. If there is continuity, connect the Connector X33-30 and proceed to the next step.
4. Disconnect the Connector X102.
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From To Value
A. If there is no continuity, there is an open circuit condition in the 1KAUX low side control circuit, wire BL 1.0.
B. If there is continuity, connect the Connector X102 and proceed to the next step.
5. Disconnect the Connector 1F1K.
From To Value
A. If there is no continuity, there is an open circuit condition in the 1KAUX low side control circuit, wire BL 1.0.
has been resolved.
operation.
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3440-(DTC 8322)-Auxiliary power relay low side ECU driver circuit

over temperature failure
Context:
circuit for an over temperature/current condition. If the ECU detects an over temperature/current condition in the
1KAUX low side circuit, this fault will occur.
Cause:
The ECU has detected an over temperature/current condition in the 1KAUX low side control circuit.
1. Faulty 1KAUX, coil.

2. Faulty 1KAUX, low side circuit wiring.
Solution:
Continue wiith Step 6.
3441 (DTC 6422) - Auxiliary power relay low side driver circuit short to battery failure

Remove the 1KAUX.
From To Value
A. If the value is within the specified range, continue with Step 4.
4. Check the 1KAUX low side control circuit for a short to high source condition.
Disconnect connector 1KAUX from the ECU.
From To Value
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A. If there is continuity, there is a short circuit condition in the 1KAUX low side circuit, wire BK 0.75. Locate and
5. Check the 1KAUX low side circuit for a short to key power condition.
From To Value
A. If there is voltage, there is a short to key power in the 1KAUX low side circuit, wire BK 0.75. Locate and repair
has been resolved.
operation.
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3441 (DTC 6422)-Auxiliary power relay low side driver circuit short
to battery failure
Context:
circuit for a short to high source condition. If the ECU detects a short to high source condition in the 1KAUX low side
circuit, this fault will occur.
Cause:
The ECU has detected a short to high source condition in the 1KAUX control circuit, low side.

2. Faulty 1KAUX low side control circuit, short to high source condition.
Solution:
Remove the 1KAUX.
From To Value
B. If the value is infinite, the 1KAUX has failed internally. Replace the 1KAUX.
3. Check the 1KAUX low side control circuit for a short to high source condition.
The key must in the ON position.
From To Value
A. If there is voltage, there is a short to high source condition in the 1KAUX low side control circuit, wire BK 0.75.
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has been resolved.
operation.
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3442-(DTC 7522)-Auxiliary power relay low side driver circuit short

to ground failure
Context:
control circuit for a short to ground condition. If the ECU detects a short to ground condition in the 1KAUX low side
circuit, this fault will occur.
Cause:
The ECU has detected a short to ground condition in the 1KAUX control circuit, low side.
1. Faulty 1KAUX, internal short.

2. Faulty 1KAUX low side control circuit, short to ground condition.
Solution:
Remove the 1KAUX.
From To Value
3. Check the 1KAUX low side control circuit for a short to ground condition.
Remove the 1KAUX.
From To Value
A. If there is continuity, there is a short to ground condition in the 1KAUX low side control circuit, wire BK 0.75.
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has been resolved.
operation.
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3443-(DTC F3A2)-Torque limitation due to excessive coolant

temperature
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:
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
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
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
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

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
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

Context:
The Engine Control Unit (ECU) A158 monitors engine speed using two software monitoring levels. Level one moni-
toring monitors engine control and components. Level two monitors for defective processes in level one monitoring.
If the ECU determines that there is a difference greater than 320.00 RPM between the two monitoring levels, a cali-
bration error is assumed and this fault will occur.
Solution:
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3450 (DTC 3398)-eVGT actuator blocked

Context:
The eVGT actuator A-9003 controller sends and receives information at regular intervals to and from the Engine
Control Unit (ECU) A-9000 via the engine Controller Area Network (CAN). If the eVGT actuator A-9003 controller
determines that a control failure exists, this fault will occur.
Cause:
The ECU A-9000 has reported, via the engine sensor CAN bus, that the eVGT actuator A-9003 controller has reported
that a control failure exists.

3. Faulty eVGT actuator A-9003 controller, hardware or firmware.
Solution:
2. Check the eVGT actuator A-9003 controller supply voltage.
Disconnect the engine (EN) harness from the eVGT actuator A-9003 controller at connector X-9012.
With the key switch in the ON position, use a multimeter to check for voltage on the engine (EN) harness side:
From To Value
X-9012 pin 4 X-9012 pin 3 There should be 24 V .

3. Determine the condition of the eVGT actuator A-9003 controller CAN circuit.
With the key switch in the OFF position, use a multimeter to measure the resistance of the CAN connection on the
engine (EN) harness side:
From To Value

4. Check for other engine CAN faults.
Use EST to determine if other CAN faults exist.
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A. If other faults do exist, use the appropriate vehicle service manual information to locate and repair the faulted
CAN condition.
B. If no other faults exist, the vehicle (VE) or engine (EN) harness wiring is damaged between the network harness
splice and the eVGT actuator A-9003 controller connector X-9012 pin 4 and/or X-9012 pin 3, wire VE-218 or
EN-049A and/or VE-189B or EN-050A for supply power and ground or X-9012 pin 2 and/or X-9012 pin 1, wire
VE-194B or EN-047C and/or VE-201F or EN-048C for CAN signal. Locate and repair the damage to the supply
or CAN circuit wiring.
5. Check for mechanical binding and/or damage.
Verify that the eVGT mechanism and linkage is properly attached and is not restricted or blocked in any way.
Manually move the linkage to assure that it operates freely.
A. If the eVGT mechanism is free of debris and operates freely, continue with Step 6.
B. If the eVGT mechanism contains debris or is hard to operate, clean, adjust, repair or replace, as required.
6. As there is no method for field testing or re-flashing the eVGT actuator A-9003 controller, replace the eVGT actu-
ator A-9003 controller. Check to see that the fault is resolved.
has been resolved.
operation.
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3457-(DTC 1374)-Intake manifold temperature sensor voltage is

NOTE: because this fault causes inducement, it is necessary to perform the Engine Restart Counter Reset / Unlock
Inducement configuration once the fault has been resolved. See Selective Catalytic Reduction (SCR) exhaust
treatment - Configure - Engine restart counter reset (10.500), if necessary.
Context:
The Electronic Control Unit (ECU) A-9000 monitors the intake manifold temperature sensor B-9001 for a voltage
higher than expected condition. If a voltage higher than expected condition is detected and this fault occurs, the
A-9000 will jump to a fixed intake manifold temperature replacement value of 29.96 °C (85.93 °F).
Cause:
The A-9000 has detected a voltage greater than 4.93 V for longer than 500 ms in the B-9001 temperature signal
circuit.
1. Faulty B-9001 temperature signal wire, shorted to high source or open circuit condition.
Solution:
From To Value
A. If there is continuity, leave X-9003 and X-9002 disconnected and continue to Step 3.
B. If there is no continuity, there is an open circuit condition in the B-9001 temperature signal circuit, wire EN-005.
3. Check the B-9001 temperature signal circuit for a short to high source condition.
From To Value
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A. If there is continuity, there is short to high source condition in the B-9001 temperature signal circuit, wire EN-005.

From To Value

A. If the fault has been resolved, use the EST, see Selective Catalytic Reduction (SCR) exhaust treatment -
Configure - Engine restart counter reset (10.500) if necessary. to perform the Engine Restart Counter Reset
/ Unlock Inducement configuration. Then return the machine to service.
has been resolved.
operation.
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3458-(DTC 15E3)-Crankcase pressure too high

Context:
The Engine Control Unit (ECU) A158 monitors crankcase pressure by the crankcase pressure sensor. If the ECU
determines that crankcase pressure is too high, this fault will occur.
Cause:
Crankcase pressure is too high.
1. Faulty crankcase pressure sensor, wiring or internal failure.

2. Faulty engine oil level, too high.
3. Faulty blow by filter, clogged.
4. Faulty Positive Crankcase Ventilation (PCV) valve.
5. Faulty piston rings.
Solution:
1. The following faults may have caused this fault to occur. Use the Electronic Service Tool (EST) to verify the status
of these faults and diagnose first if necessary.
3624 (DTC 13A3) - Crankcase pressure sensor voltage is higher than expected
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3459-(DTC 1BD3)-Oil temperature too high

Context:
The Engine Control Unit (ECU) A158 monitors oil temperature by the oil pressure sensor with oil temperature sensor.
The value is processed by the analog to digital converter, internal to the ECU, into a physical oil temperature value.
If the ECU determines that the oil temperature value is too high, this fault will occur.
Cause:
The ECU has detected an oil temperature value greater than 174.96 °C.
1. Faulty oil pressure sensor with oil temperature sensor, implausible value.
Solution:
1. Replace the oil pressure sensor with oil temperature sensor.
Use the Electronic Service Tool (EST) to verify the status of this fault.
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3460-(DTC 2CD3)-Oil temperature too low

Context:
The Electronic Control Unit (ECU) A-9000 monitors oil temperature by the oil temperature sensor B-9000. The value
is processed by the analog to digital converter, internal to the A-9000, into a physical oil temperature value. If the
A-9000 determines that the oil temperature value is too low, this fault will occur.
Cause:
The A-9000 has detected an oil temperature value less than -35.04 °C.
1. Extreme ambient operating temperatures.

2. Faulty B-9000, implausible value.
Solution:
From To Value
A. If there is continuity, there is a short to ground in the B-9000 temperature signal circuit, wire EN-009. Locate

Use the Electronic Service Tool (EST) to verify the status of 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
Context:
The Engine Control Unit (ECU) A158 performs shut off paths which deactivate all power stages relevant to fuel in-
jection if certain internal ECU errors are detected. In order to test this function, every path is shortly activated during
ECU 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
Context:
ECU 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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3475-(DTC 9D63)-CAN timeout error from coolant water pump

actuator
Context:
For information regarding the functional operation of the Electric water pump A-91NN refer to eVGT actuator - Func-
tional description. The Electric water pump A-9105 controller is required to report information at regular intervals to
the Engine Control Unit (ECU) A-9000 via Controller Area Network (CAN). If this information is not communicated
within the allotted time frame, this ECU A-9000 timeout fault will occur.
Cause:
The ECU A-9000 has reported, via the engine sensor CAN bus, that an Electric water pump A-9105 controller timeout
has occurred.

3. Faulty Electric water pump A-9105 controller, hardware or firmware.
Solution:
2. Check for Electric water pump A-9105 controller supply voltage.
Disconnect the VE harness from the Electric water pump A-9105 actuator controller at connector X-9126 .
Use a multimeter to check for voltage on the EN harness side:
From To Value
A. If the voltage is present, continue with Step 3.

3. Determine the condition of the Electric water pump A-9105 controller CAN circuit.
Disconnect the VE harness from the Electric water pump A-9105 actuator controller at connector X-9126.
Use a multimeter to measure the resistance of the CAN connection on the VE harness side:
From To Value
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A. If other faults do exist, refer to Controller Area Network (CAN) data bus - Test (55.640) to locate and repair
B. If no other faults exist, the VE harness wiring is damaged between the power, ground, or network harness
splice and the Electric water pump A-9105 controller connector X-9126 pin 3, X-9126 pin 4 and/or X-9126 pin
2, wire BATT+ 16 (RD), IGN 11 (OR) and/or BATT- 8 (BK), for supply power and ground or X-9126 pin 1 and/or
X-9126 pin 6, wire CANH 2 12 (YE) and/or CANL 2 12 (GN) for CAN signal. Locate and repair the damage to
the ATS CAN circuit wiring.
5. As there is no method for field testing or re-flashing the Electric water pump A-9105 controller, replace the Electric
water pump A-9105 unit.
Then check to see that the fault is resolved.
has been resolved.
operation.
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3501-(DTC E1FD)-ECU internal failure - Software resets in DSM 0

Context:
The Engine Control Unit (ECU) A158 monitors for a possible error to the ECU internal software. If the ECU 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

Context:
The Engine Control Unit (ECU) A158 monitors for a possible error to the ECU internal software. If the ECU 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:
From To Value
A. If there is not approximately 24 V, charge the battery and then perform load test on the battery. If the battery

The key must be in the ON position for voltage and OFF position for continuity.
From To Value
failed conductor.
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has been resolved.
operation.
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3503-(DTC EF1D)-ECU internal failure - software resets in DSM

Context:
The Engine Control Unit (ECU) A158 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

Context:
The Engine Control Unit (ECU) A158 controls the voltage to the starter relay. The ECU receives the crank signal from
the ignition switch then energizes the starter relay. If the ECU has determines that the crank signal input has been
high for too long, this fault will occur.
Cause:
The ECU has detected that terminal 50, ECU pin 63, has been high for too long indicating that the engine has been
cranked for too long or there is a failure in key switch circuit.
1. Engine cranked for an excessive period of time.

2. Faulty OK to start 1KCC, wiring
3. Faulty key switch S1, internal failure or wiring.
Solution:
3258 (DTC 6722) - Starter relay high side driver circuit short to battery failure
3262 (DTC 7C22) - Starter relay low side driver circuit short to ground failure

3. Check the S1 wiring.
The key must be in OFF position.
From To Value
A. If there is continuity, there is a short circuit in the S1 wiring. Locate and repair the shorted conductor.

4. Check the S1 wiring.
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From To Value
A. If there is voltage there is a short circuit in the S1 wiring. Locate and repair the shorted conductor.

5. Replace the S1.
has been resolved.
operation.
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3508 (DTC FAEF)-Torque limitation active

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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3517-(DTC 19C4)-Ambient temperature sensor voltage is higher

than expected
Context:
The Engine Control Unit (ECU) A158 monitors the sensor humidity and temperature B-055 for a short to high source
or open circuit condition. If the ECU determines that a short to high source or open circuit condition is present in the
B-055, this fault will occur.
Cause:
The ECU has detected a voltage greater than 4.95 V for longer than 500 ms in the B-055 temperature signal circuit.
1. Faulty B-055 temperature signal wire, shorted to high source or open circuit.
Solution:
Disconnect the Connector XB-055.
From To Value
Connector XA158, pin 40 Connector XB-055, pin 4 There should be continuity
A. If there is continuity, leave the Connector XB-055 and Connector XA158 disconnected and continue to Step
3.
B. If there is no continuity, there is an open circuit condition in the B-055 temperature signal circuit, wire WH 0.5.
3. Check the B-055 temperature signal circuit for a short to high source condition.
From To Value
A. If there is continuity, there is short to high source condition in the B-055 temperature signal circuit, wire WH
0.5. Locate and repair the shorted conductor.
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4. Check the B-055 temperature signal circuit for a short to key power condition.
From To Value
A. If there is voltage, there is a short to key power in the B-055 temperature signal circuit, wire WH 0.5. Locate

Use the EST to verify that this fault has been resolved.
has been resolved.
operation.
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3518-(DTC 2AC4)-Ambient temperature sensor voltage is lower

than expected
Context:
The Engine Control Unit (ECU) A158 monitors the sensor humidity and temperature B-055 signal circuit. If the ECU
determines that the voltage in the temperature signal circuit of the B-055 is lower than expected or if the machine is
being operating in extremely low ambient conditions, this fault will occur. If this fault occurs, the ambient temperature
value will be frozen by the ECU at the last valid value or to a fixed replacement value of 38.96 ° if the failure is vali-
dated. Before diagnosing this fault as an electrical failure, verify that this fault is active in normal operating ambient
temperatures.
Cause:
The ECU has detected a voltage less than 200 mV for longer than 500 ms in the B-055 temperature signal circuit.
1. Extremely low ambient operating temperatures.

2. Faulty B-055 temperature signal wire, shorted to ground.
Solution:
From To Value
A. If there is continuity, there is short to ground condition in the B-055 temperature signal circuit, wire WH 0.5.

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has been resolved.
operation.
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3525-(DTC E18E)-Downstream NOx sensor internal failure (Open

Circuit Error)
Selective Catalytic Reduction (SCR) exhaust treatment - Configure - Engine restart counter reset (10.500), if
necessary.
Context:
For information regarding the functional operation of the smart Selective Catalytic Reduction SCR downstream NOx
sensor B-054 see Nitrogen Oxide (NOx) sensor - Dynamic description (55.988). The B-054 has internal monitoring
for open wire or short circuit and sends an error status in case of a detected failure. This failure is the result of an
open circuit error in the sensor NOx and/or Oxygen level circuit.
Cause:
The B-054 has reported, via CAN, to the Engine Control Unit (ECU) A158 that an open circuit condition exists in the
NOx and/or Oxygen level circuit.
1. Faulty B-054, hardware or firmware.

Solution:
Use the EST to check the status of this fault.
Then use the EST, see Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data (Downstream sensor)
(55.988), if necessary, to perform the Replacement of the Nox Downstream Sensor - Reset ECU Data configura-
tion.
Then check to see that this fault is resolved.
A. If this fault is resolved, use the EST, see Selective Catalytic Reduction (SCR) exhaust treatment - Con-
figure - Engine restart counter reset (10.500) if necessary, to perform the Engine Restart Counter Reset /
Unlock Inducement configuration. Then return the machine to service.
B. If this fault is not resolved, check the ECU for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
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3526-(DTC E28E)-Downstream Nox sensor internal failure (Short

Circuit Error)
necessary.
Context:
for open wire or short circuit and sends an error status in case of a detected failure. This failure is the result of a short
circuit error in the sensor NOx and/or Oxygen level circuit.
Cause:
The B-054 has reported, via CAN, to the Engine Control Unit (ECU) A158 that a short circuit condition exists in the
NOx and/or Oxygen level circuit.

Solution:
Then use the EST, refer to Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data (Downstream sensor)
(55.988), if necessary, to perform the Replacement of Nox Downstream Sensor - Reset ECU Data configuration.
has been resolved.
operation.
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3528-(DTC 319E)-Downstream NOx sensor values are not plausible

Context:
For information regarding the functional operation of the smart Selective Catalytic Reduction (SCR) downstream NOx
sensor B-054 see Nitrogen Oxide (NOx) sensor - Dynamic description (55.988). The B-054 delivers information
about its error status and the results of self diagnosis procedure, via CAN, to the Engine Control Unit (ECU). If the
SCR downstream NOx sensor sends the message Lambda or NOx signal not plausible, this fault will occur.
Cause:
The B-054 has reported, via CAN, to the Engine Control Unit (ECU) A158 that the Lambda or NOx signal is not
plausible.
Solution:
1. Check for related fault.
Use the Electronic Service Tool (EST) to check for fault 19071 (DTC 2DDA) - SCR catalyst efficiency lower than
first NOx production threshold level.
A. If fault 19071 (DTC 2DDA) - SCR catalyst efficiency lower than first NOx production threshold level is
present, the B-054 is poisoned. Replace the B-054. Then use EST, see Nitrogen Oxide (NOx) sensor -
Configure - Reset ECU data (Downstream sensor) (55.988), if necessary, to perform the Replacement of
Nox Downstream Sensor - Reset ECU Data configuration.
B. If fault 19071 (DTC 2DDA) - SCR catalyst efficiency lower than first NOx production threshold level is
not present, ignore this fault.
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3529-(DTC E16E)-Downstream NOx sensor internal failure (Heater

Open Circuit Error)
necessary.
Context:
for open wire or short circuit and sends an error status in case of a detected failure. This failure is the result of an
open circuit error in the sensor heater circuit.
Cause:
The B-054 has reported, via CAN, to the Engine Control Unit (ECU) A158 that an open circuit condition exists in the
heater control circuit.

Solution:
(55.988), if necessary, to perform the Replacement of the Nox Downstream Sensor - Reset ECU Data configura-
tion.
figure - Engine restart counter reset (10.500), if necessary, to perform the Engine Restart Counter Reset /
has been resolved.
operation.
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3530-(DTC E26E)-Downstream NOx sensor internal failure (Heater

Short Circuit Error)
necessary.
Context:
for open wire or short circuit and sends an error status in case of a detected failure. This failure is the result of a short
circuit error in the sensor heater circuit.
Cause:
The B-054 has reported, via CAN, to the Engine Control Unit (ECU) A158 that a short circuit condition exists in the
heater control circuit.

Solution:
Then use the EST, refer to Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data (Downstream sensor)
(55.988), if necessary, to perform the Replacement of Nox Downstream Sensor - Reset ECU Data configuration.
has been resolved.
operation.
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3531-(DTC A36E)-Downstream NOx sensor internal failure (Heater

Performance Plausibility Error)
Context:
and delivers information about its error status and the results of self diagnosis procedure, via CAN, to the Engine
Control Unit (ECU) A158. One of the monitored conditions is whether or not the SCR downstream NOx sensor A-9102
reached the appropriate operating temperature within the allotted time. Once the dew point has been reached, the
sensor has 120.0 s to reach heat up. If the sensor heat up is not completed in time, this fault will occur.
Cause:
The B-054 has reported, via CAN, to the ECU that the sensor failed to reach heater working temperature in the allotted
time.

Solution:
2. Check for other relevant faults.
Use the EST to check for the presence of fault 19050 (DTC 478E) - Downstream NOx sensor supply voltage
is out of range.
A. If fault 19050 (DTC 478E) - Downstream NOx sensor supply voltage is out of range is present, resolve
fault 19050 (DTC 478E) - Downstream NOx sensor supply voltage is out of range. Then check that this
fault is also resolved.
B. If fault 19050 (DTC 478E) - Downstream NOx sensor supply voltage is out of range is not present, continue
with Step 3.
Then use EST, see Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data (Downstream sensor) (55.988)
if necessary, to perform the Replacement of the Nox Downstream Sensor - Reset ECU Data configuration.
Run the machine and use the EST capability to view parameters to verify that the sensor has reached dew point.
A. If this fault is resolved, return the machine to service.
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has been resolved.
operation.
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3533 (DTC 9D6E)-CAN timeout error from downstream NOx sensor

necessary.
Context:
The Selective Catalytic Reduction (SCR) downstream NOx sensor B-054 is required to report information at regular
intervals to the Engine Control Unit (ECU) A158 via CAN. If this information is not communicated within the allotted
time frame, this ECU timeout fault will occur.
Cause:
The ECU has reported, via the engine sensor CAN bus, that a B-054 timeout of the B-054 message has occurred.

Solution:
2. Check for the presence of supply voltage fault.
Use EST to determine the presence of fault 19050 (DTC 478E) - Downstream NOx sensor supply voltage is
out of range.
A. If fault 19050 (DTC 478E) - Downstream NOx sensor supply voltage is out of range is present, resolve
fault 19050 (DTC 478E) - Downstream NOx sensor supply voltage is out of range. Then check that this
B. If fault 19050 (DTC 478E) - Downstream NOx sensor supply voltage is out of range is not present, continue
with Step 3.
3. Determine the condition of the SCR downstream NOx sensor CAN circuit.
Disconnect the After Treatment System (ATS) vehicle (VE) harness from the B-054 at the Connector XB-054.
Use a multimeter to measure the resistance of the CAN circuit on the ATS vehicle (VE) harness side:
From To Value
Connector XB-054, pin 3 Connector XB-054, pin 4 There should be 60 Ω

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(55.988) if necessary, to perform the Replacement of Nox Downstream Sensor - Reset ECU Data configuration.
5. Check for other engine ATS CAN faults.
A. If other faults do exist, see Controller Area Network (CAN) data bus - Test (55.640) to locate and repair the
faulted condition.
B. If no other faults exist, the ATS vehicle (VE) harness wiring is damaged between the network harness splice
and the B-054 Connector XB-054, pin 3 and/or Connector XB-054, pin 4, wire GN 0.75 and/or YE 0.75.
Locate and repair the damage to the ATS CAN circuit wiring.
has been resolved.
operation.
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3549 (DTC 1C54)-Intake air humidity sensor voltage is higher than

expected for too long
Context:
The Engine Control Unit (ECU) A158 monitors the efficiency of the sensor humidity and temperature B-055. The
B-055 is sensitive to water droplets, which can cause a short to high source condition. Normally, the sensor will dry
after a few minutes of engine operation. If the ECU detects that this fault is still present 8.00 min after engine start,
it is assumed that this is a short to high source electrical failure that is not related to water droplets and this fault will
occur.
Cause:
The ECU has detected a voltage greater than 3.6 V for a period greater than 500 ms after 8.00 min of engine start.
1. Faulty B-055, wet condition for a period greater than 8.00 min.
3. Faulty B-055 humidity signal wire, shorted to power.
Solution:
From To Value
A. If there is continuity, there is short to high source condition in the B-055 signal circuit, wire WH 0.5. Locate and

From To Value
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A. If there is voltage, there is a short to key power condition in the B-055 signal circuit, wire WH 0.5. Locate and

has been resolved.
operation.
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3557-(DTC FB54)-Intake air humidity sensor voltage is higher than

expected
Context:
The Engine control Unit (ECU) A158 monitors the voltage of the sensor humidity and temperature B-055 signal circuit.
The B-055 is sensitive to water droplets, which can cause a voltage higher than expected condition. Normally, the
sensor will dry after a few minutes of engine operation. Two stage monitoring is conducted to verify if water droplets
or an actual electrical failure is the cause of a voltage higher than expected reading by the ECU. If this fault occurs,
the ECU has determined that water droplets into the B-055 is the cause.
Cause:
The ECU has detected a voltage greater than 3.6 V for a period greater than 500 ms after engine start caused by
water droplets into the B-055.
Solution:
3549 (DTC 1C54) - Intake air humidity sensor voltage is higher than expected for too long
B. If the fault is not active, the B-055 is experiencing a temporary short circuit condition due to water droplets into
the sensor. This fault should resolve itself after a approximately 8.00 - 10.00 min of engine operation. If the
fault remains active after approximately 8.00 - 10.00 min and 3549 (DTC 1C54) - Intake air humidity sensor
voltage is higher than expected for too long does not set, check the ECU for the appropriate software and
has been resolved.
operation.
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3565-(DTC F11F)-SCR inducement warning due to distance/time

is active - Level 1
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. See Selective Catalytic
Reduction (SCR) exhaust treatment - Configure - Engine restart counter reset (10.500), if necessary.
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 Unit (ECU) A158 predetermined length of time will trigger this fault.
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is active - Level 2
Context:
an Engine Control Unit (ECU) A158 predetermined length of time will trigger this fault. Since this fault is part of the
inducement strategy, it may be necessary to perform the Engine Restart Counter Reset / Unlock Inducement configu-
ration 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. See Selective Catalytic Reduction (SCR) exhaust treatment
- Configure - Engine restart counter reset (10.500), if necessary.
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3581-(DTC FD8F)-Torque limitation is active

Context:
an Engine Control Unit (ECU) A158 predetermined length of time will trigger this fault.
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3594-(DTC F7EF)-Torque limitation caused by SCR catalyst

protection
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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is active - Level 4
Context:
this fault to occur. Any one of many Selective Catalytic Reduction (SCR) displayed faults that remains active for
an Engine Control Unit (ECU) A158 predetermined length of time will trigger this fault. Since this fault is part of
the inducement strategy that may result in an inducement lock condition, it may be necessary to perform the Engine
Restart Counter Reset / Unlock Inducement configuration and/or SCR Fault Repair Verification Test with the Electronic
Service Tool (EST) before you return the machine to service, unless these were both accomplished as part of the
resolution of the fault causing this fault. See Selective Catalytic Reduction (SCR) exhaust treatment - Configure
- Engine restart counter reset (10.500) and/or Selective Catalytic Reduction (SCR) exhaust treatment - Service
instruction - SCR fault repair verification test (10.500) , if necessary.
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3614 (DTC E698)-eVGT motor effort too high

Context:
The eVGT actuator controller sends and receives information at regular intervals to and from the Engine Control Unit
(ECU) A158 via the engine Controller Area Network (CAN). The eVGT actuator controller provides and monitors a
Pulse Width Modulated (PWM) signal to the eVGT actuator motor used to operate the eVGT mechanism. An upper
threshold of 80 % signal On-time for 60.00 s exists to determine whether the eVGT is operating properly mechanically.
If the eVGT actuator controller exceeds this threshold, this fault will occur.
Cause:
The ECU has reported, via the engine sensor CAN bus, that the eVGT actuator controller has reported that too much
effort is required to operate the eVGT.
1. Faulty eVGT actuator mechanism, mechanically blocked or stuck.
Solution:
1. Check eVGT actuator mechanism operation.
A. If the eVGT mechanism contains debris or is hard to operate, then clean, adjust, repair or replace, as required.
B. If the eVGT mechanism is free of debris and operates freely, check the ECU for the appropriate software and
re-flash, if necessary
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3616-(DTC F1EF)-Torque limitation caused by turbo charger

protection
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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3617-(DTC FB8F)-SCR inducement warning due to distance/time

is active - Level 9
Context:
This fault is only for informational purposes and requires no action other than the resolution of the active fault 19071
(DTC 2DDA) - SCR catalyst efficiency lower than first NOx production threshold level which after an Engine Con-
trol Unit (ECU) A158 predetermined length of time causes this fault to occur. Since this fault is part of the inducement
strategy that may result in an inducement lock condition, it may be necessary to perform the Engine Restart Counter
Reset / Unlock Inducement configuration and/or SCR Fault Repair Verification Test with the Electronic Service Tool
(EST) before you return the machine to service, unless these were both accomplished as part of the resolution of the
fault causing this fault. See Selective Catalytic Reduction (SCR) exhaust treatment - Configure - Engine restart
counter reset (10.500) and/or Selective Catalytic Reduction (SCR) exhaust treatment - Service instruction -
SCR fault repair verification test (10.500) , if necessary.
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3619-(DTC F5AF)-SCR inducement warning due to distance/time

is active - Level 7
Context:
(DTC 4BCA) - DEF/AdBlue concentration is out of range which after an Engine Control Unit (ECU) A158 predeter-
mined length of time causes this fault to occur. 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. See Selective Catalytic Reduction (SCR) exhaust treatment - Configure - Engine restart counter reset
(10.500), if necessary.
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is active - Level 8
Context:
(DTC 4BCA) - DEF/AdBlue concentration is out of range which after an Engine Control Unit (ECU) A158 prede-
termined length of time causes this fault to occur.
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is active - Level 5
Context:
this fault to occur. Any one of many Selective Catalytic Reduction (SCR) displayed faults that remains active for
an Engine Control Unit (ECU) A158 predetermined length of time will trigger this fault. Since this fault is part of
the inducement strategy that may result in an inducement lock condition, it may be necessary to perform the Engine
Restart Counter Reset / Unlock Inducement configuration and/or SCR Fault Repair Verification Test with the Electronic
Service Tool (EST) before you return the machine to service, unless these were both accomplished as part of the
resolution of the fault causing this fault. See Selective Catalytic Reduction (SCR) exhaust treatment - Configure
- Engine restart counter reset (10.500) and/or Selective Catalytic Reduction (SCR) exhaust treatment - Service
instruction - SCR fault repair verification test (10.500) , if necessary.
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3623-(DTC 3CAE)-Downstream NOx sensor lambda signal deviation

- NOx sensor possible removal detected
necessary.
Context:
for operating conditions and reports status along with sensed data. If the sensor lambda data value is outside the
values established by the minimum/maximum curves specified in the Engine Control Unit (ECU) A158, dependent on
the lambda value itself, this fault will occur.
Cause:
The ECU has determined that the B-054 is not measuring correct lambda values.

Solution:
1. Determine proper installation of the B-054.
Remove and re-install, if necessary, the B-054 to assure that it is properly aligned and securely installed.
A. If the fault is resolved, use EST, see Selective Catalytic Reduction (SCR) exhaust treatment - Configure
- Engine restart counter reset (10.500), if necessary, to perform the Engine Restart Counter Reset / Un-
lock Inducement configuration. Then perform the SCR Fault Repair Verification Test, see Selective Catalytic
B. If the fault is not resolved, continue with Step 2.

A. If the fault is resolved, use EST to perform the SCR Fault Repair Verification Test, see Selective Catalytic
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3624-(DTC 13A3)-Crankcase pressure sensor voltage is higher

than expected
Context:
The Engine Control Unit (ECU) A-9000 monitors the crankcase pressure sensor B-9009 signal circuit. If the A-9000
determines that the voltage in the pressure signal circuit is higher than expected, this fault will occur.
Cause:
circuit.

2. Faulty B-9009 pressure signal circuit, short to high source or open circuit condition.
Solution:
From To Value
A. If there is continuity, leave the connectors disconnected and continue to Step 3.
From To Value
A. If there is continuity, there is a short to high source condition in the B-9009 signal circuit, wire EN-045. Locate
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From To Value

Use the EST to verify that DTC 13A3 - Crankcase pressure sensor voltage is higher than expected has been
resolved.
has been resolved.
operation.
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3625-(DTC 24A3)-Crankcase pressure sensor voltage is lower than

expected
Context:
The Engine Control Unit (ECU) A-9000 monitors the crankcase pressure sensor B-9009 pressure signal circuit. If the
A-9000 determines that the voltage in the pressure signal circuit is lower than expected, this fault will occur.
Cause:
circuit.

Solution:
From To Value

Use the EST to verify that DTC 24A3 - Crankcase pressure sensor voltage is lower than expected has been
resolved.
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has been resolved.
operation.
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3626-(DTC 37B3)-Crankcase pressure has exceeded tolerance limit

Context:
The Engine control Unit (ECU) A158 monitors crankcase pressure during after using the crankcase pressure sensor.
If the ECU determines that crankcase pressure is greater than 12.04 cm H₂₂O (4.74 in H₂₂O) during after run, this fault
will occur.
Cause:
The ECU has determined that crankcase pressure has exceeded 12.04 cm H₂₂O (4.74 in H₂₂O) during after run.
1. Excessive crankcase pressure.

2. Faulty PCV valve, positive crankcase ventilation.
4. Faulty crankcase pressure sensor, wiring or internal failure.
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3628-(DTC 22A3)-Crankcase pressure too low

Context:
The Engine Control Unit (ECU) A158 monitors crankcase pressure by the crankcase pressure sensor. If the ECU
determines that crankcase pressure is lower than –0.05 bar, this fault will occur.
Cause:
The ECU has determined that crankcase pressure is too low.
1. Faulty crankcase pressure sensor, wiring.

2. Faulty crankcase pressure sensor, internal failure.
Solution:
3625 (DTC 24A3) - Crankcase pressure sensor voltage is lower than expected

3. Replace the crankcase pressure sensor.
has been resolved.
operation.
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3638-(DTC F4EF)-Torque limitation caused by engine brake

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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3647 (DTC 1338)-Over boost failure

Context:
The Engine Control Unit (ECU) A-9000 monitors boost pressure using the intake boost pressure sensor B-9001. If
the A-9000 determines that boost pressure is higher than expected based on engine speed and ambient pressure.
Cause:
Boost pressure is higher than expected.
1. Higher than normal environmental ambient pressure.

2. Electronic Variable Geometric Turbocharger (EVGT) actuator sticking or blocked. (If equipped)
3. EVGT linkage disconnected or damaged. (If equipped)
4. Faulty turbocharger wastegate or linkage. (If equipped)
Solution:
DTC 1D64 - Intake manifold pressure sensor voltage is higher than expected
A. If the fault is active, diagnose it first and then return to this fault, DTC 1338 - Over boost failure.

3. Visually inspect the Electronic Variable Geometric Turbocharger (EVGT) actuation (If equipped). Verify that the
EVGT mechanism and linkage is properly attached and is not restricted or blocked in any way.
Visually inspect the turbocharger wastegate (If equipped). Verify that the linkage is not damaged or disconnected.
Verify that the machine is not being operated in extreme ambient pressure condition which may have triggered
this fault to occur.
A. If any failures are found, repair as necessary.
B. If there are no failures found, continue to Step 4.

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From To Value
B. If the specified values are not measured, Locate and repair the faulty conductor.
Use the EST to verify the status of this fault, DTC 1338 - Over boost failure.

6. Replace turbocharger wastegate (if equipped) or replace EVGT (if equipped).
Use the EST to verify the status of this fault, DTC 1338 - Over boost failure.
has been resolved.
operation.
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3652-(DTC 911B)-CAN A Bus off passive failure

Context:
CAN Node A Bus, internal to the ECU. If the ECU senses that CAN Node A Bus is not functioning properly, this fault
will occur.
Cause:
ECU has sensed a “Bus Off” state to be present at the CAN Node A.

Solution:
A. If other vehicle CAN faults do exist, resolve the vehicle CAN faults, then check that this fault is also resolved.
B. If other vehicle CAN faults do not exist, continue with Step 3.

Disconnect the vehicle (VE) harness from the ECU at the connector Connector XA158.
From To Value
Connector XA158, pin 1 chassis ground There should be 24 V
4.
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From To Value
Connector XA158, pin 3 chassis ground There should be continuity
From To Value
From To Value
circuit.
has been resolved.
operation.
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3680-(DTC E536)-Engine speed limitation via fuel injection cut off

is active
Context:
This is an information only fault and requires no action, another active fault has caused this fault to occur. The Engine
Control Unit (ECU) A158 performs fuel injection cut off to limit engine speed to a controllable range. This procedure
is triggered if engine speed has exceeded 1200 RPM and if certain ECU internal failures which concern the reliability
of the accelerator pedal signal, fuel injection parameters or engine speed are detected. If this fault occurs, this fuel
injection cut off procedure is active.
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3686 (DTC 3D1C)-DOC upstream temperature sensor signal drift

at cold start
Context:
The Engine Control Unit (ECU) A158 monitors the DOC upstream exhaust gas temperature sensor B-049 signal. If
the ECU determines that ambient pressure is at least 0.8 bar (11.6 psi) and the last driving cycle was for longer than
5.00 s with a temperature of at least 70.0 °C (157.9 °F) at least once, this fault will occur.
Cause:
The ECU determines that the B-049 temperature signal has drifted at cold start.
1. Sudden change in ambient temperature.

Solution:
2. Check the following related faults:
19066 (DTC 1899) - Upstream oxidation catalyst temperature sensor voltage is higher than expected
3838 (DTC 2999) - Upstream oxidation catalyst temperature sensor voltage is lower than expected
19040 (DTC 352C) - Upstream oxidation catalyst temperature sensor comparison to a calculated temper-
ature value failure

3. Use the EST to compare the B-049 temperature value to the SCR downstream exhaust gas temperature sensor
B-022 and SCR upstream exhaust gas temperature sensor B-021 temperature values. Monitor for possible signal
drift due to a rapid change in ambient temperature. The sensors should have similar characteristics.
Monitoring must be done after a cold soak condition to avoid any residual heat.
A. If no faults are found, continue to Step 4.
B. If any faults are found, verify that a rapid change in ambient temperature has not occurred that has caused this
fault to occur.
Perform an engine cold start to verify that this fault has been resolved.
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has been resolved.
operation.
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3687-(DTC 3E1C)-SCR upstream temperature sensor signal drift

at cold start
Context:
The Engine Control Unit (ECU) A158 monitors the SCR upstream exhaust gas temperature sensor B-021 signal. If
the ECU determines that the B-021 temperature signal has drifted at cold start, this fault will occur.
Cause:
The ECU determines that the B-021 temperature signal has drifted at cold start.

3. Faulty B-021.
Solution:
19019 (DTC 1A1A) - Upstream SCR catalyst temperature sensor voltage is higher than expected
19020 (DTC 2B1A) - Upstream SCR catalyst temperature sensor voltage is lower than expected
19041 (DTC 362C) - Upstream SCR temperature sensor comparison to a calculated temperature value fail-
ure
19069 (DTC 181A) - Upstream SCR catalyst temperature too high
19070 (DTC 291A) - Upstream SCR catalyst temperature too low

Perform a engine cold start and then use the EST to verify the status of this fault.
has been resolved.
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operation.
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3688 (DTC 4F15)-Water in fuel sensor or sensor circuit failure

NOTE: this fault code is for the Water in Fuel sensor with black connector housing. If the connector housing of the
sensor is white take care that the pins 2 and 3 are reversed.
Context:
The water in fuel sensor S158-5 provides a diagnostic self-test signal (less than 3.9 V for 2.5 s +/- 20%) at key-ON. If
the Engine Control Unit (ECU) A158 does not sense the diagnostic self-test signal, this fault will occur and there will
be no monitoring of water content in the fuel supply.
Cause:
The ECU has not received an acceptable S158-5 self-test signal.
1. Faulty S158-5 circuit wiring, damaged.

2. Faulty S158-5, internal failure.
Solution:
Use the Easy Engine software provided on the Electronic Service Tool (EST) to check the fault status.
B. If the fault is no longer present or is in an inactive state, Continue with Step 7.

2. Use the EST to check the status of the related fault
3146 (DTC 4415) - Water in fuel detected or water in fuel circuit failure
A. If fault 3146 (DTC 4415) - Water in fuel detected or water in fuel circuit failure is active, resolve fault 3146
(DTC 4415) - Water in fuel detected or water in fuel circuit failure, then determine if fault is also resolved.
B. If fault 3146 (DTC 4415) - Water in fuel detected or water in fuel circuit failure is not active,continue with
Step 3.
3. Check the S158-5 for the initial self-test voltage pulse.
Carefully back probe the S158-5 at the Connector XS158-5, pin 1.
With the help of an assistant, use a multimeter to perform the following test at Key-ON:
From To Value
Connector XS158-5, pin 1 Ground There should be less than 3.9 V for
2.5 s +/- 20%
NOTE: the signal line should switch to battery voltage after the self-test period.
A. If the self-test is successful, continue with Step 4.
B. If the self-test is not successful, the S158-5 has failed internally. Replace the sensor.
Disconnect the water in fuel sensor at the Connector XS158-5.
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ness:
From To Value
Connector XS158-5, pin 3 Connector X33-30 , pin B There should be continuity
From To Value
From To Value
circuit condition in the wiring. Use the appropriate vehicle service manual and schematics to diagnose and
repair the wiring.
XA158 and Connector XS158-5 disconnected, connect the Connector X33-30 and continue with Step 5.
5. Check for open, short and grounded circuit conditions in the water in fuel sensor circuit.
ness:
From To Value
Connector XS158-5, pin 3 Connector X102, pin 21 There should be continuity
repair the wiring.
XS158-5 disconnected, connect the Connector X102 and continue with Step 6.
6. Check for open, short and grounded circuit conditions in the water in fuel sensor circuit.
ness:
From To Value
Connector XS158-5, pin 3 Connector 1F1K, pin A3 There should be continuity
repair the wiring.
XS158-5 disconnected, connect the Connector 1F1K and continue with Step 7.
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7. Check for key switch voltage supply to S158-5.
If it has not been reconnected, reconnect the vehicle (VE) harness to the ECU at the Connector XA158.
With the key switch in an ON position, use a multimeter to perform the following test, on the vehicle (VE) harness
side:
From To Value
Connector XS158-5, pin 3 Ground There should be key switch voltage
A. If there is key switch voltage present, check the ECU for the appropriate software and re-flash, if necessary.
B. If key switch voltage is not present, use the appropriate vehicle service manual and schematics to diagnose
and repair the wiring.
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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3699 (DTC E56D)-ECU EEPROM memory failure - EEPData1 block

Context:
The Engine control Unit (ECU) A158 monitors the EEPROM block internal to the ECU. If the ECU 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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3700 (DTC 3754)-Intake air humidity sensor value is not plausible

Context:
The Engine Control Unit (ECU) A158 monitors the sensor humidity and temperature B-055 signal circuit for a signal
sticking condition. If the change in the B-055 relative humidity signal value is less than 1.00 % per 1.00 s, this fault
will occur.
Cause:
The ECU has determined that the B-055 humidity signal value is not plausible.
1. Faulty B-055, humidity signal circuit.

Solution:
3557 (DTC FB54) - Intake air humidity sensor voltage is higher than expected
3549 (DTC 1C54) - Intake air humidity sensor voltage is higher than expected for too long
19043 (DTC 2D54) - Intake air humidity sensor voltage is lower than expected

has been resolved.
operation.
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3703 (DTC 2B36)-The minimum rail pressure value necessary to

allow fuel injection has not been reached
Context:
The Engine Control Unit (ECU) A158 monitors the rail pressure sensor for the necessary minimum pressure to allow
fuel injection. If the ECU determines that fuel pressure is below 180.0 bar (2610.0 psi), fuel injection will not be
allowed and this fault will occur.
Cause:
The minimum rail pressure value necessary to allow fuel injection has not been reached.
1. Faulty rail pressure sensor, wiring or internal failure.

2. Faulty fuel injection system, low pressure side. (clogged fuel filter, leakage or blockage)
3. Faulty gear pump pressure, too low.
6. Faulty Pressure relief valve (PRV), stuck open.
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3735-(DTC 8355)-Fuel metering unit has an over-temperature error

Context:
For more information on the fuel metering unit see Injection control - Dynamic description (55.010). The Engine
control Unit (ECU) monitors the fuel metering unit circuit for an over temperature/current condition. If an over temper-
ature/current condition is detected, this fault will occur.
Cause:
The A-9000 has detected an over temperature/current condition in the Y-9000 circuit.

Solution:
Continue to Step 6.
2. Check fuel metering unit Y-9000 for an internal failure.
From To Value
X-9007 pin 1 X-9007 pin 2 There should be 2.8 - 3.2 Ω.
A. If there is between 2.8 - 3.2 Ω, leave X-9007 disconnected and continue to Step 3.
B. If there is not between 2.8 - 3.2 Ω, the Y-9000 has failed internally. Replace the Y-9000.
3. Check the Y-9000 wiring for a short circuit condition.
From To Value
A. If there is continuity, there is a short circuit in the Y-9000 wiring. locate and repair the shorted conductor.

4. Check the Y-9000 wiring for a short to key power condition.
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From To Value
A. If there is voltage, there is a short to key power condition in the Y-9000 wiring. Locate the repair the shorted
conductor.

Use the EST to verify the status of DTC 8355 - Fuel metering unit has an over-temperature error.
has been resolved.
operation.
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3738-(DTC E71D)-ECU internal failure - ROM error

Context:
The Engine Control Unit (ECU) A158 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
Context:
The Engine Control Unit (ECU) A158 performs shut off paths which deactivate all power stages relevant to injection if
certain internal ECU errors are detected. In order to test the correct functioning of the shut off procedure, every path
is shortly activated during ECU initialization to activate the fuel injection power stage. Since the ECU 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

Context:
this test, each injection path is shortly activated during ECU 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

Context:
this test, each injection path is shortly activated during ECU initialization. If a time-out error occurs during this test,
Solution:
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3742-(DTC E43D)-ECU internal failure - SPI errors during MoCSOP

execution
Context:
this test, each injection path is shortly activated during ECU initialization. If a Serial Peripheral Interface (SPI) com-
munication error is detected during this test, this fault will occur.
Solution:
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3743-(DTC E53D)-ECU internal failure - Undervoltage monitoring

error
Context:
ECU 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
Context:
The Engine Control Unit (ECU) A158 performs shut off paths which deactivate all power stages relevant to fuel injec-
tion if certain internal ECU errors are detected. In order to test this function, every path is shortly activated during ECU
initialization. Since the shut off is active, no fuel injection should occur during this test. If an implausible 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

Context:
The Engine control Unit (ECU) A158 performs shut off paths which deactivate all power stages relevant to fuel injection
if certain internal ECU errors are detected. In order to test this function, every path is shortly activated during ECU
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

Context:
The Engine Control Unit (ECU) A158 performs shut off paths which deactivate all power stages relevant to injection if
certain internal ECU errors are detected. In order to test the correct functioning of the shut off procedure, every path
is shortly activated during ECU initialization to activate the fuel injection power stage. Since the ECU 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
Context:
The Engine Control Unit (ECU) A158 performs an internal plausibility check of the accelerator pedal position signal
and the low idle switch, for function monitoring. If the ECU detects a implausible value between the accelerator pedal
position sensor and the low idle switch, this fault will occur.
Cause:
The ECU has detected an implausible value, internally, of the throttle pedal.
Solution:
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3750-(DTC EC36)-ECU internal failure - Fuel injection energizing

time is not plausible
Context:
The Engine Control Unit (ECU) A158 monitors injector energizing time. If the ECU determines that the energizing
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
Context:
The Engine Control Unit (ECU) A158 monitors for injector energizing start time. If the ECU determines that the ener-
gizing 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
Context:
The Engine Control Unit (ECU) A158 monitors the Zero Fuel quantity Calibration (ZFC) and Zero Fuel quantity during
Low idle (ZFL). The ZFC and ZFL are used to correct pilot injection quantity, as needed. The ECU monitors these
functions for plausibility. If either range is outside of the minimum limit range, this fault will occur. The ZFC is also
used to monitor the efficiency of the fuel injectors. Use the appropriate service manual to test the fuel injectors for
internal and external leakage. Also, test the high pressure fuel system for any internal leakage. If no faults are found,
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 for the appropriate software and re-flash, if necessary.
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3753-(DTC E5DD)-ECU internal failure - Injection quantity correction

Context:
Engine performance is assisted by the addition of pilot injections, main injections and three post injections. The En-
gine Control Unit (ECU) A158 monitors the efficiency of these injections and provides injection quantity corrections, if
necessary. If the ECU determines that excessive corrections to injection quantity are being made, there is a calibra-
tion error and this fault will occur.
Solution:
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3754-(DTC E6DD)-ECU internal failure - Rail pressure plausibility

Context:
The Engine Control Unit (ECU) A158 monitors fuel rail pressure for proper engine performance as well as safety
concerns. Fuel rail pressure is monitored by the ECU to check if the ECU is functioning properly. If ECU detects an
implausible rail pressure during monitoring, the ECU is not functioning correctly and this fault will occur.
Solution:
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3755-(DTC E7DD)-ECU internal failure - Torque request comparison

Context:
The Engine Control Unit (ECU) A158 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 has a calibration error and this fault will occur.
Solution:
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3756-(DTC E1DD)-ECU internal failure - Post injection quantity

Context:
Engine performance is assisted by the addition of pilot injections, main injections and three post injections. The Engine
Control Unit (ECU) A158 monitors the start angle and efficiency of post Injection 2. If the ECU 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
Context:
Engine performance is assisted by the addition of pilot injections, main injections and three post injections. The Engine
Control Unit (ECU) A158 monitors the post Injection 2 shut off quantity in normal mode. If the ECU detects that the
post Injection 2 shut off quantity has exceeded 5.00 mg in normal mode, this fault will occur.
Solution:
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3758 (DTC E3DD)-Post injection efficiency failure

Context:
Engine performance is assisted by the addition of pilot injections, main injections and post injections. The Engine
Control Unit (ECU) A158 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 ECU 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.

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
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
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 rail

control exceeds maximum torque limit
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 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
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 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

Context:
The Engine Control Unit (ECU) A158 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 the supply wiring of the ECU.

Solution:
2. Check the ECU supply wiring.
From To Value
A. If there is not approximately 24 V, check the charging system for proper operation and repair as necessary.


has been resolved.
operation.
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3763-(DTC ECDD)-ECU 5 volt supply voltage is lower than expected

Context:
The Engine Control Unit (ECU) A158 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

Context:
The Engine Control Unit (ECU) A158 monitors the ignition switch. When the ECU determines that the ignition switch
has been turned OFF, it will go into after run. The after run disconnection relay K-9106 controls the voltage to the
main relay which allows the ECU to store failures into memory (and other relevant machine operating parameters)
before being turned OFF. If the ECU determines that the after run cycle was interrupted three consecutive times, this
fault will occur.
Cause:
The ECU has detected an interruption in the after run process.
1. Premature use of the battery disconnect switch. (if equipped)

2. Faulty battery voltage.
3. Faulty K-9106, internal failure or loose connection.
4. Faulty K-9102, internal failure or loose connection.
5. Faulty fuse F-9105.
6. Faulty K-9106, wiring.
Solution:
From To Value
Battery 1 (+) terminal Battery 2 (–) terminal There should be approximately 24 V.
A. If there is approximately 24 V, continue to Step 3.
B. If there is not approximately 24 V, there is a battery or charging system fault. Repair as necessary.
DTC 5971 - After run relay low side driver circuit open or short to ground failure
DTC 5171 - After run relay high side driver circuit open failure
DTC 6771 - After run relay low side driver circuit short to battery failure
DTC 8671 - After run relay low side ECU driver circuit over temperature failure
DTC 8271 - After run relay high side ECU driver circuit over temperature failure
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DTC 6471 - After run relay high side driver circuit short to ground failure
A. If any of the listed faults are active, diagnose them first and then return to this fault, DTC F561 - ECU after
run power interruption.

4. Check the K-9106 for an internal failure.
Remove the K-9106.
From To Value
X-9123 pin 1 X-9123 pin 2 The resistance should be between
70 - 130 Ω.
A. If the resistance is between 70 - 130 Ω, leave the K-9106 disconnected and continue to Step 5.
B. If the resistance is not within the specified range, the K-9106 has failed internally. Replace the K-9106.
5. Check the K-9106 wiring.
Use a multimeter to perform the following voltage check from the K-9106 relay socket:
From To Value
X-9123 pin 3 Chassis ground. There should be approximately 24 V.
A. If there is not approximately 24 V, there is a fault in the wiring from the battery to the K-9106. Locate and
repair the faulty conductor.

6. Check the fuse F-9105.
Remove the F-9105.
Use a multimeter to determine the condition of the fuse.
A. If there is no continuity, the F-9105 has failed. Replace the F-9105.

7. Check the main relay K-9102 for an internal failure.
Remove the K-9102.
Use a multimeter to check the coil resistance.

There should be 70 - 130 Ω
A. If the resistance is between 70 - 130 Ω, leave the K-9102 disconnected and continue to Step 8.
8. Check the K-9106 to the main relay K-9102 wiring.
Use a multimeter to perform the following continuity check from the K-9106 relay socket to the K-9102 relay
socket:
From To Value
X-9123 pin 4 the K-9102 socket pin 2 There should be continuity.
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A. The specified value is not detected, there is a fault in the wiring between the relays.Locate and repair the
faulty conductor.
B. If the specified value has been detected, continue to Step 9.

Use a multimeter to perform the following voltage check from the K-9102 relay socket:
From To Value
the socket of K-9102 pin 1 Chassis ground There should be approximately 24 V.
A. If there is not approximately 24 V, there is a fault in the wiring from the battery to the K-9102. Locate and
repair the faulty conductor.

From To Value
the socket of K-9102 pin 3 Chassis ground There should be continuity.
A. If there is no continuity, there is a broken path to ground in the K-9102 wiring. Locate and repair the broken
conductor.
B. If there is continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary.
continue operation.
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3767-(DTC E81D)-ECU internal failure - 'WDA active' reported due

to errors in query/response communication
Context:
The Engine Control Unit (ECU) A158 monitors the communication 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
Context:
voltage supplier. If the battery voltage is greater than 8.00 V, the shut off path test is not active and the ECU detects
a low voltage condition during this test, this fault will occur.
Solution:
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3769-(DTC EA1D)-ECU internal failure - 'ABE active' reported due

to overvoltage detection
Context:
voltage supplier. If the shut off path test is not active and the ECU detects a high voltage condition during this test,
Solution:
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3770-(DTC EB1D)-ECU internal failure - 'WDA/ABE active' reported

Context:
voltage supplier. This is performed continuously as long as the shut off path test is not active and battery voltage is
greater than 8.00 V. If the WDA/ABE communication wire becomes active for an unknown reason during this moni-
toring, this fault will occur.
Solution:
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3799-(DTC F345)-Fuel pressure relief valve is forced to open,

perform pressure shock
Context:
For more information on the fuel injection system see Injection control - Dynamic description (55.010). To deter-
mine mechanical wear out or to send the system into limp home mode, the Engine Control Unit (ECU) A158 can force
the fuel pressure relief valve open. This action consists of two steps, waiting for the rail pressure to build up and
then performing the pressure shock. If the ECU commands this operation, this fault will occur. Once a rail pressure
sensor failure is detected or maximum rail pressure is exceeded, the system will go into a limp home mode. If this
fault occurs, the ECU has determined that a pressure shock has occurred, other fuel related system faults can occur
due to the increase in fuel pressure.
Solution:
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3805-(DTC 1D85)-Maximum rail pressure exceeded

necessary.
Context:
The Engine Control Unit (ECU) A158 monitors fuel rail pressure during limp home mode. If the A158 determines that
fuel pressure has exceeded 2250.0 bar (32625.0 psi) during lime home mode, this fault will occur.
Cause:
Maximum fuel pressure has been exceeded.
1. Faulty fuel metering unit, wiring or mechanical failure.

2. Faulty Pressure Relief Valve (PRV), clogged.
3. Faulty fuel injectors, electrical or mechanical failure.
4. Faulty fuel return lines.
5. Faulty gear pump pressure, too high.
Solution:
1. Use the Electronic Service Tool to check for related faults. The following faults may have caused this fault:
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3808-(DTC 3C65)-High pressure pump fuel delivery quantity at low

idle is too high
Context:
For more information on the fuel injection system see Injection control - Dynamic description (55.010). The En-
gine Control Unit (ECU) A158 controls fuel delivery by the fuel metering unit. If the ECU determines that proper fuel
pressure can not be reached at engine idle speed, leakage in the system is assumed and this fault will occur.
Cause:
The ECU has determined that commanded fuel rail pressure is lower than expected at engine idle speed.
1. Faulty fuel injectors, internal leakage or stuck open.

2. Faulty pressure relief valve, leaking.
6. Faulty low pressure fuel lines, leaking. (air entrance)
8. Faulty electric lift pump. (if applicable)
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3810 (DTC 4125)-Rail pressure sensor value is intermittent

Context:
The Engine Control Unit (ECU) A158 monitors the fuel rail pressure sensor B-9004 for an intermittent connection
condition. If the A-9000 detects five or more pressure jumps of greater than 350.00 bar within 10.00 ms and the time
between the pressure jumps is greater than 3.00 s, this fault will occur.
Cause:
The ECU has detected an intermittent connection in the B-9004 circuit.
1. Faulty Rail pressure sensor, internal failure.

2. Faulty Rail pressure sensor, wiring.
Solution:
2. Check the B-9004 circuit for an intermittent open circuit condition.
connection condition:
From To Value
A. If there is intermittent or no continuity, there is an intermittent open or open circuit condition in the B-9004
circuit. Locate and repair the damaged conductor.

3. Check the B-9004 circuit for a short circuit condition.
Use a multimeter to perform the following wiring checks while shaking the harness to promote an intermittent
connection condition:
From To Value
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From To Value
A. If the specified values are not measured, there is a short circuit condition in the B-9004 circuit, wire EN-002.

Use the EST to verify the status of this fault, DTC 4125 - Rail pressure sensor value is intermittent.
has been resolved.
operation.
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3811-(DTC E22D)-ECU internal failure - Sensor 5 volt supply 1

necessary.
Context:
The Engine Control Unit (ECU) A158 provides three independent 5.0 V voltage supplies for sensors. These voltages
are monitored by hardware within the ECU to make sure they are within a given range. This given range is defined
by the ECU hardware and cannot be calibrated. If a sensor supply 1 reference voltage is out of range, this fault will
occur.
Cause:
The ECU sensor supply 1 reference voltage is out of range.
1. Faulty SCR pressure sensor B-9100 or sensor supply wire.

2. Faulty air filter clogging pressure sensor B-9102 or sensor supply wire.
3. Faulty oil pressure and temperature sensor B-9000 or sensor supply wire.
4. Faulty intake manifold pressure and temperature sensor B-9001 or sensor supply wire.
5. Faulty crankcase pressure sensor B-9009 or sensor supply wire.
Solution:
2. Disconnect each connector one at a time, use EST to monitor the status of DTC E22D - ECU internal failure -
Sensor 5 volt supply 1.
- SCR pressure sensor B-9100 connector X-9108
- Air filter clogging pressure sensor B-9102 connector X-9102
- Oil pressure and temperature sensor B-9000 connector X-9004
- Intake manifold pressure and temperature sensor B-9001 connector X-9003
- Crankcase pressure sensor B-9009 connector X-9023
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From To Value
if necessary.
has been resolved.
operation.
03 (55.100) Wiring harnesses - Electrical schematic sheet 05 (55.100)
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3812-(DTC 115D)-ECU temperature sensor 1 is too high

Context:
The Engine Control Unit (ECU) A158 monitors ECU internal temperature by the use of two internal temperature sen-
sors. If temperature sensor 1 monitors a temperature greater than 175 °C (347 °F), this fault will occur.
Cause:
The ECU 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

Context:
The UCM temperature is less than -60 °C (-76 °F) .
Cause:
The internal UCM temperature is less than normal.
1. Low ambient temperatures.

2. Faulty Engine Control Unit (ECU) A158.
Solution:
Connect the Electronic Service Tool to the service tool connector.
To check for fault codes: Start and operate the machine.
A. The fault code is not recorded again. Go to step 3 to check for an intermittent condition.
B. Fault code 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. The ambient temperature is less 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. The ambient temperature is less warmer than -60 °C (-76 °F). Go to step 3.
3. Verify that the wiring and connectors are free of damage.
Turn the ignition switch OFF.
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 are tight and secure.
Verify the connections from the battery to the ECU are tight and secure.
Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment from the battery to the ECU.
A. The harness is not damaged and all connections are secure. Temporarily replace the ECU 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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3814-(DTC E55D)-ECU temperature sensor error detected

Context:
The Engine Control Unit (ECU) A158 performs a signal check of the signal of each digital temperature sensor internal
to the ECU. If an error message sent from the sensor is detected, this fault will occur. Temperature value will be frozen
at the last valid value for a preliminary failure and a fixed value of 39.96 °C (103.93 °F) if the failure is validated.
Solution:
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3838-(DTC 2999)-Upstream oxidation catalyst temperature sensor

necessary.
Context:
The Engine Control Unit (ECU) A158 monitors the DOC upstream exhaust gas temperature sensor B-049 circuit volt-
age. If the ECU detects a voltage less than 407.00 mV in the DOC upstream exhaust gas temperature sensor B-049
signal circuit, this fault will occur. The temperature value is frozen at the last valid value or at 574.0 °C (1065.2 °F) for
a validated failure.
Cause:
The ECU has detected a voltage less than 407.00 mV in the B-049 signal circuit.

Solution:
From To Value
A. If there is continuity, there is a short to ground condition. Locate and repair the shorted conductor.

A. If the fault has been resolved, use EST, see Selective Catalytic Reduction (SCR) exhaust treatment - Con-
Unlock Inducement configuration then return the machine to service.
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has been resolved.
operation.
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3858 (DTC 3598)-CAN communication error between ECU and eVGT

actuator
Context:
The eVGT actuator DOC upstream temperature sensor controller sends and receives information at regular intervals
to and from the Engine Control Unit (ECU) via the engine Controller Area Network (CAN). If the eVGT actuator DOC
upstream temperature sensor controller determines that a general error exists, this fault will occur.
Cause:
The ECU has reported, via the engine sensor CAN bus, that the eVGT actuator DOC upstream temperature sensor
controller has reported that a general error exists.

3. Faulty eVGT actuator DOC upstream temperature sensor controller, hardware or firmware.
Solution:
2. Check the eVGT actuator DOC upstream temperature sensor controller supply voltage.
Disconnect the engine (EN) harness from the eVGT actuator DOC upstream temperature sensor controller at
connector X-9012.
From To Value

From To Value

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CAN condition.
VE-194B or EN-047C and/or VE-201F or EN-048C for CAN signal. Locate and repair the damage to the CAN
circuit wiring.
has been resolved.
operation.
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3861 (DTC 3498)-eVGT power supply electrical failure

Context:
upstream temperature sensor controller determines that an electrical problem exists, this fault will occur.
Cause:
controller has reported that an electrical problem exists.

Solution:
connector X-9012.
From To Value

From To Value

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CAN condition.
VE-194B or EN-047C and/or VE-201F or EN-048C for CAN signal. Locate and repair the damage to the supply
or CAN circuit wiring.
has been resolved.
operation.
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3865 (DTC 4898)-eVGT system failure

Context:
upstream temperature sensor controller determines that a system failure exists, this fault will occur.
Cause:
controller has reported that a system failure exists.

Solution:
connector X-9012.
From To Value

From To Value

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CAN condition.
VE-194B or EN-047C and/or VE-201F or EN-048C for CAN signal. Locate and repair the damage to the CAN
circuit wiring.
has been resolved.
operation.
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3868 (DTC 8998)-eVGT actuator over temperature error

NOTE: the eVGT actuator DOC upstream temperature sensor controller uses an internal temperature sensor to de-
termine if an electrical overload condition exists. An excessively hot environment could influence this fault, as all of
the temperature rise may not be exclusively current draw.
Context:
upstream temperature sensor controller determines that an over temperature, greater than 145.0 °C (293.0 °F), con-
dition exists, this fault will occur.
Cause:
controller has reported that an over temperature condition exists.

Solution:
Continue with Step .
connector X-9012.
From To Value
X-9012 pin 4 X-9012 pin 3 There should be between 10.0 -
15.0 V.
A. If the voltage is within range, leave connector X-9012 disconnected and continue with Step 3.
B. If the voltage is not within range, continue with Step 5.

B. If the eVGT mechanism contains debris or is hard to operate, then clean, adjust, repair or replace, as required.
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5. Check for other supply faults.
Use EST to determine if other supply faults exist.
supply voltage condition.
B. If no other supply voltage faults exist, the vehicle (VE) or engine (EN) harness wiring is damaged between the
network harness splice and the eVGT actuator A-9003 controller connector X-9012 pin 4 and/or X-9012 pin
3, wire VE-218 or EN-049A and/or VE-189B or EN-050A. Locate and repair the damage to the supply voltage
and ground circuit wiring.
has been resolved.
operation.
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3870-(DTC 936B)-CAN communication failure between vehicle

controller and ECU - BC2ECU1 message
Context:
the CAN Node A Bus, internal to the ECU. The ECU receives and responds to proprietary Body Computer (BC)
Cause:
ECU has sensed a BC message timeout.

Solution:
A. If related vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that this fault code is
also resolved.

From To Value
4.
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From To Value
From To Value
From To Value
circuit.
has been resolved.
operation.
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3877-(DTC 647D)-Supply UB1 short to battery failure

Context:
The Engine Control Unit (ECU) A158, monitors the supply UB1 circuit. If the ECU detects that the UB1 supply circuit
has a short to battery power condition, this fault will occur.
Cause:
The ECU 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.
From To Value
Connector XA158, pin 50 All pins in the Connector XA158 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
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 key battery power condition.
From To Value
Connector XA158, pin 50 Chassis ground There should be no voltage.
A. If there is voltage, there is a short to key 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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Context:
Cause:

Solution:
From To Value
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
conductor.
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has been resolved.
operation.
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Context:
Cause:

2. Faulty ECU, software.
Solution:
From To Value
conductor.

From To Value
conductor.
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has been resolved.
operation.
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3881-(DTC 757D)-Supply UB1 circuit short to ground failure

necessary.
Context:
The Electronic Control Unit (ECU) A158, monitors the supply UB1 circuit. If the ECU detects that the UB1 supply
circuit has a short to ground condition, this fault will occur.
Cause:
The ECU 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
conductor.

Use a multimeter to perform the following continuity test:
From To Value
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 : RCU
Context:
has a short to ground condition, this fault will occur.
Cause:

Solution:
From To Value
conductor.

From To Value
ductor.
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has been resolved.
operation.
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3883-(DTC 797D)-Supply UB3 short to ground failure

Context:
has a short to ground condition, this fault will occur.
Cause:

Solution:
From To Value
conductor.

From To Value
ductor.
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has been resolved.
operation.
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3903-(DTC 1A15)-Fuel temperature is too high

Context:
The Engine Control Unit (ECU) monitors the fuel temperature sensor B-9002. If the ECU detects a fuel temperature
higher than 90 °C (194 °F), this fault will occur.
Cause:
The ECU has detected a fuel temperature greater than 90 °C (194 °F).
1. Faulty fuel cooling, clogged. (if equipped)

2. High ambient temperature.
3. Faulty Coolant temperature sensor, internal failure.
4. Faulty Coolant temperature sensor, 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.

3. Check the Coolant temperature sensor signal circuit for a short circuit condition.
Disconnect connector Fuel temperature sensor.
From To Value

4. Check the B-9002 for a short to key power condition.
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From To Value

Use the EST to verify the status of 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
Context:
The Engine Control Unit (ECU) A158 monitors the grid heater relay K1-7 control circuit for an over temperature con-
dition. If an over temperature condition is detected, this fault will occur.
Cause:
The ECU has detected an over temperature condition in the K1-7 control circuit.

2. Faulty K1-7 control circuit, short to high source condition.
3. Faulty of the software of the ECU.
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.

Remove the K1-7.
From To Value
K1-7, pin 85 K1-7, pin 86 The coil resistance should be
between 70.0 - 130.0 Ω (70.0 -
130.0 Ω)
A. If the value is not within the specified value, the K1-7 has failed internally. Replace the K1-7.
B. If the value is within the specified range, leave the K1-7 disconnected and continue to Step 4.
4. Check the K1-7 signal circuit for a short to high source condition.
From To Value
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A. If there is continuity, there is a short circuit condition in the K1-7 signal circuit, wire BL 0.75.
5. Check the K1-7 for a short to key power condition.
From To Value
A. If there is voltage, there is a short to key power condition in the K1-7 signal circuit, wire BL 0.75.
has been resolved.
operation.
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3910-(DTC 4155)-Fuel metering unit intermittent electrical

connection
Context:
For information on the fuel metering unit refer to Injection control - Dynamic description (55.010). A loose contact in
the wiring of the fuel metering unit can result in a malfunction of the fuel metering unit and can result in irregular engine
running or possible fuel pressure failures. The Engine Control Unit (ECU) has an internal counter which increments
each time an intermittent connection is recognized and decrements if the time between intermittent connections is
greater than 3 s. If the internal counter exceeds 1000 counts, this fault will occur.
Cause:
The ECU internal intermittent connection counter has exceeded 1000 counts.
1. Faulty fuel metering unit, coil.

2. Faulty fuel metering unit connector X-9007.
Solution:
B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active,
continue to Step 6.
2. Check the condition of the Y-9000 connector X-9007.
Disconnect the engine (EN) harness from the Y-9000 at connector X-9007.
Inspect the connector X-9007 contacts for corrosion, damage and proper connection.
A. If the condition of the X-9007 contacts are good, leave the X-9007 disconnected and continue to Step 3.
B. If the X-9007 is faulty, refer to the appropriate service manual to repair or replace the engine (EN) harness as
necessary.
From To Value
(2.8 - 3.2 Ω).
4. Check the condition of the Y-9000 control circuit.
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Disconnect connector X-9002 from the engine (EN) harness.
Use a multimeter to perform the following continuity test in the engine (EN) harness while shaking the engine (EN)
harness to promote an intermittent fault:
From To Value
X-9002 pin 58 X-9007 pin 1 There should be no intermittent
continuity.
X-9002 pin 83 X-9007 pin 2 There should be no intermittent
continuity.
A. If you have intermittent continuity when shaking the engine (EN) harness between connector X-9002 pin 58
and X-9007 pin 1 wire EN-015, there is a damaged conductor in this circuit. Use the appropriate service
manual to locate and repair the damaged conductor.
B. If you have intermittent continuity when shaking the engine (EN) harness between connector X-9002 pin 83
and X-9007 pin 2 wire EN-016, there is a damaged conductor in this circuit. Use the appropriate service
manual to locate and repair the damaged conductor.
C. If neither circuit has intermittent continuity during this test, continue to Step 5.
5. Check the A-9000 connector X-9002 to all other pins in the harness.
From To Value
X-9002 All other pins There should be no intermittent
continuity.
A. If there is continuity, refer to the appropriate service manual to locate and repair the damaged conductor.
has been resolved.
operation.
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3911-(DTC 6455)-Fuel metering unit is shorted to battery voltage

at the high side
Context:
The Engine Control Unit (ECU) monitors the fuel metering unit high side driver circuit for a short to battery power
condition. If the ECU detects a short to battery power, this fault will occur.
Cause:
The ECU has detected a short to battery power in the fuel metering unit high side driver circuit.

2. Faulty fuel metering unit wiring, short to battery power condition.
Solution:
2. Check the Y-9000 for an internal short.
From To Value
X-9007 pin 1 X-9007 pin 2 The value should be between 2.8 -
3.2 Ω (2.8 - 3.2 Ω).
3. Check the Y-9000 high side driver circuit for a short to battery power condition.
From To Value
A. If there is continuity, there is a short circuit condition in the Y-9000 high side driver circuit, wire EN-015. Locate
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4. Check the Y-9000 high side driver circuit for a short to key power condition.
From To Value
A. If there is voltage, there is a short to key power condition in the Y-9000 high side driver circuit, wire EN-015.
B. If there is no voltage, check the ECU A-9000 for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
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3912-(DTC 7555)-Fuel metering unit is shorted to ground at the

high side
Context:
For more information no the fuel metering unit refer to Injection control - Dynamic description (55.010). If the
Engine Control Unit (ECU) detects a short circuit to ground in the fuel metering unit high side, this fault will occur.
Cause:
The ECU has detected a short to ground in the fuel metering unit circuit, high side.
1. Fuel metering unit internal short to ground condition.

2. Short to ground condition in the fuel metering unit circuit, high side.
Solution:
Connect the Electronic Service Tool (EST) to the diagnostic port.
Continue to Step 4.
2. Check the Y-9000 for an internal short to ground condition.
From To Value
(2.8 - 3.2 Ω).
A. If the value is in the specified range, leave X-9007 disconnected and continue to Step 3.
3. Check for a short to ground condition in the (EN) harness at the A-9000 connector X-9002.
The key must be at the OFF position.
From To Value
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A. If there is continuity, there is a short to ground condition in the engine (EN) harness, wire EN-015. Use the
has been resolved.
operation.
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3916-(DTC 1745)-Fuel pressure relief valve has reached maximum

allowed open time
necessary.
Context:
For more information on the fuel injection system, see Injection control - Dynamic description (55.010). The Pres-
sure Relief Valve (PRV), integrated to the fuel rail, will open in the event of excessive fuel rail pressure. The Engine
Control Unit (ECU) A158 senses, counts and records the number and duration of PRV openings. If the ECU deter-
mines that the PRV has been open for a duration greater than 5.00 h, this fault will occur.
Cause:
The ECU has recorded a PRV opening for greater than 5.00 h.
1. Faulty fuel injection system, causing PRV to open for an extended period of time.
2. Faulty low pressure fuel lines, clogged fuel filter, faulty charge gear pump, faulty lift pump (if equipped).
3. Faulty fuel metering unit, internal failure or wiring.
4. Faulty PRV, mechanical failure.
5. Faulty rail pressure sensor, implausible value.
Solution:
1. Use the Electronic Service Tool (EST) to check if any of the listed faults are active:
3108 (DTC 7755) - Fuel metering unit is shorted to ground at the low side
3309 (DTC 1865) - Fuel rail pressure has exceeded maximum limit
3754 (DTC E6DD) - ECU internal failure - Rail pressure plausibility
3110 (DTC 1225) - Rail pressure sensor value is above maximum offset
3111 (DTC 2325) - Rail pressure sensor value is below minimum offset
3978 (DTC 16E5) - Prefilter fuel pressure sensor voltage is lower than expected
A. If any of the listed faults are active, diagnose them first, and then return to this fault.
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2. Check for leakage, clogging or damage that would allow air to enter the low pressure side of the fuel system.
Visually and tactually inspect the low pressure side of the fuel system for leaks, clogs or air entry damage. Inspect
gear pump for appropriate pressure.
A. If leakage, clogging, air entry, damage or low gear pump pressure is found, repair of replace fittings, filters,
lines, etc., as needed.
B. If no leakage, clogging, air entry, damage or low gear pump pressure is found, continue with Step 3.
3. Replace the fuel metering unit.
Use the EST to verify the status of this fault code.
A. If the fault has been resolved, see Pressure regulating valve - Configure - Reset ECU data (10.218) for the
Replacement of the Rail Pressure Metering Unit - Reset ECU Data. Then use EST and see Selective Catalytic
Reduction (SCR) exhaust treatment - Configure - Engine restart counter reset (10.500) if necessary, to
perform the Engine Restart Counter Reset / Unlock Inducement configuration then return the machine to ser-
vice.

4. Replace the PRV.
A. If the fault has been resolved, see Common rail Relief valve - Configure - Reset ECU data (10.218) for
the Replacement of the Rail Pressure Relief Valve (PRV) - Reset ECU Data. Then use EST and see Selec-
tive Catalytic Reduction (SCR) exhaust treatment - Configure - Engine restart counter reset (10.500) if
necessary, to perform the Engine Restart Counter Reset / Unlock Inducement configuration then return the
machine to service.

B. If fault has not been resolved, Check the ECU for the appropriate software and re-flash, if necessary.
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3930-(DTC FC8F)-SCR inducement warning due to distance/time

is active - Level 10
NOTE: since this fault is part of the inducement strategy that may result in an inducement lock condition, it may be
necessary to perform the Engine Restart Counter Reset / Unlock Inducement configuration and/or SCR Fault Repair
Verification Test with the Electronic Service Tool (EST) before you return the machine to service, unless these were
both accomplished as part of the resolution of the fault causing this fault. See Selective Catalytic Reduction (SCR)
exhaust treatment - Configure - Engine restart counter reset (10.500) and/or Selective Catalytic Reduction
(SCR) exhaust treatment - Service instruction - SCR fault repair verification test (10.500) , if necessary.
Context:
(DTC 2DDA) - SCR catalyst efficiency lower than first NOx production threshold level which after an Engine
Control Unit (ECU) A158 predetermined length of time causes this fault to occur.
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3936 (DTC E52D)-ECU internal: error sensor supplies voltage

tracker
Context:
The Engine Control Unit (ECU) A158 monitors the external voltage tracker for the ECU internal 5 V supply. If the ECU
determines that the voltage is too high or too low, this fault will occur.
Solution:
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3961-(DTC ED2D)-CAN communication failure - External

torque/speed checksum and counter
Context:
the CAN Node A Bus, internal to the ECU. The ECU provides checksum and counter functionality to assure torque/
speed message integrity and completeness. If the ECU senses an error in the rolling counter and checksum of the
torque/speed message, this fault will occur.
Cause:
ECU has sensed an error in the rolling counter and checksum of the torque/speed message.

Solution:
A. If related vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that this fault code is
also resolved.

From To Value
4.
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From To Value
From To Value
From To Value
circuit.
has been resolved.
operation.
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3962 (DTC 49C3)-Crankcase pressure too high for too long

Context:
The Engine Control Unit (ECU) A158 monitors crankcase pressure using the crankcase pressure sensor. If the ECU
determines that crankcase pressure is too high for too long, this fault will occur.
Cause:
The difference in crankcase pressure to expected crankcase pressure has exceeded 16.06 cm H₂₂O (6.32 in H₂₂O).
1. Faulty the wiring or internal failure of the crankcase pressure sensor.

2. Fuel in oil dilution.
3. Faulty fuel injectors, leaking.
5. Excessive turbocharger boost pressure.
Solution:
1. Use the Electronic Service Tool (EST) to check for the following related faults. If any of the faults are active,
diagnose them first and then return to this fault.
3963 (DTC 4AC3) - Crankcase pressure too high and oil pressure too low - Fuel in oil suspected
3647 (DTC 1338) - Over boost failure
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3963-(DTC 4AC3)-Crankcase pressure too high and oil pressure

too low - Fuel in oil suspected
Context:
The Engine Control Unit (ECU) A158 monitors crankcase pressure using the crankcase pressure sensor and the
engine oil pressure using the oil pressure sensor. If the ECU determines that oil pressure is lower than expected and
a high crankcase pressure fault was detected in the previous driving cycle, this fault will occur.
Cause:
Oil pressure is lower than expected and crankcase pressure has exceeded 1019.74 cm H₂₂O (401.47 in H₂₂O) for at
least 20.00 s.
1. Faulty engine oil, fuel contamination or level low.

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3964-(DTC 125D)-ECU temperature sensor 2 is too high

Context:
The Engine Control Unit (ECU) A158 monitors ECU internal temperature by the use of two internal temperature sen-
sors. If temperature sensor 2 monitors a temperature greater than 175 °C (347 °F), this fault will occur.
Cause:
The ECU 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

Context:
The UCM temperature is less than -60 °C (-76 °F) .
Cause:
The internal UCM temperature is less than normal.
1. Low ambient temperatures.

2. Faulty Engine Control Unit (ECU) A158.
Solution:
Connect the Electronic Service Tool to the service tool connector.
To check for fault codes: Start and operate the machine.
A. This fault code is not recorded again. Go to step 3 to check for an intermittent condition.
B. This fault code 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. The ambient temperature is less 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. The ambient temperature is less warmer than -60 °C (-76 °F). Go to step 3.
3. Verify that the wiring and connectors are free of damage.
Turn the ignition switch OFF.
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 are tight and secure.
Verify the connections from the battery to the ECU are tight and secure.
Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment from the battery to the ECU.
A. The harness is not damaged and all connections are secure. Temporarily replace the ECU 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
Context:
The Engine Control Unit (ECU) A158 monitors the ECU temperature sensor, which is internal to the ECU, for a voltage
higher than expected condition. If the ECU 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
Context:
The Engine Control Unit (ECU) A158 monitors the ECU temperature sensor, which is internal to the ECU, for a voltage
lower than expected condition. If the ECU 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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3968-(DTC 5171)-After run relay high side driver circuit open failure
Context:
The Engine Control Unit (ECU) monitors the ignition switch. When the ECU determines that the ignition switch has
been turned OFF, it will go into after run. The after run disconnection relay controls the voltage to the main relay which
allows the ECU to store failures into memory (and other relevant machine operating parameters) before being turned
OFF.
Cause:
The ECU has detected an open circuit condition in the K-9106 circuit, high side.
1. Faulty, after run disconnection relay coil.

2. Open circuit condition in the after run disconnection relay circuit, high side.
Solution:
2. Check the after run disconnection relay for an internal failure.
Remove the after run disconnection relay.
From To Value
70 - 130 Ω.
A. If the resistance is between 70 - 130 Ω, go to Step 3.
3. Check for an open circuit condition in the K-9106 circuit, high side.
Disconnect the K-9106 connector X-9123.
From To Value
A. If there is no continuity, there is an open circuit condition in the vehicle (VE) harness, wire VE-177. Refer to
the appropriate service manual to locate and repair the broken conductor.
B. If there is continuity, check the A-9000 for the appropriate software and re-flash, if necessary.
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has been resolved.
operation.
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3969-(DTC 8271)-After run relay high side ECU driver circuit over
temperature failure
Context:
The Engine Control Unit (ECU) monitors the ignition switch. When the ECU A-9000 determines that the ignition
switch has been turned OFF, it will go into after run. The after run disconnection relay K-9106 controls the operation
of the main relay which allows the ECU A-9000 to store failures into memory (and other relevant machine operating
parameters) before being turned OFF.
Cause:
The ECU has detected an over temperature condition in the after run disconnection relay circuit, high side.
1. Faulty ECU, voltage supply.

2. Faulty after run disconnection relay, internal short.
3. Faulty after run disconnection relay high side circuit, short to ground.
Solution:
2. Check the battery supply to the ECU A-9000.
Disconnect the ECU A-9000 connector X-9001
From To Value
X-9001 pin 1 chassis ground There should be approximately 24 V
A. If there is approximately 24 V, leave connector X-9001 disconnected and continue to Step 3.
B. If there is greater than approximately 24 V, there is a fault in the battery charging system. See the appropriate
service manual to troubleshoot the battery charging system failure.
3. Check the after run disconnection relay K-9106 coil for an internal failure.
Remove the after run disconnection relay K-9106.
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From To Value
X-9123 pin 1 X-9123 pin 2 There should be between 70 - 130 Ω.
B. If the value is not within the specified range, the after run disconnection relay K-9106 has failed internally.
Replace the after run disconnection relay K-9106.
4. Check the after run disconnection relay K-9106 high side circuit for a short to ground condition.
From To Value
A. If there is continuity, there is a short to ground condition in the after run disconnection relay K-9106 high side
circuit, wire VE-177. Locate and repair the shorted conductor.
has been resolved.
operation.
02 (55.100)
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3970-(DTC 6371)-After run relay high side driver circuit short to

battery
Context:
OFF.
Cause:
The ECU has detected a short to high source condition in the after run disconnection relay, high side driver circuit.
1. Open circuit condition in the after run disconnection relay high side circuit.
2. Short to high source condition in the after run disconnection relay high side circuit.
Solution:
2. Measure the after run disconnection relay K-9106 high side circuit for an open condition.
Disconnect the ECU A-9000 connector X-9001.
Disconnect the after run disconnection relay K-9106 connector X-9123.
From To Value
A. If there is continuity, leave X-9123 and X-9001 disconnected and continue to Step 3.
B. If there is no continuity, there is an open circuit condition between X-9123 pin 1 and X-9001 pin 22. Use the
3. Measure the voltage on the high side signal wire.
From To Value
A. If there is voltage, there is a short to high source condition in the vehicle (VE) harness wire VE-177. Use the
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has been resolved.
operation.
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3971-(DTC 6471)-After run relay high side drive circuit short to

ground failure
Context:
OFF.
Cause:
The ECU has detected a short to ground condition in the after run disconnection relay circuit, high side.
1. Faulty after run disconnection relay coil.

2. Short to ground condition in the after run disconnection relay circuit, high side.
Solution:
2. Check the after run disconnection relay coil.
From To Value
70 - 130 Ω.
A. If the resistance measurement is between 70 - 130 Ω, continue to Step 3.
B. If the resistance value is not within the specified range, the after run disconnection relay K-9106 has failed
internally. Replace the K-9106.
3. Check the after run disconnection relay K-9106 high side wire for a short to ground condition.
Disconnect the after run disconnection relay K-9106 connector X-9123.
From To Value
A. If there is continuity, there is a short circuit to ground condition in the vehicle (VE) harness, wire VE-177. Use
the appropriate service manual to locate and repair the shorted conductor.
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has been resolved.
operation.
02 (55.100)
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3973-(DTC 8671)-After run relay low side ECU drive circuit over
temperature failure
Context:
been turned OFF, it will go into after run. The after run disconnection relay controls the operation of the main relay
which allows the ECU to store failures into memory (and other relevant machine operating parameters) before being
turned OFF.
Cause:
The ECU has detected an over temperature/current condition in the after run disconnection relay K-9106 circuit, low
side.
1. Faulty ECU voltage supply.

2. Faulty after run disconnection relay, internal short.
3. Faulty after run disconnection relay low side circuit, short to high source.
Solution:
2. Check the battery supply to the ECU A-9000.
Disconnect the ECU A-9000 connector X-9001
From To Value
A. If there is approximately 24 V, leave connector X-9001 disconnected and continue to Step 3.
B. If there is greater than approximately 24 V, there is a fault in the battery charging system. See the appropriate
service manual to troubleshoot the battery charging system failure.
3. Check the after run disconnection relay K-9106 coil for an internal failure.
Remove the after run disconnection relay K-9106.
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From To Value
X-9123 pin 1 X-9123 pin 2 There should be between 70 - 130 Ω.
B. If the value is not within the specified range, the after run disconnection relay K-9106 has failed internally.
Replace the after run disconnection relay K-9106.
4. Check the after run disconnection relay K-9106 low side circuit for a short to high source condition.
From To Value
A. If there is continuity, there is a short to high source condition in the after run disconnection relay K-9106 low
side circuit, wire VE-178. Locate and repair the shorted conductor.

5. Check the after run disconnection relay K-9106 low side circuit for a short to key power condition.
From To Value
A. If there is voltage, there is short to key power condition in the after run disconnection relay K-9106 low side
circuit, wire VE-178. Locate and repair the shorted conductor.
has been resolved.
operation.
02 (55.100)
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3974-After run relay low side driver circuit short to battery failure
Context:
OFF.
Cause:
The ECU has detected a short to high source condition in the after run disconnection relay circuit, low side.
1. Faulty after run disconnection relay.

2. Short to high source condition in the after run disconnection relay circuit, low side.
Solution:
From To Value
X-9123 pin 2 X-9123 pin 1 There should be between 70 - 130 Ω
(70 - 130 Ω).
A. If there is between 70 - 130 Ω (70 - 130 Ω), go to Step 3.
B. If the value is not within specification, the K-9106 has failed internally. Replace the K-9106.
3. Check the K-9106 low side circuit for an open circuit condition.
Disconnect X-9123.
Disconnect X-9001.
Use a multimeter to perform the following continuity test.
From To Value
A. If there is continuity, leave X-9123 and X-9001 disconnected and go to Step 3.
B. If there is no continuity, there is an open circuit condition in the vehicle (VE) harness, wire VE-178. Refer to
the appropriate service manual to locate and repair the broken conductor.
4. Check the K-9106 low circuit for a short to high source condition.
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From To Value
A. If there is voltage, there is a short to high source condition in the vehicle (VE) harness, wire VE-178. Refer to
B. If there is no voltage, check the A-9000 for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
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3977-(DTC 15E5)-Prefilter fuel pressure sensor voltage is higher

than expected
Context:
The Engine Control Unit (ECU) monitors the prefilter fuel pressure sensor signal circuit for a voltage higher than
expected condition. If ECU detects a voltage greater than 4.92 V in the prefilter fuel pressure sensor signal circuit,
Cause:
The ECU has detected a voltage greater than 4.92 V in the prefilter fuel pressure sensor signal circuit.
1. Faulty prefilter fuel pressure sensor, internal failure.

2. Faulty prefilter fuel pressure sensor wiring, short to high source or open circuit condition.
3. Faulty the software of the ECU
Solution:
2. Check the prefilter fuel pressure sensor signal circuit for an open circuit condition.
From To Value
A. If there is no continuity, there is an open circuit condition in the B-9006 signal circuit, wire EN-036. Locate and

From To Value
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From To Value

Use the EST to verify the status of this fault, DTC 15E5 - Prefilter fuel pressure sensor voltage is higher than
expected.
A. If the fault has been resolved, return the machine the service.
has been resolved.
operation.
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3978-(DTC 16E5)-Prefilter fuel pressure sensor voltage is lower

than expected
Context:
The Engine Control Unit (ECU) monitors the fuel prefilter pressure sensor signal circuit for a voltage lower than ex-
pected condition. If the ECU detects a voltage less than 203.00 mV, this fault will occur.
Cause:
The ECU has detected a voltage less than 203.00 mV in the prefilter fuel pressure sensor signal circuit.
1. Faulty prefilter fuel pressure sensor, internal failure.

2. Faulty prefilter fuel pressure sensor wiring, short to ground condition.
Solution:
2. Check the prefilter fuel pressure sensor signal circuit for a short to ground condition.
From To Value
A. If there is continuity, there is a short to ground condition in the B-9006 signal circuit. Locate and repair the
shorted conductor.

Use the EST to verify the status of this fault, DTC 16E5 - Prefilter fuel pressure sensor voltage is lower than
expected.
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has been resolved.
operation.
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3981-After run relay low side driver circuit open or short to ground
failure
Context:
OFF.
Cause:
The ECU has detected a short to ground condition or an open circuit condition in the after run disconnection relay,
low side driver circuit.
1. Faulty after run disconnection relay coil.

2. Short to ground condition in the after run disconnection relay circuit, low side.
3. Open circuit condition in the after run disconnection relay circuit, low side.
Solution:
From To Value
K-9106 TERMINAL 85 K-9106 TERMINAL 86 The resistance should be between
70 - 130 Ω (70 - 130 Ω).
A. If the resistance measurement is between 70 - 130 Ω (70 - 130 Ω), continue to Step 3.
B. If the resistance value is not within the specified range, the K-9106 has failed internally. Replace the K-9106.
3. Check the K-9106 low side wire for a short to ground condition.
Disconnect the K-9106 connector X-9123.
From To Value
A. If there is no continuity, leave both connectors disconnected and continue to Step 4.
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B. If there is continuity, there is a short circuit to ground condition in the vehicle (VE) harness, wire VE-178. Use
4. Check the K-9106 low side wire for an open circuit condition.
From To Value
A. If there is continuity, check the A-9000 for the appropriate software and re-flash, if necessary.
B. If there is no continuity, there is an open circuit condition in the vehicle (VE) harness, wire VE-178. Use the
has been resolved.
operation.
02 (55.100)
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3985-(DTC 1758)-Exhaust gas pressure sensor voltage is higher

than expected
Context:
The Engine Control Unit (ECU) monitors the exhaust gas absolute pressure sensor signal circuit. If the ECU deter-
mines that the exhaust gas absolute pressure sensor voltage is greater than 4.8 V for a period greater than 500 ms.
Cause:
The ECU has determined that the exhaust gas absolute pressure sensor voltage is greater than 4.8 V for a period
greater than 500 ms.
1. Faulty exhaust gas absolute pressure sensor signal circuit, short to high source condition.
2. Faulty exhaust gas absolute pressure sensor, internal failure.
Solution:
2. Check the exhaust gas absolute pressure sensor pressure signal circuit for an open circuit condition.
From To Value
From To Value
A. If there is continuity, there is a short to high source condition in the B-9005 pressure signal circuit, wire EN-035.
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From To Value
A. If there is voltage, there is a short to key power condition in the B-9005 pressure signal circuit, wire EN-035.

Use the EST to verify that DTC 1758 - Exhaust gas pressure sensor voltage is higher than expected has been
resolved.
has been resolved.
operation.
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3986-(DTC 275D)-Exhaust gas pressure sensor voltage is lower

than expected
Context:
The Engine Control Unit (ECU) monitors the exhaust gas absolute pressure sensor signal circuit for a voltage lower
than expected condition. If the ECU determines that the exhaust gas absolute pressure sensor voltage is less than
200 mV for a period greater than 500 ms.
Cause:
The ECU has determined that the exhaust gas absolute pressure sensor voltage is less than 200 mV for a period
greater than 500 ms.
1. Faulty exhaust gas absolute pressure sensor signal circuit, short to ground condition.
2. Faulty exhaust gas absolute pressure sensor, internal failure.
Solution:
2. Check the exhaust gas absolute pressure sensor signal circuit for a short to ground condition.
From To Value
A. If there is continuity, there is a short to ground in the B-9005 pressure signal circuit, wire EN-035. Locate and

Use the EST to verify that DTC 2858 - Exhaust gas pressure sensor voltage is lower than expected has been
resolved.
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has been resolved.
operation.
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4113-Logical error at FNR switch

NOTICE: check fuses 4F32 and 4F33, replace as needed.
Cause:
1. FNR switch faulty.

2. Faulty reading from the component.
3. Connectors not mated fully, pins not pushed into connector fully, bent pin or broken wire at rear of the connector.
4. Wiring or circuits open.
5. Wiring or circuits shorted.
Solution:
1. Verify that the fault code is still active, refer to 0000-Retrieving fault codes (55.408).
Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence.
(1) Turn the key switch to RUN position.
(2) Clear all fault codes.
(3) To check for fault code: start and operate the machine.
A. OK – Fault is not recorded again. OK for return to service.
B. NOT OK – Fault code 4113 is recorded again. Go to Step 2.

2. Check power circuit to FNR switch.
(1) Disconnect the Connector B12X3 and turn the key switch ON.
(2) Inspect the pin A of the Connector B12X3. Clean the connections.
(3) Take a voltage reading at pin A of the Connector B12X3, a reading of 24 V should be obtained.
A. NOT OK — Check the fuse 4F33. Return to Step 1 to confirm elimination of fault.
B. OK — Go to step 3.
3. Check circuit from pin A of the Connector B12X3 to pin A3 of the Connector 4F4K.
(1) Take an Ohm reading from pin A of the Connector B12X3 to pin A3 of the Connector 4F4K.
(2) If circuit is open, take an Ohm reading from pin A of the Connector B12X3 to Connector SPL_X33-10_2.
(3) From Connector SPL_X33-10_2 to pin 25 of the Connector X101.
(4) From pin 25 of the Connector X101 to pin 1 of the Connector XA1.
(5) From pin 1 of the Connector XA1 to pin A3 of the Connector 4F4K.
A. NOT OK — Determine the break between connectors and repair. Return to Step 1 to confirm elimination of
fault.
4. Check gear selection at FNR switch.
(1) Disconnect the Connector B12X3 and the Connector B12X2.
(2) Inspect all pins on the Connector B12X3 and the Connector B12X2. Clean the connections.
(3) Take Ohm readings as listed below, continuity should be obtained.
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(4) Place range selector in 1st gear, place FNR in F position. From pin A of the Connector B12X3 to: pin B of the
Connector B12X3, pin B of the Connector B12X2 and pin D of the Connector B12X2.
(5) Place range selector in 1st gear, place FNR in R position. From pin A of the Connector B12X3 to: pin C of
the Connector B12X3, pin B of the Connector B12X2 and pin D of the Connector B12X2.
(6) Place range selector in 2nd gear, place FNR in F position. From pin A of the Connector B12X3 to: pin B of
the Connector B12X3 and pin D of the Connector B12X2.
(7) Place range selector in 2nd gear, place FNR in R position. From pin A of the Connector B12X3 to: pin C of
(8) Place range selector in 3rd gear, place FNR switch F position. From pin A of the Connector B12X3 to: pin B
of the Connector B12X3, pin C of the Connector B12X2 and pin D of the Connector B12X2.
(9) Place range selector in 3rd gear, place FNR in R position. From pin A of the Connector B12X3 to: pin C of
(10) Place range selector in 4th gear, place FNR in F position. From pin A of the Connector B12X3 to: pin B of the
Connector B12X3, pin B of the Connector B12X2, pin C of the Connector B12X2 and pin D of the Connector
B12X2.
(11) Place the range selector in any gear, place the FNR in N position. From pin A of the Connector B12X3 to
pin D of the Connector B12X3.
A. NOT OK — Replace FNR switch. Return to step 1 to confirm elimination of fault.
5. Check for open circuit between FNR switch and transmission electronic control module.
(2) Disconnect the Connector XA1 from the transmission electronic control module.
(3) Inspect the pins 22, 43, 63, 64 and 65 of the Connector XA1. Clean the connections.
(4) Check for continuity in the following circuits.
(5) Check for open circuit between the pin B of the Connector B12X3 and pin 43 of the Connector XA1.
(6) Check for open circuit between the pin C of the Connector B12X3 and pin 64 of the Connector XA1.
(9) Check for open circuit between the pin D of the Connector B12X2 and pin 22 of the Connector XA1.
fault.
B. OK — Go to Step 6.
6. Replace the transmission electronic control module.
(1). Remove and replace the transmission electronic control module.
A. Return to Step 1 to confirm elimination of fault.

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4114-Logical error at direction select signal

Cause:

Solution:
B. NOT OK – Fault code 4114 is recorded again. Go to Step 2.

2. Check the power circuit to FNR switch.
fault.
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B12X2.
fault.

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4116-Logical error at park brake status

NOTICE: Check fuses 2F11 and 4F33, replace fuses as needed.
Cause:
1. Parking brake switch faulty.

Solution:
Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occur-
rence.
A. NOT OK – Fault code 4116 is recorded again. Go to Step 2.
B. OK – Fault is not recorded again. OK for return to service.

2. Check the parking brake relay.
(1). Remove the parking brake relay 2K115 from the Connector 2F2K.
(2). Replace the parking brake relay with a known good relay.
B. NOT OK — Go to Step 3.
C. OK — Replace the defective relay.

3. Check the power circuit parking brake relay.
(1). Take voltage reading at pin B9 (30) of the Connector 2F2K, a reading of 24 V should be obtained.
A. NOT OK — Check fuse 4F33. Return to Step 1 to confirm elimination of fault.
4. Check function of parking brake switch.
(1). Disconnect the Connector XS16.
(2). Inspect all pins on the Connector XS16. Clean the connections.
(3). Place the parking brake switch in the release parking brake position, measure Ohm between pins 2 and 3
on the parking brake switch, continuity should be obtained.
A. NOT OK— Replace the parking brake switch. Return to Step 1 to confirm elimination of fault.
B. OK— Go to Step 5.
5. Check the power circuit to the parking brake switch.
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(2). Turn the key switch ON.
(3). Take a voltage reading at pin 2 of the Connector XS16, a reading of 24 V should be obtained.
A. NOT OK— Check the fuse 2F11 in the Connector 2F2K, if fuse is not blown go to Step 6, if fuse is blown
replace and return to Step 1 to confirm elimination of fault.
B. OK— If you have power at the parking brake switch go to Step 7.

6. Check the circuit.
Take an Ohm reading from pin 2 of the Connector XS16 to pin A1 of the Connector 2F2K.
(1). If circuit is open, take an Ohm reading from pin 2 of the Connector XS16 to pin 3 of the Connector X33-5.
(2). From pin 3 of the Connector X33-5 to pin 6 of Connector X101.
(3). From pin 6 of the Connector X101 to pin A1 of the Connector 2F2K.
A. NOT OK— Determine the break between connectors and repair. Return to Step 1 to confirm elimination of
fault.
7. Check the circuit between parking brake switch and Advanced Instrument Cluster.
(2). Disconnect the Connector XCN2 from the Advanced Instrument Cluster.
(3). Inspect the pin 6 of the Connector XCN2. Clean the connections.
(4). Check circuit between the pin 1 of the Connector XS16 and the pin 6 of the Connector XCN2 there should
be continuity.
fault.
8. Check for open circuit between the Advanced Instrument Cluster and the parking brake relay.
(1). Disconnect the Connector XCN1.
(3). Check for continuity the circuit between pin B10 (85) of the Connector 2F2K and pin 14 of the Connector
XCN1.
fault.
9. Check for open circuit between the parking brake relay and the parking brake solenoid.
(2). Disconnect the Connector XY16 from parking brake solenoid.
(3). Inspect the pins on Connector XY16. Clean the connections.
(4). Check for open circuit between from pin B9 (30) of the Connector 2F2K and pin 1 of the Connector XY16.
(5). If circuit is open check from pin B10 (85) of the Connector 2F2K to pin 14 of the Connector XCN1.
fault.
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10. Check the ground circuit of the parking brake solenoid.
(1). Disconnect the Connector XY16 from the parking brake solenoid.
(3). Check for open circuit between pin 2 of the Connector XY16 and ground stud Connector X31CF1-2.
fault.

11. Check the parking brake solenoid.
(2) Take an Ohm reading on the solenoid, a reading of 40.3 Ω at 20 °C (68.0 °F) should be obtained.
A. NOT OK— Replace solenoid. Return to Step 1 to confirm elimination of fault.

12. Replace the Advanced Instrument Cluster.
(1). Remove the Advanced Instrument Cluster.

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4117-Logic error at direction select signal 2

Cause:

Solution:

2. Check power circuit to FNR switch.
(3) Turn the key switch ON.
fault.
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B12X2.
fault.

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4133-Short circuit to battery voltage or open circuit at transmission

sump temperature sensor input
Cause:
1. Failed the thermocouple.

2. Faulty reading from component.
Solution:
A. Fault code 4133 is recorded again. Go to Step 2.
B. The fault is not recorded again. OK for return to service.

2. Disconnect the Connector XA9 at the valve body.
(1) Take an Ohm reading at the valve body from pin 8 to pin 9, a reading of 988 Ω at 27 °C (80.6 °F) and 1.44 k Ω
at 80 °C (176.0 °F) should be obtained.
A. NOT OK – Replace the valve body, internal harness. Return to Step 1 to confirm elimination of fault.
B. OK – Go to Step 3.
(1). Disconnect the Connector XA1 from the transmission electronic control module.
(2). Inspect the pins 39 and 46 of the Connector XA1. Clean connections.
(3). Check from pin 8 of the Connector XA9 to pin 39 of the Connector XA1.
(5). If circuit is open, check from pin 8 of the Connector XA9 to pin 16 of the Connector X33-20 .
(6). Check from pin 16 of the Connector X33-20 to pin 39 of the Connector XA1.
(7). If circuit is open check from pin 9 of the Connector XA9 to pin 17 of the Connector X33-20.
(8). Check from pin 17 Connector X33-20 to pin 46 of the Connector XA1.
A. NOT OK – Determine the break between connectors and repair. Return to Step 1 to confirm elimination of fault.
(1) Remove and replace the transmission electronic control module.

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4134-Short circuit to ground at transmission sump temperature

sensor input
Cause:
1. Failed the thermocouple.

Solution:
A. The fault is not recorded again. OK for return to service.
B. Fault code 4134 is recorded again. Go to Step 2.

(1). Disconnect the Connector XA1 from the transmission electronic control module.
(2). Inspect the pins 39 and 46 of the Connector XA1. Clean connections.
(5). If circuit is open, check from pin 8 of the Connector XA9 to pin 16 of the Connector X33-20 .
(7). If circuit is open check from pin 9 of the Connector XA9 to pin 17 of the Connector X33-20.
(8). Check from pin 17 Connector X33-20 to pin 46 of the Connector XA1.

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4135-Short circuit to battery voltage or open circuit at retarder/

torque converter temperature sensor input
Cause:
1. Failed the temperature sensor.

Solution:

(1). Disconnect the Connector XA1 from the transmission control module.
(2). Inspect the pins 46 and 49 of the Connector XA1. Clean the connections.
(3). Check from pin 1 of the Connector XB15 to pin 46 of the Connector XA1.
(5). If circuit is open, check from pin 1 of the Connector XB15 to pin 17 of the Connector X33-20.
(7). If circuit is open check from pin 2 of the Connector XB15 to pin 6 of the Connector X33-20.

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4136-Short circuit to ground at retarder/ torque converter

temperature sensor input
Cause:
1. Failed the temperature sensor.

Solution:


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4137-Short circuit to battery voltage or open circuit at parking

brake sensor input
NOTICE: Check the fuses 2F11 and 4F33, replace fuses as needed.
Cause:

Solution:
Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occur-
rence.

2. Check the parking brake relay.
(2). Replace the parking brake relay with a known good relay.
B. NOT OK — Go to Step 3.
C. OK — Replace the defective relay.

3. Check the power circuit parking brake relay.
(1). Take voltage reading at pin B9 (30) of the Connector 2F2K, a reading of 24 V should be obtained.
A. NOT OK — Check fuse 4F33. Return to Step 1 to confirm elimination of fault.
4. Check function of parking brake switch.
(2). Inspect all pins on the Connector XS16. Clean the connections.
(3). Place the parking brake switch in the release parking brake position, measure Ohm between pins 2 and 3
on the parking brake switch, continuity should be obtained.
A. NOT OK— Replace the parking brake switch. Return to Step 1 to confirm elimination of fault.
5. Check the power circuit to the parking brake switch.
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(2). Turn the key switch ON.
(3). Take a voltage reading at pin 2 of the Connector XS16, a reading of 24 V should be obtained.
A. NOT OK— Check the fuse 2F11 in the Connector 2F2K, if fuse is not blown go to Step 6, if fuse is blown
replace and return to Step 1 to confirm elimination of fault.
B. OK— If you have power at the parking brake switch go to Step 7.

Take an Ohm reading from pin 2 of the Connector XS16 to pin A1 of the Connector 2F2K.
(1). If circuit is open, take an Ohm reading from pin 2 of the Connector XS16 to pin 3 of the Connector X33-5.
(2). From pin 3 of the Connector X33-5 to pin 6 of the Connector X101.
(3). From pin 6 of the Connector X101 to pin A1 of the Connector 2F2K.
fault.
7. Check the circuit between parking brake switch and Advanced Instrument Cluster.
(2). Disconnect the Connector XCN2 from the Advanced Instrument Cluster.
(4). Check circuit between the pin 1 of the Connector XS16 and the pin 6 of the Connector XCN2 there should
be continuity.
A. NOT OK— Determine break between connectors and repair. Return to Step 1 to confirm elimination of fault.
8. Check for open circuit between the Advanced Instrument Cluster and the parking brake relay.
(1). Disconnect the Connector XCN1.
(3). Check for continuity the circuit between pin B10 (85) of the Connector 2F2K and pin 14 of the Connector
XCN1.
9. Check for open circuit between the parking brake relay and the parking brake solenoid.
(2). Disconnect the Connector XY16 from parking brake solenoid.
(4). Check for open circuit between from pin B9 (30) of the Connector 2F2K and pin 1 of the Connector XY16.
(5). If circuit is open check from pin B10 (85) of the Connector 2F2K to pin 14 of the Connector XCN1.
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10. Check the ground circuit of the parking brake solenoid.
(3). Check for open circuit between pin 2 of the Connector XY16 and ground stud Connector X31CF1-2.

11. Check the parking brake solenoid.
(2) Take an Ohm reading on the solenoid, a reading of 40.3 Ω at 20 °C (68.0 °F) should be obtained.
A. NOT OK— Replace solenoid. Return to Step 1 to confirm elimination of fault.

(1). Remove the Advanced Instrument Cluster.

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4145-Short circuit to battery voltage or open circuit at engine speed

input
Cause:
1. Failed the engine speed sensor.

Solution:

(1) Disconnect the Connector XB1.
(2) Inspect pins on the Connector XB1. Clean the connections.
(4) Inspect pins 3 and 19 of the Connector XA1. Clean the connections.
(5) Check from pin 1 of the Connector XB1 to pin 19 of the Connector XA1.
(6) If circuit is open, check from the pin 1 of the Connector XB1 to pin 2 of the Connector X33-20.
(7) From the pin 2 of the Connector X33-20 to pin 19 of the Connector XA1.
3. Replace the engine speed sensor.
(1) Remove and replace the engine speed sensor.
B. NOT OK— If fault is recorded again go to Step 4.

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A. Remove and replace the transmission electronic control module.
B. Return to Step 1 to confirm elimination of fault.

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4146-Short circuit to ground at engine speed input

Cause:

Solution:

(3) Clean female pins by installing and removing.
(6) Clean female pins by installing and removing.
(8) If circuit is open, check from pin 1 of the Connector XB1 to pin 2 of the Connector X33-20.
(9) From pin 2 of the Connector X33-20 to pin 19 of the Connector XA1.

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B. Return to Step 1 to confirm elimination of fault. If fault is recorded again contact Technical Services Group for
assistance.
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4147-Logical error at engine speed input

NOTE: This fault code is reset after power up of the transmission electronic control module. It is also reset if the signal
is above zero speed threshold.
Cause:

Solution:


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4148-Short circuit to battery voltage or open circuit at turbine

speed input
Cause:
1. Failed the turbine speed sensor.

Solution:

(1) Disconnect the Connector XB2 at turbine speed sensor.
3. Replace the turbine speed sensor.
(1) Remove and replace the turbine speed sensor.

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4149-Short circuit to ground at turbine speed input

Cause:

Solution:


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4150-Logical error at turbine speed input

NOTE: This fault code is reset after power up of the transmission electronic control module.
Cause:

Solution:


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4151-Short circuit to battery voltage or open circuit at internal

speed input
Cause:
1. Failed the intermediate speed sensor.

Solution:

(1) Disconnect the Connector XB3 at intermediate speed sensor.
3. Replace the intermediate speed sensor.
(1) Remove and replace the intermediate speed sensor.

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4152-Short circuit to ground at internal speed input

Cause:

Solution:


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4153-Logical error at internal speed input

NOTE: This fault code is reset after power up of the transmission electronic control module.
Cause:

Solution:


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4154-Short circuit to battery voltage or open circuit at output speed

input
NOTICE: Check the fuse 4F33.
Cause:
1. Incorrect output speed reading.

Solution:

2. Check the power to output speed sensor.
(1) Disconnect the Connector XB4 at output speed sensor.
(4) Take a voltage reading at pin 3 of the Connector XB4, a reading of 24 V should be obtained.
A. NOT OK— Check the fuse 4F33. Return to Step 1 to confirm elimination of fault.
3. Check the power circuit.
(1) Take an Ohm reading from pin 3 of the Connector XB4 to pin A3 of the Connector 4F4K.
(2) If circuit is open, take an Ohm reading from pin 3 of the Connector XB4 to pin 18 of the Connector X33-20.
(3) Check from pin 18 of the Connector X33-20 to the Connector SPL_X33–10_2.
(4) Check from Connector SPL_X33–10_2 to pin 25 of the Connector X101.
(5) Check from pin 25 of the Connector X101 to pin 1 of the Connector XA5.
(6) Check from pin 1 of the Connector XA5 to pin A3 of the Connector 4F4K
fault.
4. Check the Circuit.
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(5) If circuit is open check from pin 1 of the Connector XB4 to pin 20 of the Connector X33-20.
(6) Check from pin 20 of the Connector X33-20 to pin 4 of the Connector XA1.
A. NOT OK— Determine the break between the connectors and repair. Return to Step 1 to confirm elimination of
fault.
5. Replace the output speed sensor.
(1) Remove and replace the output speed sensor.

A. Return to Step 1 to confirm the elimination of fault.

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4155-Short circuit to ground at output speed input

Cause:

Solution:

fault.
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fault.


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4156-Logical error at output speed input

Cause:

Solution:

fault.
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fault.


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4158-Output speed zero, doesn't fit to other speed signals

Cause:

Solution:

fault.
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fault.


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4160-Invalid gear range restriction (CAN)

NOTICE: check the fuse 4F33.
Cause:
1. Failed the Advanced Instrument Cluster.

Solution:
1. Verify that the fault code is still active, refer to the Instrument cluster - Special instruction (55.408) .
(2) Clear all the fault codes.

2. Check the CAN circuit.
(1) Disconnect the Connector XCN1.
(2) Inspect pins in the Connector XCN1. Clean the connections.
(5) Check from pin 3 of the Connector XCN1 to pin 25 of the Connector XA1.
fault.
(1) Remove and replace the Advanced Instrument Cluster.

A. Return to the Step 1 to confirm elimination of fault.

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4186-Invalid park brake status (CAN)

Cause:

Solution:
1. Verify that the fault code is still active, refer to the Instrument cluster - Special instruction (55.408).

fault.


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4209-Short circuit to battery voltage at clutch K1

Cause:
1. K1 clutch not operative, the transmission goes into limp home mode.
Solution:
1. Verify that the fault code is still active, refer to the Verify that the fault code is still active, refer to the 0000-Retriev-
ing fault codes (55.408).
A. NOT OK – Fault code 4209 is recorded again. Go to the Step 2.

2. Disconnect the connector at the valve body.
(1) Take Ohm reading at the valve body from pin 3 to pin 7, a reading of 19 Ω at 27 °C (80.6 °F) should be obtained.
A. NOT OK – Replace Y3 solenoid. Return to the Step 1 to confirm elimination of fault.
B. OK – Go to the Step 3.
(2) Inspect pin 32 of the Connector XA1. Clean the connections.
(3) Check from pin 3 of the Connector XA9 to pin 32 of the Connector XA1.
(4) If circuit is open check from pin 3 of the Connector XA9 to pin 11 of the Connector X33-20.

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4210-Short circuit to ground at clutch K1

Cause:
Solution:
1. Verify that the fault code is still active, refer to the 0000-Retrieving fault codes (55.408).


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4211-Open circuit at clutch K1

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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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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4228-Short circuit to battery voltage at clutch KV

Cause:
1. KV clutch not operative, the transmission goes into limp home mode.
Solution:


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4229-Short circuit to ground at clutch KV

Cause:
Solution:


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4230-Open circuit at clutch KV

Cause:
Solution:


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4231-Short circuit to battery voltage at clutch KR

Cause:
1. KR clutch not operative, the transmission goes into limp home mode.
Solution:


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4232-Short circuit to ground at clutch KR

Cause:
Solution:


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4233-Open circuit at clutch KR

Cause:
Solution:


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4241-Short circuit to ground at backup alarm relay

NOTICE: Check the fuse 3F25, replace as needed.
Cause:
1. Backup alarm does not work.

3. Connectors not mated fully, pins not pushed into the connector fully, bent pin or broken wire at rear of the connector.
Solution:
B. OK – Fault is not recorded again. OK for return to the service.

2. Check the relay.
(1) Remove the backup alarm relay.
(2) Replace the relay with known good relay.
B. NOT OK – Go to Step 3.
C. OK – Replace the defective relay.

(1) Check for the voltage at the pin D9 (86) of the Connector 3F3K, a reading of 24 V should be obtained.
(2) If there is no voltage, remove relay and fuse 3F25.
(3) Check from pin A5 of the Connector 3F3K to pin D9 (86) of the Connector 3F3K.
4. Check the control circuit.
(1) Turn the key switch ON, place the FNR selector in the R position, release the parking brake and press the foot
brake.
(2) Check for ground at the pin B10 (85) of the Connector 3F3K, a reading of continuity should be obtained.
(5) Check from pin B10 (85) of the Connector 3F3K to pin 7 of the Connector XA1.
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(1) Check for voltage at the pin B9 (30) of the Connector 3F3K, a reading of 24 V should be obtained.
(3) Take an Ohm reading from pin D9 (86) of the Connector 3F3K to pin B9 (30) of the Connector 3F3K.

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4242-Short circuit to battery voltage at backup alarm relay

Cause:

Solution:

2. Check the relay.

brake.
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4243-Open circuit at backup alarm relay

Cause:

Solution:

2. Check the relay.

brake.
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4273-Slippage at clutch K1
NOTICE: check the clutch pressures. Refer to Powershift transmission - Dynamic description (21.113) and the
Clutch - Dynamic description - Transmission Clutch Calibration (21.155).
Cause:
1. Failed speed the sensor.

Solution:

2. Refer to Powershift transmission - Dynamic description (21.113) to perform pressure checks and transmission
troubleshooting.
A. OK – No errors were found during the troubleshooting. Go to Step 3.
B. NOT OK – Repair the transmission as needed.

3. Refer to 4153-Logical error at internal speed input (55.020) and troubleshoot intermediate speed sensor ( Con-
nector XB3). Do not replace the transmission electronic control module at this time.
A. OK – Go to Step.4.
4. Refer to 4156-Logical error at output speed input (55.020) and troubleshoot output speed sensor
( Connector XB4).
A. OK – Go to Step 5.

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Cause:

Solution:

troubleshooting.

( Connector XB4).

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Cause:

Solution:

troubleshooting.

( Connector XB4).

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Cause:

Solution:

troubleshooting.

( Connector XB4).

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4277-Slippage at clutch KV
Cause:

Solution:

troubleshooting.

( Connector XB4).

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4278-Slippage at clutch KR
Cause:

Solution:

troubleshooting.

( Connector XB4).

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4279-Overtemp sump
NOTICE: check the transmission oil level, check the oil type.
Cause:
1. Transmission temperature is above set value.

Solution:

2. Stop the machine operations.
(1) Run the engine at 1500 RPM.
(2) Check the fan operation.
(3) Check the cooling core for clogs.
A. NOT OK – Repair the fan or clear clogs from cooling core. Return to Step 1 to confirm elimination of fault.
(1) Take an Ohm reading at the valve body from pin 8 to pin 9, a reading of 988 Ω at 27 °C (80.6 °F), 1.44k Ω at
80 °C (176.0 °F) should be obtained.
A. NOT OK – Replace the valve body internal harness. Return to Step 1 to confirm elimination of fault.
(2) Inspect the pins 39 and 46 of the Connector XA1. Clean the connections.
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4281-Engine overspeed
Cause:

Solution:


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B. Return to Step 1 to confirm elimination of fault. If fault is recorded again contact Technical Services Group for
assistance.
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4282-TCM sensed a voltage at oil filter maintenance switch out of

the allowed range (dirty filter)
Cause:
1. Filter the clogged.

Solution:

2. Replace the filter.
C. OK – Fault is not recorded again. OK for return to service.

3. Disconnect the Connector XS17-9 at transmission oil filter pressure switch.
(1) Inspect pins on the Connector XS17-9 and oil filter pressure switch. Clean the connections.
(2) Take an Ohm reading at the oil filter pressure switch, a reading of 510 Ω at 20 °C (68.0 °F) should be obtained.
A. NOT OK – Replace the switch. Return to Step 1 to confirm elimination of fault.
(2) Inspect pins 17 and 46 of the Connector XA1. Clean connections.
(3) Check from pin 1 of the Connector XS17-9 to pin 46 of the Connector XA1.
(4) If circuit is open, check from pin 1 of the Connector XS17-9 to pin 17 of the Connector X33-20.
(6) Check from pin 2 of the Connector XS17-9 to pin 17 of the Connector XA1.
(7) If circuit is open, check from pin 2 of the Connector XS17-9 to pin 28 of the Connector X33-20.
A. NOT OK – Determine break between connectors and repair. Return to Step 1 to confirm elimination of fault.
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4284-Overspeed output
Cause:
1. Output the speed reading erratic

Solution:

A. NOT OK— Go to Step 3.
(1) Take an Ohm reading from pin 3 of the Connector XB4 to the Connector SPL_X33–10_2. Check buss bar
terminal for correct tension or corrosion, test buss bar from pin to pin for continuity.
fault.
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fault.


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4290-Transmission input torque overload

Cause:
1. The transmission electronic control module calculates a transmission input torque above the defined thresholds.
Solution:
B. NOT OK – Fault code 4290 is recorded again. Go to the Step 2.

2. Calibrate the clutches.
(1) Calibrate the clutches accord to Clutch - Dynamic description - Transmission Clutch Calibration (21.155).
A. OK – Return to the Step 1 to confirm the elimination of fault.
B. NOT OK – Repair or replace the transmission as needed.

3. Perform the engine stall test.
(1) Check the engine stall speeds.
A. OK – Go to the Step 4.
B. NOT OK – Repair or replace the engine or transmission as needed.

A. Return to the Step 1 to confirm the elimination of fault.

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4291-Overtemp converter output

Cause:
1. Failed temperature sensor.

Solution:

2. Stop the machine operations.
(1) Run the engine at 1500 RPM.
(2) Check the fan operation.
(3) Check the cooling core for clogs.
A. NOT OK – Repair the fan or clear clogs from cooling core. Return to Step 1 to confirm elimination of fault.
3. Disconnect the Connector XB15 at torque converter output temperature sensor.
(1) Take an Ohm reading at the sensor, a reading of 60k Ω at 20 °C (68 °F) and 6.53k Ω at 93 °C (199.4 °F) should
be obtained.
A. NOT OK – Replace the sensor. Return to Step 1 to confirm elimination of fault.
4. Check circuit.
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4292-Short circuit to ground at joystick status indicator

Cause:
1. Vehicle the transmission operations stopped, can not select gears.

Solution:
1. Verify that the fault code is still active, refer to 0000-Retrieving fault codes (55.408) .

(1) Disconnect the Connector B12X3.
fault.
4. Check the gear selection at FNR switch.
(2) Inspect all pins on the Connector B12X3 and on the Connector B12X2. Clean the connections.
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(4) Place the range selector in 1st gear, place the FNR in F position. From pin A of the Connector B12X3 to: pin
B of the Connector B12X3, pin B of the Connector B12X2 and pin D of the Connector B12X2.
(5) Place the range selector in 1st gear, place the FNR in R position. From pin A of the Connector B12X3 to: pin
C of the Connector B12X3, pin B of the Connector B12X2 and pin D of the Connector B12X2.
(6) Place the range selector in 2nd gear, place the FNR in F position. From pin A of the Connector B12X3 to: pin
B of the Connector B12X3 and pin D of the Connector B12X2.
(7) Place the range selector in 2nd gear, place the FNR in R position. From pin A of the Connector B12X3 to: pin
C of the Connector B12X3 and pin D of the Connector B12X2.
(8) Place the range selector in 3rd gear, place the FNR switch F position. From pin A of the Connector B12X3 to:
pin B of the Connector B12X3, pin C of the Connector B12X2 and pin D of the Connector B12X2.
(9) Place the range selector in 3rd gear, place the FNR in R position. From pin A of the Connector B12X3 to: pin
(10) Place the range selector in 4th gear, place the FNR in F position. From pin A of the Connector B12X3 to:
pin B of the Connector B12X3, pin B of the Connector B12X2, pin C of the Connector B12X2 and pin D of the
Connector B12X2.
(11) Place the range selector in any gear, place the the FNR in N position. From pin A of the Connector B12X3
to pin D of the Connector B12X3.
A. NOT OK — Replace the FNR switch. Return to step 1 to confirm elimination of fault.
5. Check for open circuit between the FNR switch and transmission electronic control module.
fault.

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4293-Short circuit to battery voltage at joystick status indicator

Cause:

Solution:

(1) Disconnect the Connector B12X3.
fault.
4. Check the gear selection at FNR switch.
(2) Inspect all pins on the Connector B12X3 and on the Connector B12X2. Clean the connections.
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Connector B12X2.
fault.

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4294-Open circuit at joystick status indicator

Cause:
1. Burnt-out indicator light in the FNR enable the switch.

Solution:

2. If equipped, activate the forward-neutral-reverse (FNR) auxiliary enable switch on the side console by pushing
down at the top of the switch.
(1) Operate the auxiliary FNR switch at the loader controls.
(2) Observe the light in the auxiliary enable switch on the side console, does the light illuminate.
A. NOT OK — Replace the switch. Return to Step 1 to confirm elimination of fault.
(1) Disconnect the Connector B12X3 and turn key switch ON.
fault.
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Connector B12X2.
fault.
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4305-Short circuit to battery voltage at power supply for sensors

NOTICE: check the fuses 4F32 and 4F33, replace as needed.
Cause:
1. Over voltage to the transmission electronic control module.

Solution:

2. Check the equipment voltage.
(1) Start and run engine at high idle.
(2) Check the output voltage of alternator.
A. NOT OK – Repair the electrical system as needed. Return to the Step 1 to confirm elimination of fault.

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4306-Short circuit to ground at power supply for sensors

NOTICE: check the fuses 4F32 and 4F33, replace as needed.
Cause:

Solution:

A. NOT OK – Repair the electrical system as needed. Return to the Step 1 to confirm elimination of fault.

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4307-Low voltage at battery

Cause:
1. Under voltage to the transmission electronic control module.

Solution:
1. Verify that the fault code is still active, refer to the 0000-Retrieving fault codes (55.408) .

A. NOT OK – Repair the electrical system as needed. Return to Step 1 to confirm elimination of fault.

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4308-High voltage at battery

Cause:

Solution:


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4309-Error at valve power supply VPS1

Cause:

Solution:


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4310-Error valve power supply VPS2

Cause:

Solution:


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4325-VehicleID#1 timeout
Cause:

2. Blown the fuse 1F1.
Solution:
1. The EST will have to be used to retrieve and transmission faults do to lack of communication with the Advanced
Instrument Cluster from the transmission electronic control module. Verify that the fault code is still active, refer
to the 0000-Retrieving fault codes (55.408). Prior to clearing fault codes write down all fault codes, number of
occurrences, and engine hours at last occurrence.
(2) Clear all the fault codes, the EST will have to used to read and clear fault codes from the transmission electronic
control module.

2. Verify the voltage at fuse 1F1.
(3) Check for voltage at the pins 14 and 20 of the Connector XCN2.
(4) If no voltage or low voltage, check for corrosion or loose terminal tension at pins 14 and 20.
(5) Check from pins 14 and 20 of the Connector XCN2 to pin A1 of the Connector 1F1K.
A. NOT OK— Determine the break between the connectors and repair. Return to the Step 1 to confirm elimination
of fault.
B. OK— Go to the Step 3.

(4) Inspect the pins 25 and 26 of the Connector XA1. Clean the connections.
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A. NOT OK— Determine the break between connectors and repair. Return to the Step 1 to confirm elimination of
fault.
B. OK— Go to the Step 3.

4. Check the grounding circuit.
(1) Disconnect the Connector XCN1 and the Connector XCN2.
(2) Inspect the pins 6 and 12 of the Connector XCN1 and the pins 15 and 22 of the Connector XCN2. Clean the
connections.
(3) Check the circuit from pins 6 and 12 of the Connector XCN1, pins 15 and 22 of the Connector XCN2 to
ground, a reading of continuity should be obtained.
(4) If circuit is open, check circuit from pins 15 and 22 of the Connector XCN2 to Connector X31ST-1 on the
steering column ground upper stud.
(5) Check the circuit from pin 6 of the Connector XCN1 to pin 5 of the Connector X33-4.
(6) Check the circuit from pin 5 of the Connector X33-4 to pin 1 of the Connector X101.
(7) Check the circuit from pin 1 of the Connector X101 to the Connector X31SC-5 on the cab ground block.
(8) Check the circuit from pin 12 of the Connector XCN1 to Connector X31ST-1 on the steering column ground
upper stud.
A. NOT OK— Determine the break and repair. Return to the Step 1 to confirm elimination of fault.
B. OK — Go to the Step 5.


schematic sheet 09 (55.100) Harnesses and connectors - Electrical schematic sheet 15 (55.100) Harnesses
and connectors - Electrical schematic sheet 16 (55.100) Harnesses and connectors - Electrical schematic
sheet 18 (55.100)
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4326-Illegal ID request via CAN

Cause:
1. CAN communication interrupted during the normal operation.

Solution:

2. Check the configuration of the advanced instrument cluster and the transmission electronic control module using
the EST.
A. NOT OK – Update the advanced instrument cluster and the transmission electronic control module as required.
Return to the Step 1 to confirm elimination of fault.

and connectors - Electrical schematic sheet 19 (55.100)
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4337-General EEPROM fault

Cause:
1. Failed the transmission electronic control module.
Solution:


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4338-Configuration error
Cause:
Solution:

2. (1) Reprogram the correct configuration for the vehicle.
B. NOT OK – Fault is recorded again, Go to Step 3.


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4339-Application error
Cause:
Solution:


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4341-Clutch failure
Cause:

2. Clutch the calibration lost from the memory.
Solution:

2. (1) Calibrate the clutches.
B. NOT OK – Fault is recorded again, Go to the Step 3.


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4342-Clutch adjustment data lost

Cause:

2. Clutch the adjustment data lost from the memory.
Solution:

2. (1) Calibrate the clutches.
B. NOT OK – Fault is recorded again, Go to the Step 3.


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5155-UCM Ground disconnection

Control Module : UCM
Cause:
UCM Ground sense connection loosed.
1. Connection of the Connector XCN1A.

2. Quality of the pin 7 of the Connector XCN1A.
3. Lack of continuity between the pin 7 of the Connector XCN1A and battery minus (-).
Solution:
1. Turn the key switch OFF and wait for power down.
Make sure that the Connector XCN1A is locked to the UCM. If the fault is present and active, continue with Step
2.
Disconnect the Connector XCN1A. Lock the pin 7 of the Connector XCN1A inside the connector harness side.
Perform short singe wire pull-check to verify if pin is fasten enough. Reconnect the Connector XCN1A. If the fault
is present and active, continue with Step 3.
Disconnect the Connector XCN1A. Straight the pin 7 to avoid accidental contact to other pins or replace the pin
7 on harness side. Reconnect the Connector XCN1A. If the fault is present and active, continue with Step 4.
Disconnect the Connector XCN1A. Fix the wire 100_31 at cab ground outer hole (ground stud) or replace the
existing wire with a new one. Reconnect the Connector XCN1A.
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5159-Error at Fuse 5F2

Cause:
1. Error at the fuse 5F2 (blown, open circuit).

2. Error at wiring.
1. Fuse 5F2 is blown.

2. Lack of continuity between the pin 26 of the Connector XCN1A and Connector X15A_SP3.
Solution:
Pull the fuse 5F2 and verify if the fuse is not blown. If the fuse 5F2 is blown, replace it. If the fault is present and
active, continue with Step 2.
2. Turn the key switch OFF and wait for power down. Disconnect the Connector XCN1A.
Perform continuity test between the pin 26 of the Connector XCN1A and Connector X15A_SP3 to detect open
circuit:
- Segment 1: from pin 26 of the Connector XCN1A to pin 2 of the fuse 5F2.
- Segment 2: from pin 1 of the fuse 5F2 to pin 3 of the Connector X_UCM2.
- Segment 3: from pin 3 of the Connector X_UCM2 to Connector X15A_SP3.
Once the open circuit is detected, fix the screws or pins or replace wire to eliminate open circuit.
Reconnect the Connector XCN1A.
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Cause:

2. Error at wiring.

2. Lack of continuity between the pins 7 and 13 of the Connector XCN2A and Connector X15A_SP3.
Solution:
Perform continuity test between the pins 7 and 13 of the Connector XCN2A and Connector X15A_SP3 to detect
open circuit:
- Segment 1a: from pin 7 of the Connector XCN2A to pin 2 of the fuse 5F3.
- Segment 1b: from pin 13 of the Connector XCN2A to pin 2 of the fuse 5F3.
Reconnect Connector XCN2A.
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Cause:

2. Error at wiring.

2. Lack of continuity between the pins 2 and 3 of the Connector XCN3B and Connector X15A_SP3.
Solution:
1. Turn key switch OFF and wait for power down.

2. Turn key switch OFF and wait for power down. Disconnect the Connector XCN3B.
Perform continuity test between the pins 2 and 3 of the Connector XCN3B and Connector X15A_SP3 to detect
open circuit:
- Segment 1a: from pin 2 of the Connector XCN3B to pin 2 of the fuse 5F4.
- Segment 1b: from pin 3 of the Connector XCN3B to pin 2 of the fuse 5F4.
Reconnect the Connector XCN3B.
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Cause:

2. Error at wiring.

2. Lack of continuity between the pins 8 and 9 of the Connector XCN3B and Connector X15A_SP3.
Solution:
2. Turn the key switch OFF and wait for power down. Disconnect the Connector XCN3B.
Perform continuity test between the pins 8 and 9 of the Connector XCN3B and Connector X15A_SP3 to detect
open circuit:
- Segment 1a: from pin 8 of the Connector XCN3B to pin 2 of the fuse 5F5.
- Segment 1b: from pin 9 of the Connector XCN3B to pin 2 of the fuse 5F5.
Reconnect Connector XCN3B.
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Cause:

2. Error at wiring.
1. The fuse 5F6 is blown.

2. Lack of continuity between the pins 7 and 13 of the Connector XCN3A and Connector X15A_SP3.
Solution:
Pull the fuse 5F6 and verify if fuse is not blown. If the fuse 5F6 is blown, replace it.
If the fault is present and active, continue with Step 2.
Perform continuity test between the pins 7 and 13 of the Connector XCN3A and Connector X15A_SP3 to detect
open circuit:
- Segment 1a: from pin 7 of the Connector XCN3A to pin 2 of the fuse 5F6.
- Segment 1b: from pin 13 of the Connector XCN3A to pin 2 of the fuse 5F6.
Reconnect Connector XCN3A.
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5164-Open Circuit at Wheel Motor Valve Y8.2

Cause:
Open circuit at wheel motor Y8.2.
1. Connection of the Connector XCN2A and Connector XCN1B and Connector XY8-2.
2. Quality of the 19 of the Connector XCN2A.
3. Quality of the 10 of the Connector XCN1B.
4. Lack of continuity between the pin 19 of the Connector XCN2A and pin 1 of the Connector XY8-2.
5. Lack of continuity between the pin 10 of the Connector XCN1B and the pin 2 of the Connector XY8-2.
Solution:
Reconnect the Connector XCN2A. Make sure that the connector is locked to the controller interface.
2. Reconnect the Connector XCN1B.
Make sure that the connector is locked to the controller interface. If the fault is present and active, continue with
Step 3.
3. Reconnect the Connector XY8-2.
Make sure that the connector is locked to valve. If the fault is present and active, continue with Step 4.
4. Disconnect the Connector XCN2A.
Lock the pin 19 inside the Connector XCN2A harness side. Perform short single wire pull-check to verify if pin
is fasten enough. Reconnect the Connector XCN2A. If the fault is present and active, continue with Step 5.
5. Disconnect the Connector XCN2A. Straight the pin 19 to avoid accidental contact to other pins or replace the pin
19 on harness side. Reconnect the Connector XCN2A. If the fault is present and active, continue with Step 6.
6. Disconnect the Connector XCN1B.
Lock the pin 10 inside the Connector XCN1B harness side. Perform short single wire pull-check to verify if pin
is fasten enough. Reconnect the Connector XCN1B. If the fault is present and active, continue with Step 7.
Straight the pin 10 to avoid accidental contact to other pins or replace the pin 10 on harness side. Reconnect the
Connector XCN1B. If the fault is present and active, continue with Step 8.
8. Disconnect the Connector XCN2A and the Connector XY8-2. Perform continuity test between the pin 19 of the
Connector XCN2A and pin 1 of the Connector XY8-2 to detect the open circuit:
- Segment 1: from pin 19 of the Connector XCN2A to pin 14 of the Connector X_UCM1 .
- Segment 2: from pin 14 of the Connector X_UCM1 to pin 33 of the Connector X102.
- Segment 3: from pin 33 of the Connector X102 to pin 34 of the Connector X38-8.
- Segment 4: from pin 34 of the Connector X38-8 to pin 1 of the Connector XY8-2.
Once the open circuit is detected, fix the screws or pins or replace wire to eliminate the open circuit.
9. Perform continuity test between the pin 10 of the Connector XCN1B to pin 13 of the Connector X_UCM2 (Value:
continuity detected). Once the open circuit is detected, fix the screws or pins or replace wire to eliminate the open
circuit. If the fault is present and active, continue with Step 10.
10. Perform continuity test between the pin 10 of the Connector XCN1B and the pin 2 of the Connector XY8-2 to
detect the open circuit:
- Segment 1: from pin 10 of the Connector XCN1B and pin 13 of the Connector X_UCM2.
- Segment 2: from pin 13 of the Connector X_UCM2 and pin 24 of the Connector X101.
- Segment 3: from pin 24 of the Connector X101 and pin 35 of the Connector X38-8.
- Segment 4: from pin 35 of the Connector X38-8 to pin 2 of the Connector XY8-2.
Reconnect the Connector XCN2A and the Connector XY8-2.
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5165-Open Circuit or Short Circuit to battery at Wheel Motor Valve

Y8.2
Cause:
Open circuit or short circuit to battery at wheel motor Y8.2.
1. Connection of the Connector XCN2A, the Connector XCN1B and the Connector XY8-2.
3. Quality of the pin 10 of the Connector XCN1B.
4. Lack of continuity between the pin 19 of the Connector XCN2A and the pin 1 of the Connector XY8-2.
5. Incorrect voltage at the pin 19 of the Connector XCN2A against system ground.
7. Incorrect voltage at the pin 10 of the Connector XCN1B against system ground.
Solution:
1. Turn the key switch OFF and wait for power down. Reconnect the Connector XCN2A.
Make sure that the connector is locked to the UCM. If the fault is present and active, continue with Step 2.
Connector XCN2A. If the fault is present and active, continue with Step 6.
8. Disconnect the Connector XCN2A and the Connector XY8-2. Perform continuity test between the pin 19 of the
Connector XCN2A and the pin 1 of the Connector XY8-2 to detect open circuit:
- Segment 1: from pin 19 of the Connector XCN2A to pin 14 of the Connector X_UCM1.
- Segment 2: from the pin 14 of the Connector X_UCM1 to the pin 33 of the Connector X102.
- Segment 3: from the pin 33 of the Connector X102 to the pin 34 of the Connector X38-8.
- Segment 4: from the pin 34 of the Connector X38-8 to the pin 1 of the Connector XY8-2.
Reconnect the Connector XCN2A and the Connector XY8-2. Once the open circuit is detected, fix the screws
or pins or replace wire to eliminate open circuit. If the fault is present and active, continue with Step 9.
9. Disconnect the Connector XCN2A and the Connector X_UCM1.
Perform voltage measurement at the pin 19 of the Connector XCN2A against system ground (Value V=0V).
Once the short crcuit to battery is detected, inspect the interfaces of segment (pin quality, pin crossed to each
others) and insolation of wiring. Fix the issues by using new pins, eliminate failed wires and replace by new ones.
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10. Reconnect the Connector X_UCM1 and disconnect the Connector X102.
Once the short circuit to battery is detected, inspect the interfaces of segment (pin quality, pin crossed to each
11. Reconnect the Connector X102 and disconnect the Connector X38-8 .
12. Perform continuity test between the Connector XCN1B and the pin 2 of the Connector XY8-2 to detect open
circuit:
- Segment 1: from the pin 10 of the Connector XCN1B to the pin 13 of the Connector X_UCM2.
Once the open circuit is detected, fix the screws or pins or replace wire to eliminate the open circuit. If the fault
is present and active, continue with Step 13.
13. Disconnect the Connector XCN1B and the Connector X_UCM2
Perform voltage measurement at the pin 10 of the Connector XCN1B against system ground (Value V=0V).
15. Reconnect the Connector X101 and disconnect the Connector X38-8.
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5166-Short Circuit to ground at Wheel Motor Valve Y8.2

Cause:
Short circuit to ground at wheel motor Y8.2

3. Continuity between the pin 19 of the Connector XCN2A and the system ground (battery minus).
4. Continuity between the pin 10 of the Connector XCN1B and the system ground (battery minus).
Solution:

Perform continuity test between the pin 19 of the Connector XCN2A and the system ground (Value: no continuity
detected). Once the short circuit to ground is detected, inspect the interfaces of segment (pin quality, pin crossed
to each others) and insolation of wiring. Fix the issues by using new pins, eliminate failed wires and replace by
new ones. If the fault is present and active, continue with Step 6.
Perform voltage measurement between the pin 19 of the Connector XCN2A against the system ground (Value:
no continuity detected). Once the short circuit to battery is detected, inspect the interfaces of segment (pin quality,
pin crossed to each others) and insolation of wiring. Fix the issues by using new pins, eliminate failed wires and
replace by new ones. If the fault is present and active, continue with Step 8.
8. Disconnect the Connector XCN1B and the Connector X_UCM2.
Perform continuity test between the pin 10 of the Connector XCN1B and the system ground. (Value: no conti-
nuity detected). Once the short circuit to battery is detected, inspect the interfaces of segment (pin quality, pin
crossed to each others) and insolation of wiring. Fix the issues by using new pins, eliminate failed wires and
Perform continuity test between the pin 10 of the Connector XCN1B and the system ground (Value: no continuity
detected). Once the short circuit to battery is detected, inspect the interfaces of segment (pin quality, pin crossed
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new ones.
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5167-Short Circuit to power circuit at Wheel Motor Valve Y8.2

Cause:
Short circuit to power at wheel motor Y8.2.
4. Incorrect voltage at the pin 19 of the Connector XCN2A against the system ground.
5. Incorrect voltage at the pin 10 of the Connector XCN1B against the system ground.
Solution:

Reconnect the Connector XCN2A. Make sure that the connector is locked to the UCM. If the fault is present and
Make sure that the connector is locked to the valve. If the fault is present and active, continue with Step 4.
Perform voltage measurement between the pin 19 of the Connector XCN2A against the system ground (Value
V=0V). Once the short circuit to battery is detected, inspect the interfaces of segment (pin quality, pin crossed to
each others) and insolation of wiring. Fix the issues by using new pins, eliminate failed wires and replace by new
ones. If the fault is present and active, continue with Step 9.
Perform voltage measurement of the pin 19 of the Connector XCN2A against the system ground (Value V=0V).
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Perform voltage measurement of the pin 10 of the Connector XCN1B against the system ground (Value V=0V).
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5169-Open Circuit at FWD On/Off Valve Y8.1

Cause:
Open circuit at FWD On/Off Valve Y8.1
Solution:
Lock the pin 25 inside the Connector XCN2A harness side. Perform short single wire pull-check to verify if pin is
fasten enough. Reconnect the Connector XCN2A. If the fault is present and active, continue with Step 5.
Straight the pin 25 to avoid accidental contact to other pins or replace the pin 25 on the harness side. Reconnect
the Connector XCN2A. If the fault is present and active, continue with Step 6.
Lock the pin 30 inside the Connector XCN1B harness side. Perform short single wire pull-check to verify if pin is
fasten enough. Reconnect the Connector XCN1B. If the fault is present and active, continue with Step 7.
the Connector XCN1B. If the fault is present and active, continue with Step 8.
8. Disconnect the Connector XCN2A and the Connector XY8-1.
Perform continuity test between the pin 25 of the Connector XCN2A and the pin 1 of the Connector XY8-1 to
detect open circuit:
- Segment 1: from the pin 25 of the Connector XCN2A to the pin 15 of the Connector X_UCM1.
Once the open circuit is detected, fix the screws or pins or replace wire to eliminate open circuit. Reconnect the
Connector XCN2A and the Connector XY8-1. If the fault is present and active, continue with Step 9.
9. Disconnect the Connector XCN1B and the Connector XY8-1.
Perform continuity test between the pin 30 of the Connector XCN1B and the pin 2 of the Connector XY8-1 to
detect open crcuit:
Reconnect the Connector XCN2A and the Connector XY8-1.
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5170-Open Circuit or Short Circuit to battery at FWD On/Off Valve

Y8.1
Cause:
Open circuit or short circuit to the battery at FWD On/Off Valve Y8.1
5. Incorrect voltage of the pin 25 of the Connector XCN2A against the system ground.
7. Incorrect voltage of the pin 30 of the Connector XCN1B against the system ground.
Solution:
Straight the pin 30 to avoid accidental contact to other pins or replace the pin on the harness side. Reconnect
- Segment 1: from pin 25 of the Connector XCN2A to the pin 15 of the Connector X_UCM1
- Segment 2: from the pin 15 of the Connector X_UCM1 to the pin 34 of the Connector X102
- Segment 3: from the pin 34 of the Connector X102 to the pin 36 of the Connector X38-8
- Segment 4: from the pin 36 of the Connector X38-8 to the pin 1 of the Connector XY8-1
Perform voltage measurement at the pin 25 of the Connector XCN2A against the system ground (Value V=0V).
Once the short circuit to the battery is detected, inspect the interfaces of segment (pin quality, pin crossed to
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12. Disconnect the Connector XCN1B and the Connector XY8-1. Perform the continuity test between the pin 30 of
the Connector XCN1B and the pin 2 of the Connector XY8-1 to detect open circuit:
Connector XCN1B and the Connector XY8-1. If the fault is present and active, continue with Step 13.
Perform the voltage measurement at the pin 30 of the Connector XCN1B against the system ground (Value
V=0V). Once the short circuit to the battery is detected, inspect the interfaces of segment (pin quality, pin crossed
new ones.
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5171-Short Circuit to ground at FWD On/Off Valve Y8.1

Cause:
Short circuit to the ground at FWD on/off valve Y8.1

Solution:

Lock the pin 25 inside the Connector XCN2A harness side. Perform the short single wire pull-check to verify if
pin is fasten enough. Reconnect the Connector XCN2A. If the fault is present and active, continue with Step 2.
Straight the pin 25 to avoid an accidental contact to other pins or replace the pin 25 on the harness side. Recon-
nect the Connector XCN2A. If the fault is present and active, continue with Step 3.
Lock the pin 30 inside the Connector XCN1B harness side. Perform the short single wire pull-check to verify if
pin is fasten enough. Reconnect the Connector XCN1B. If the fault is present and active, continue with Step 4.
no continuity detected). Once the short circuit to the battery is detected, inspect the interfaces of segment (pin
quality, pin crossed to each others) and insolation of wiring. Fix the issues by using new pins, eliminate failed
wires and replace by new ones. If the fault is present and active, continue with Step 8.
Perform continuity test between the pin 30 of the Connector XCN1B and the system ground. (Value: no conti-
nuity detected). Once the short circuit to the battery is detected, inspect the interfaces of segment (pin quality,
pin crossed to each others) and insolation of wiring. Fix the issues by using new pins, eliminate failed wires and
9. Reconnect the Connector X_UCM2 and disconnect the Connector X101 .
Perform continuity test between the pin 30 of the Connector XCN1B and thr system ground (Value: no continuity
detected). Once the short circuit to the battery is detected, inspect the interfaces of segment (pin quality, pin
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new ones.
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5172-Short Circuit to power circuit at FWD On/Off Valve Y8.1

Cause:
Short circuit to power at wheel motor Y8.2.
4. Incorrect voltage at the pin 19 of the Connector XCN2A against the system ground.
5. Incorrect voltage at the pin 10 of the Connector XCN1B against the system ground.
Solution:

Lock the pun 30 inside the Connector XCN1B harness side. Perform short single wire pull-check to verify if pin
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Once the short circuit to the battery is detected, inspect the interfaces of segment (pin quality, pin crossed to each
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5174-Open Circuit at FWD Forward Pump Valve Y8.5

Cause:
Open circuit at FWD forward pump valve Y8.5
Solution:

- Segment 3: from the pin 44 of the Connector X101 to the pin 1 of the Connector X33-30 .
Once the open circuit is detected, fix the screws or pins or replace wire to eliminate open circuit. If the fault is
present and active, continue with Step 10.
10. Reconnect the Connector XCN1B and the Connector XY8-5.
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5175-Open Circuit or Short Circuit to battery at FWD Forward Pump

Valve Y8.5
Cause:
Open circuit or short circuit to the battery at FWD forward pump valve Y8.5
1. Connection of the Connector XCN2A, Connector XCN1B and the Connector XY8-5.
6. Lack of continuity between the pin 2 of the Connector XCN1B and the pin 2 of the Connector XY8-5
Solution:

Straight the pin 2 to avoid an accidental contact to other pins or replace the pin 2 on the harness side. Reconnect
Perform voltage measurement of the pin 5 of the e Connector XCN2A against the system ground (Value V=0V).
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5176-Short Circuit to ground at FWD Forward Pump Valve Y8.5

Cause:
Short circuit to ground at FWD forward pump valve Y8.5

Solution:

8. Disconnect the Connector XCN1B and Connector X_UCM2.
Perform continuity test between the pin 2 of the Connector XCN1B and the system ground. (Value: no continuity
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replace by new ones.
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5177-Short Circuit to power at FWD Forward Pump Valve Y8.5

Cause:
Short circuit to power at FWD forward pump valve Y8.5.
Solution:

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Perform voltage measurement of the pin 2 of the at Connector XCN1B against the system ground (Value V=0V).
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5179-Open Circuit at FWD Reverse Pump Valve Y8.6

Cause:
Open circuit at FWD reverse pump valve Y8.5.
Solution:

9. Disconnect the Connector XCN1B and the Connector XY8-6. Perform continuity test between the pin 2 of the
Connector XCN1B and the pin 2 of the Connector XY8-6 to detect open circuit:
Once the open circuit is detected, fix the screws or pins or replace wire to eliminate open circuit. If the fault is
10. Reconnect the Connector XCN1B and the Connector XY8-6.
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5180-Open Circuit or Short Circuit to battery at FWD Reverse Pump

Valve Y8.6
Cause:
Open circuit or short circuit to battery at FWD reverse pump valve Y8.6.
Solution:

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Perform voltage measurement of the pin 6 of the at Connector XCN2A against the system ground (Value V=0V).
12. Disconnect the Connector XCN1B and the Connector XY8-6. Perform continuity test between the pin 2 of the
Connector XCN1B and the pin 2 of the Connector XY8-6 to detect open circuit:
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5181-Short Circuit to ground at FWD Reverse Pump Valve Y8.6

Cause:
Short circuit to ground at FWD reverse pump valve Y8.6.

Solution:

detected). Once the short circuit to the ground is detected, inspect the interfaces of segment (pin quality, pin
detected). Once the short circuit to the ground is detected, inspect the interfaces of segment (pin quality, pin
8. Disconnect the Connector XCN1B and the Connector X_UCM2 .
Perform continuity test between the pin 2 of the Connector XCN1B and the system ground. (Value: no continuity
9. Reconnect the Connector X_UCM2 and disconnect the Connector X101 .
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replace by new ones.
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5182-Short Circuit to power at FWD Reverse Pump Valve Y8.6

Cause:
Short circuit to power at FWD reverse pump valve Y8.6.
Solution:

Make sure that the connectoris locked to the UCM. If the fault is present and active, continue with Step 3.
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Perform voltage measurement of the pin2 of the Connector XCN1B against the system ground (Value V=0V).
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5184-Timeout of cycling message AIC2UCM

Cause:
Error in communication on the CAN1 system Bus between the AIC and the UCM during initialization.
1. The AIC is not capable to transmit message during expected cycle time.
2. The CAN BUS is overloaded, message lost from time to time.
3. Any other CAN node creates error frames.
4. The AIC software failure: CAN ID missing or wrong in the AIC.
Solution:
1. Connect the Electronic Service Tool (EST) and reprogram the AIC and the UCM.
Turn the key switch OFF and wait for power down. Disconnect the EST. Turn the key switch ON. If the fault is
Verify that the fuse 1F1 is not blown. If the fuse 1F1 is blown, replace it. If the fault is present and active, continue
with Step 3.
3. Reconnect the Connector XCN2.
Make sure that the connector is locked at the AIC interface. If the fault is present and active, continue with Step
4.
Perform the CAN resistance measurement between the pin 3 of the Connector XCN1 of the AIC and the pin 4
of the Connector XCN1 (Value R= 60 Ω). If measurement results 120 Ω:
- second 120 Ω resistor is missing;
- check the CAN Bus wiring to the AIC and the EDC.
If measurement results < 60 Ω:
- more than two resistors are installed (should be only in the AIC and the EDC);
- at least one resistor is wrong (> 120 Ω).
Install the can analyzer. Connect the can analyzer to the Connector X123 and turn the key switch ON.
When error frames are present: one of active the CAN nodes creates error frames.
Try to find out what the CAN node is the source of issue.
Disconnect node by node and repeat the CAN check. When the CAN ID 14F60117 + correct software down-
loaded + all other tests above have been successfully, replace the AIC.
Disconnect the AIC Connector XCN2 and pull the fuse 1F1. Perform continuity test between the AIC interface
and the pin 14 of the Connector XCN2 and the pin 2 of the fuse 1F1 to detect an open circuit:
- Segment 1: in the AIC from the pin 14 of the Connector XCN2 to the pin 10 of the Connector X33-5.
- Segment 2: from the pin 10 of the Connector X33-5 to the pin 7 of the Connector X101.
- Segment 3: from the pin 7 of the Connector X101 to the pin 2 of the fuse 1F1.
Once the open circuit is detected, fix the screws or the pins or replace the wire or repair the splices to eliminate
open circuit. If the fault is present and active, continue with Step 7.
7. Perform continuity test between the pin 20 of the Connector XCN2 of the AIC and the pin 2 of the fuse 1F1 to
detect an open circuit:
the open circuit. If the fault is present and active, continue with Step 8.
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8. Perform continuity test between the pin 1 of the fuse 1F1 and cab lower power stud - switched battery (Value:
continuity detected). Once the open circuit is detected, fix the screws or the pins or replace the wire or repair the
splices to eliminate the open circuit. If the fault is present and active, continue with Step 9.
9. Turn the key switch OFF and wait for power down and disconnect the Connector XCN2 of the AIC.
Perform continuity test between the pin 15 of the Connector XCN2 of the AIC and the steering column ground
upper stud to detect an open circuit (Value: continuity detected). Once the open circuit is detected, fix the screws
or the pins or replace the wire or repair the splices to eliminate the open circuit. If the fault is present and active,
10. Perform continuity test between the pin 22 of the Connector XCN2 of the AIC and the steering column ground
upper stud to detect an open circuit (Value: continuity detected). Once the open circuit is detected, fix the screws
or the pins or replace the wire or repair the splices to eliminate the open circuit. Reconnect the Connector XCN2
of the AIC. If the fault is present and active, continue with Step 11.
Disconnect the Connector XCN1 of the AIC and pull the fuse 1F1.
Perform continuity test between the pin 1 of the Connector XCN1 of the AIC and the fuse 1F1 to detect an open
circuit:
Segment 1: in the AIC from the pin 1 of the Connector XCN1 to the pin 11 of the Connector X33-5.
Segment 2: from the pin 11 of the Connector X33-5 to the pin 8 of the Connector X101.
Segment 3: from the pin 8 of the Connector X101 to the pin 2 of the fuse 1F1.
the open circuit.
Reconnect the Connector XCN1 of the AIC and the fuse 1F1.
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5185-Timeout of first cycling message AIC2UCM1

Cause:
Error in communication on the CAN1 system Bus between the AIC and the during initialization.
1. The AIC is not capable to transmit message during expected cycle time.
2. The CAN Bus1 is interrupted by open circuit or short circuit faults at wiring.
3. The CAN Bus is temporarily overloaded.
5. The AIC software failure: CAN ID missing or wrong in the AIC.
Solution:
1. Connect the Electronic Service Tool (EST) and reprogram the AIC and the UCM.
Turn the key switch OFF and wait for power down and disconnect the EST.
Turn the key switch ON. If the fault is present and active, continue with Step 2.
Verify that the fuse 1F1 is not blown. If the fuse 1F1 is blown, replace it. If the fault is present and active, continue
with Step 3.
3. Reconnect the Connector XCN1.
Make sure that the connector is locked at the AIC interface. If the fault is present and active, continue with Step
4.
Perform the CAN resistance measurement between the pin 3 of the Connector XCN1 of the AIC interface and
the pin 4 of the Connector XCN1 (Value R= 60 Ω).
If measurement results 120 Ω:
- second 120 Ω resistor is missing.
If measurement results < 60 Ω:
- more than two resistors are installed (should be only in the AIC and in the EDC).
Install the can analyzer. Connect the can analyzer to the Connector X123 and turn the key switch ON. When
error frames are existing: one of active the CAN nodes creates error frames. Try to find out what the CAN node
is the source of issue. Disconnect node by node and repeat the CAN check. When the CAN ID 14F60117 +
correct software downloaded + all other tests above have been successfully, replace the AIC.
Disconnect the Connector XCN1 of the AIC and the Connector XCN1B of the UCM.
Perform continuity test between the pin 3 of the Connector XCN1 of the AIC and the pin 34 of the Connector
XCN1B of the UCM to detect an open circuit:
- Segment 3: from the pin 46 of the Connector X102 to the pin 8 of the Connector X_UCM2.
- Segment 4: from the pin 8 of the Connector X_UCM2 to the pin 34 of the Connector XCN1B.
Once the open circuit is detected, fix the screws or pins or replace wire or repair splices to eliminate open circuit.
Reconnect the Connector XCN1 of the AIC the and the Connector XCN1B of the UCM. If the fault is present
and active, continue with Step 7.
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7. Disconnect the Connector XCN1 of the AIC and the Connector XCN1B of the UCM.
XCN1B of the UCM to detect open circuit:
- Segment 1: in the AIC from the pin 4 of the Connector XCN1 from the pin 15 of the Connector X33-2.
Reconnect the Connector XCN1 of the AIC and the Connector XCN1B of the UCM. If the fault is present and
Perform continuity test between the pin 14 of the Connector XCN2 and the fuse 1F1 to detect the open circuit:
- Segment 1: from the pin 14 of the Connector XCN2 of the AIC to the pin 10 of the Connector X33-5.
9. Perform continuity test between the pin 20 of the Connector XCN2 of the AIC and the fuse 1F1 to detect open
circuit:
- Segment 3: from the pin 7 of the Connector X101 to the pin 2 of the fuse 1F1..
Once the open circuit is detected, fix the screws or pins or replace wire or repair splices to eliminate the open
circuit.
10. Perform continuity test between the pin 1 of the fuse 1F1 and the cab lower power stud - switched battery (Value:
continuity detected). Once the open circuit is detected, fix the screws or pins or replace wire or repair splices to
eliminate the open circuit. If the fault is present and active, continue with Step 11.
11. Perform continuity test between the pin 23 of the Connector XCN2 of the AIC and the pin 6 of the ignition key
S1 (switched power position). (Value: continuity detected). Once the open circuit is detected, fix the screws or
pins or replace wire or repair splices to eliminate the open circuit.
Reconnect the Connector XCN2 and the fuse 1F1. If the fault is present and active, continue with Step 12.
12. Turn key switch OFF and wait for power down and disconnect the Connector XCN2 of the AIC.
Perform continuity test between the pin 15 of the Connector XCN2 of the AIC and steering column ground upper
stud to detect the open circuit. Once the open circuit is detected, fix the screws or pins or replace wire or repair
splices to eliminate the open circuit. If the fault is present and active, continue with Step 13.
13. Perform continuity test between the pin 22 of the Connector XCN2 of the AIC and steering column ground upper
stud to detect the open circuit. Once the open circuit is detected, fix the screws or pins or replace wire or repair
splices to eliminate the open circuit. Reconnect the Connector XCN2.
Perform continuity test between the pin 1 of the Connector XCN1 of the AIC and the fuse 1F1 to detect the open
circuit:
circuit.
Reconnect the Connector XCN1 and the fuse 1F1.
sheet 20 (55.100)
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5186-Timeout of cycling message EEC1 or EEC2

Cause:
Error in communication on the CAN1 system bus between the AIC and the UCM during initialization.
1. The EDC is not capable to transmit message during expected cycle time.
Solution:
1. Verify the EDC, the UCM and the AIC SOFTWARE versions:
connect service tool (EST) and reprogram the EDC, the AIC and the UCM.
Turn key switch OFF and wait for power down and disconnect connect service tool (EST).
Turn key switch ON. If the fault is present and active, continue with Step 2.
Check that fuse 1F2 is not blown, if the fuse 1F2 is blown, replace it. If the fault is present and active, continue
with Step 3.
Perform the CAN resistance measurement between the pin 3 of the Connector XCN1 of the AIC and the pin 4 of
the Connector XCN1 (Value R= 60 Ω).
Measurement result 120 Ω:
Measurement result < 60 Ω:
- more than two resistors installed (should be only in the AIC and the EDC);
Install can analyzer and connect to the Connector X123.
Turn key switch ON and check the CAN communication.
When error frames are existing: one of active the CAN nodes creates error frames.
Disconnect node by node and repeat the CAN check.
When the CAN IDs 0CF00400 and 0CF00300 are existing + correct SOFTWARE downloaded + all other tests
above and below have been successfully → replace HW of the:
1. UCM.
→ quick check (errors still existing?).
2. EDC.
Reconnect the Connector XCN1 and the Connector XCN1B.
Make sure that connectors are locked to the EDC controller, the UCM controller and the AIC interface.
Verify that in the Connector XA158 of the EDC is connected and locked.
Repeat the CAN resistance measurement. If the fault is present and active, continue with Step 6.
Check ground connection to EDC controller: verify ground wires at ground stud at rear frame.
If necessary connect and fixed ground wire to ground stud. If the fault is present and active, continue with Step 7.
Check ground connection to the EDC controller.
Carefully disconnect the Connector XA158 of the EDC.
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Perform continuity test between the pins 3, 5, 28, 29, 52, 75, 76 of the Connector XA158 of the EDC and the
ground stud rear frame (Value: continuity detected). Once the Open Circuit is detected, fix the screws or pins or
replace wire or repair splices to eliminate Open Circuit. If the fault is present and active, continue with Step 8.
Check power connection to the EDC controller.
Carefully disconnect the Connector XA158 of the EDC. Perform continuity test between the Connector XA158
of the EDC and the fuse 1F2 to detect the open circuit:
- Segment 1: from the pin 1, 25, 26, 49, 73 of the Connector XA158 of the EDC to the pins 10, 12 of the Connector
X33-40.
- Segment 2: from the pins 10, 12 of the Connector X33-40 to the pin 1 of the Connector X104-2.
- Segment 3: from the pin 1 of the Connector X104-2 to the pin 2 of the fuse 1F2.
circuit.
Perform continuity test between the pin 1 of the fuse 1F2 and cab upper power stud - unswitched battery (Value:
continuity detected). Once the open circuit is detected, fix the screws or pins or replace wire or repair splices to
eliminate the open circuit.
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5187-Timeout of cycling TCU1 or TCU2 CAN messages

Cause:
Error in communication on the CAN1 system bus between the AIC and the UCM during initialization.
1. The TCU is not capable to transmit message during expected cycle time.
Solution:
1. Use the AIC screen and verify the TCU and the AIC SOFTWARE versions.
Connect service tool (EST) and reprogram the AIC.
Turn key switch OFF and wait for power down and disconnect connect service tool (EST). Turn the key switch
ON.
NOTE: The TCU can not be reprogrammed by service tool. Special ZF tool needed or replace the TCU by a
newer one.
Check that the fuse 4F32 and/or the fuse 4F33 is not blown, if the fuses 4F32 and/or 4F33 is blown, replace it.
Perform the CAN resistance measurement between the CAN high and the CAN low at the CAN Bus 1 (Value R=
60 Ω).
Measure the Connector X123 between the pin D and the pin C.
- more than two resistors installed (should be only in the AIC and in the EDC);
Install can analyzer and connect to the Connector X123.
Disconnect node by node and repeat the CAN check. When the CAN IDs 18FF1E03 and 18FF1F03 are existing
+ correct SOFTWARE downloaded + all other tests above and below have been successfully, replace hardware.
1. TCU.
→ quick check (errors still existing?).
2. UCM.
Reconnect the Connector XA1 and the Connector XCN1B.
Make sure that connectors are locked to the TCU controller and to the UCM controller. Repeat the CAN resistance
measurement.
Check ground connection to the TCU controller and ground block: verify the ground wires at cab ground block.
If necessary connect and fixed the ground wire to cab ground block.
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Check ground connection to the TCU controller.

Disconnect the Connector XA1. Perform continuity test between the pins 1, 2 of the Connector XA1 of the TCU
and the cab ground block or alternative cab ground (Value: continuity detected).
circuit.
Disconnect the Connector XA1 and check power connection to the TCU controller. Perform continuity test be-
tween the Connector XA1 of the TCU and the fuse 4F32 to detect the open circuit:
- Segment 1: from the pins 23, 68 of the Connector XA1 of the TCU to the pin 5 of the Connector X102.
circuit.
9. Perform continuity test between the Connector XA1 of the TCU and the fuse 4F33 to detect the open circuit:
- Segment 1: from the pin 45 of the Connector XA1 of the TCU to the pin 25 of the Connector X101.
circuit.
10. Perform continuity test between the pin 1 of the fuse 4F32 and the cab lower power stud - switched battery to
detect the open circuit.
circuit.
11. Perform continuity test between between the pin 1 of the fuse 4F33 and the pin 6 of the key switch S1 (position
ON) to detect the open circuit:
Segment 1: from the pin 1 of the fuse 4F32 to the pin 9 of the Connector X101.
Segment 2: from the pin 9 of the Connector X101 to the pin 14 of the Connector X33-5.
Segment 3: from the pin 14 of the Connector X33-5 to the pin 6 of the key switch S1.
circuit.
sheet 19 (55.100)
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5188-Actual tire circumference error

Cause:
Error in communication on the CAN1 system bus between the AIC and the UCM during initialization. Either transmitted
value from the AIC to the UCM is not in expected range or initialized tire circumference parameter in the UCM reset
to out of range parameter during normal operation.
1. The AIC SOFTWARE failure.

2. The AIC reset variable and execute initialization process during normal operation.
3. The AIC power or ground connection is not stable.
4. The CAN Bus 1 is interrupted by the OC or by the SC faults at wiring.
5. The CAN BUS is temporarily overloaded.
Solution:
1. Verify the UCM and the AIC SOFTWARE versions: Connect service tool (EST) and reprogram the AIC and the
UCM.
Turn key switch OFF and wait for power down and disconnect the connect service tool (EST).
Check that the fuse 1F1 is not blown, if the fuse 1F1 is blown, replace it.
circuit.
4. Perform continuity test between the pin 20 of the Connector XCN2 of the AIC and the fuse 1F1 to detect the
open circuit:
circuit.
circuit.
6. Perform continuity test between the pin 23 of the Connector XCN2 of the AIC and the pin 6 of the key switch S1
(switched power position) to detect the open circuit.
circuit.
Reconnect the Connector XCN2 of the AIC and the fuse 1F1.
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Disconnect the Connector XCN2 of the AIC.

Perform continuity test between the pin 15 of the Connector XCN1 and the steering column ground upper stud
to detect the open circuit. Once the open circuit is detected, fix the screws or pins or replace wire or repair splices
to eliminate the open circuit. If the fault is present and active, continue with Step 8.
8. Perform continuity test between the pin 22 of the Connector XCN2 and the steering column ground upper stud
to detect the open circuit.
circuit.
Perform continuity test between the pin 1 of the Connector XCN1 and the pin 2 of the fuse 1F1 to detect the
open circuit:
circuit.
Perform the CAN resistance measurement between of the pin 3 of the Connector XCN1 of the AIC and the pin
4 of the Connector XCN1 (Value R= 60 Ω). Measurement result 60 Ω:
- more than two resistors installed (should be only in the AIC and in the EDC)
Install the can analyzer and connect to the Connector X123.
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5189-Main Model Info Error

Cause:
Error in communication on the CAN1 system Bus between the AIC and the UCM during initialization. Either transmit-
ted value from the AIC to the UCM is not in expected range or initialized model parameter in the UCM reset to out of
range parameter during normal operation.
1. The AIC SOFTWARE failure.

2. The AIC reset variable and execute initialization process during normal operation.
3. The AIC power or ground connection is not stable.
Solution:
1. Verify the UCM and the AIC SOFTWARE versions:

Connect service tool (EST) and reprogram the AIC and the UCM.
Reconnect the Connector XCN2. Make sure that connector is locked to the UCM and to the AIC.
circuit.
5. Perform continuity test between the pin 20 of the Connector XCN2 of the AIC and the fuse 1F1 to detect the
open circuit:
circuit.
circuit.
7. Perform continuity test between the pin 23 of the Connector XCN2 and the pin 6 of the key switch S1 (switched
power position) to detect the open circuit.
circuit.
Reconnect the Connector XCN2 of the AIC and the fuse 1F1. If the fault is present and active, continue with
Step 8.
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Perform continuity test between the pin 15 of the Connector XCN1 of the AIC and the steering column ground
upper stud to detect the open circuit.
circuit.
9. Perform continuity test between the pin 22 of the Connector XCN2 and the steering column ground upper stud
to detect the open circuit.
circuit.
Perform continuity test between the pin 1 of the Connector XCN1 of the AIC and the pin 2 of the fuse 1F1 to
circuit.
of the Connector XCN1 (Value R= 60 Ω).
- check the CAN Bus wiring to the AIC and EDC.
- more than two resistors installed (should be only in the AIC and EDC);
Install CanAlyzer and connect the Connector X123.
Turn Key switch ON and check the CAN communication.
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5194-Gear Restriction Mismatch

Context:
Plausibility check between actual requested max. gear by the UCM via the AIC to the TCU and actual transmitted
max. gear information by the TCU.
Cause:
Gear restriction mismatch.
1. The CAN communication faulty.

2. The UCM not capable to transmit gear request to the AIC.
3. The AIC is not capable to transmit gear request to the TCU.
4. The TCU is not capable to transmit actual gear settings.
5. The CAN BUS is overloaded, messages lost from time to time.
7. The UCM SOFTWARE failure (variable refresh not working).
8. The AIC SOFTWARE failure (variable refresh not working).
Solution:
1. Use the AIC screen and verify the TCU and the AIC SOFTWARE versions.
Connect service tool (EST) and reprogram the AIC. Turn key switch OFF and wait for power down and disconnect
connect service tool (EST). Turn key switch ON.
NOTE: The TCU can not be reprogrammed by service tool. Special ZF tool needed or replace the TCU by a newer
one.
Perform the CAN resistance measurement between the pin 34 of the Connector XCN1B of the UCM and the pin
25 of the Connector XCN1B (Value R= 60 Ω).
Perform the CAN resistance measurement between the pin 3 of the Connector XCN1 and the pin 4 of the Con-
nector XCN1 (Value R= 60 Ω).
Install CanAlyzer and connect to the Connector X123.
Try to find out what the CAN node is the source of issue. Disconnect node by node and repeat the CAN check.
Disconnect the Connector XCN1B and the Connector XA1 of the TCU.
Perform continuity test between the pin 25 of the Connector XCN1B of the UCM and the pin 26 of the Connector
XA1 of the TCU to detect the open circuit:
- Segment 1: from the pin 25 of the Connector XCN1B of the UCM to the pin 9 of the Connector X_UCM2.
- Segment 3: from the pin 45 of the Connector X102 to the pin 26 of the Connector XA1.
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circuit.
Reconnect the Connector XCN1B of the UCM and the Connector XA1 of the TCU.
Disconnect the Connector XCN1B of the UCM and the Connector XA1 of the TCU.
- Segment 1: in the UCM from pin 34 of the Connector XCN1B to pin 8 of the Connector X_UCM2.
circuit.
XCN1B of the UCM to detect the open circuit:
Segment 1: in the AIC from the pin 3 of the Connector XCN1 to the pin 14 Connector X33-2 .
circuit.
Reconnect the Connector XCN1 of the AIC and Connector XCN1B of the UCM.
XCN1B of the UCM to detect the open circuit:
circuit.
Reconnect the Connector XCN1 of the AIC and the Connector XCN1B of the UCM.
Disconnect Connector XCN1 of the AIC and Connector XA1 of the TCU.
Perform continuity test between the pin 3 of the Connector XCN1 of the AIC and pin 25 of the Connector XA1
of the TCU to detect open circuit:
- Segment 2: from the pin 14 of the Connector X33-2 to the pin 25 of the Connector XA1.
circuit.
Reconnect the Connector XCN1 of the AIC and Connector XA1 of the TCU.
Disconnect the Connector XCN1 of the AIC and Connector XA1 of the TCU.
Perform continuity test between the pin 4 of the Connector XCN1 and the pin 26 of the Connector XA1 of the
TCU to detect the open circuit:
- Segment 2: from the pin 15 of the Connector X33-2 to the pin 26 of the Connector XA1.
circuit.
Reconnect the Connector XCN1 of the AIC and the Connector XA1 of the TCU.
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5197-Mismatch AIC CAN message versus brake pressure switch

status
Context:
Plausibility check between brake pedal signal detected by the UCM input and the CAN information transmitted by the
AIC.
Cause:
Mismatch the AIC CAN message versus brake pressure switch status.
1. Relay 2K19 faulty.

2. Lost wiring from pressure switch S18 to the UCM input.
3. Lost wire connection from relay 2k19 to the AIC input.
4. The AIC is not capable to transmit brake information to the UCM on time.
5. The CAN BUS is overloaded, messages lost from time to time.
7. The AIC software failure (variable refresh not working).
8. Debounce time for error detection in the UCM is not correct.
Solution:
1. Use the AIC screen and verify the UCM and the AIC SOFTWARE versions:
connect service tool (EST) and reprogram the AIC and the UCM.
Turn Key ON. If the fault is present and active, continue with Step 2.
2. Turn key switch ON and crank engine.
Wait for brake pressure and press the brake pedal.
Check if brake lights turns ON. If brake light remains OFF replace relay 2K19 and repeat quick function test.
If quick test is failed or if brake light turn ON but error code is still present, continue with Step 3.
Reconnect the Connector XCN2B and the Connector XCN1.
Make sure that connectors are locked to the UCM and the AIC.
Disconnect the Connector XCN2B of the UCM and pull the relay 2K19.
Perform continuity test between the pin 23 of the Connector XCN2B and the pin 2 of the pressure switch S18 to
- Segment 1: in the UCM from the pin 23 of the Connector XCN2B to the pin 9 of the Connector X_UCM1.
- Segment 3: from the pin 11 of the Connector X101 to the pin 2 of the pressure switch S18.
circuit.
5. Perform continuity test between the pin 2 of the pressure switch S18 and the pin 86 of the relay 2K19 to detect
the open circuit:
Segment 1: from the pin 2 of the pressure switch S18 to the pin 11 of the Connector X101.
Segment 2: from the pin 11 of the Connector X101 to the pin 86 of the relay 2K19.
circuit.
Disconnect the Connector XCN2B and pull the relay 2K19.
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Disconnect the Connector XCN1 of the AIC and pull the 2K19.
Perform continuity test between the pin 15 of the Connector XCN1 of the AIC and the pin 30 of the relay 2K19 to
Segment 1: from the pin 15 of the Connector XCN1 to the pin 9 of the Connector X33-4.
Segment 2: from the pin 9 of the Connector X33-4 to the pin 5 of the Connector X101.
Segment 3: from the pin 5 of the Connector X101 to the pin 30 of the relay 2K19.
circuit. Reconnect the Connector XCN1 of the AIC and the relay 2K19.
Perform the CAN resistance measurement between the pin 3 of the Connector XCN1 of the AIC and the pin 4 of
the Connector XCN1 (Value R= 60 Ω).
Install the CanAlyzer and connect to the Connector X123.
sheet 21 (55.100) Harnesses and connectors - Electrical schematic sheet 27 (55.100)
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5198-Tire circumference out of range error

Context:
Plausibility check between minimum/maximum pre-set values in the UCM and transmitted values via the CAN from
the AIC.
Cause:
Tire circumference out of range error.
1. Software failure in the UCM.

2. Software failure in the AIC (variable not refreshed after initialization or the AIC EEPROM cannot be read by the
AIC application during initialization).
3. Software modification in the AIC acc. to maximum allowed tire circumference was not done in the UCM software:
non-synchronized software change.
Solution:
1. Use the AIC screen and verify the UCM and the AIC software versions.
Connect service tool (EST) and reprogram the AIC and the UCM.
Turn key switch OFF and wait for power down and disconnect service tool (EST).
Turn key switch ON. Verify if any service bulletins are existing according to software version compatibility of the
AIC vs. the UCM.
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5199-Timeout of first cycling TCU1 or TCU2 messages

Cause:
Error in communication on the CAN1 system Bus between the TCU and the UCM during initialization.
1. Fuse 4F32 fails.

2. The TCU not connected.
3. Power or ground wire to the TCU disconnected.
4. The TCU is not capable to transmit message during expected cycletime.
5. The CAN Bus1 is interrupted by the open circuit or the short circuit faults at wiring.
8. The TCU software failure: not capable to initialize.
Solution:
1. Use the AIC screen and verify the TCU and the AIC software versions.
Connect service tool (EST) and reprogram the AIC.
Turn key switch OFF and wait for power down and disconnect service tool (EST). Turn key switch ON.
NOTE: The TCU can not be reprogrammed by the service tool. Special ZF tool needed or replace the TCU by
a new one.
Check that the fuse 4F32 and/or 4F33 is not blown, if the fuse 4F32 and/or 4F33 is blown, replace it.
Perform the CAN resistance measurement between the CAN high and the CAN low at the CAN Bus 1 (Value R=
60 Ω).
Measure the Connector X123 between the pin D and the pin C.
Turn Key switch ON and check the CAN communication.
When the CAN IDs 18FF1E03 and 18FF1F03 are existing + correct SOFTWARE downloaded + all other tests
above and below have been successfully, replace hardware:
1. The TCU
Perform a quick check: errors still existing?
2. The UCM
Reconnect the Connector XA1 and the Connector XCN1B.
Make sure that connectors are locked to the TCU and the UCM.
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Repeat the CAN resistance measurement.

Check ground connection to the EDC: verify the ground wires at the cab ground block.
If necessary connect and fixed the ground wire to cab ground block.
Check ground connection to the TCU.
Disconnect the Connector XA1. Perform continuity test between the pins 1, 2 of the Connector XA1 of the TCU
and the cab ground block or alternative cab ground (Value: continuity detected).
circuit.
circuit.
- Segment 1: from the pin 34 of the Connector XCN1B of the UCM and the pin 8 of the Connector X_UCM2.
circuit.
Disconnect the Connector XA1. Perform continuity test between the TCU and the fuse 4F32:2 to detect the
open circuit:
- Segment 1: from the pins 23, 68 of the Connector XA1 of the TCU and the pin 5 of the Connector X102.
circuit.
11. Perform continuity test between the TCU and the pin 2 of the fuse 4F33 to detect the open circuit:
- Segment 1: from the pin 45 of the Connector XA1 of the TCU to the pin 25 of the Connector X101.
circuit. If the fault is present and active, continue with Step 12.
circuit.
13. Perform continuity test between the pin 1 of the fuse 4F33 and the pin 6 of the key switch S1 (position ON). to
Segment 1: from the pin 1 of the fuse 4F32 to the pin 9 of the Connector X101.
Segment 2: from the pin 9 of the Connector X101 to the pin 14 of the Connector X33-5.
Segment 3: from the pin 14 of the Connector X33-5 to the pin 6 of the key switch S1.
Once the Open Circuit is detected, fix the screws or pins or replace wire or repair splices to eliminate Open Circuit.
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sheet 19 (55.100)
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5202-Cranking line short circuit to power error

Cause:
Cranking line short circuit to power error.
1. The UCM has not detect voltage at one dedicated input 2B_14 (crank line) longer than 4 seconds.
Solution:
Disconnect the Connector XCN2B.
Lock the pin 14 and the pin 16 inside the connector harness side.
Perform short single wire pull-check to verify if the pin is fasten enough.
Reconnect the Connector XCN2B. If the fault is present and active, continue with Step 2.
Straight pins to avoid accidental contact to other pins or replace pins on harness side.
Reconnect the Connector XCN2B. If the fault is present and active, continue with Step 3.
Disassemble the key switch S1; turn key switch in OFF position and verify functionality of the key switch S1 in the
following mode:
- Perform continuity test between the pin 15 of the key switch and the pin 50a of the key switch (Value: no continuity
detected).
detected).
In case of the continuity detection between pins at the key switch, replace the key switch by a new part.
Turn key switch ON and crank engine as usual.
Verify if the error code is not existing anymore. If the fault is present and active, continue with Step 4.
Disassemble the key switch S1.
Turn key switch in ON position and verify functionality of the key switch S1 in the following mode:
detected).
detected).
In case of the continuity detection between the pins at the key switch, replace the key switch by a new part.
Turn key switch ON and crank the engine as usual.
Turn key switch in crank position and verify functionality of the key switch S1 in the following mode:
- Perform continuity test between the pin 15 of the key switch and the pin 50a of the key switch (Value: continuity
detected).
- Perform continuity test between the pin 30 of key switch key and the pin 50a of the key switch (Value: continuity
detected).
In case of the open circuit detection between pins at the key switch, replace the key switch by a new part.
Disconnect the Connector XCN2B of the UCM and the key switch S1.
Perform continuity test between the pin 14 of the Connector XCN2B of the UCM and the pin 1 of the key switch
S1 (unswitched battery) to detect the short circuit (Value: no continuity detected).
Once the short circuit is detected, fix the issue by usage of wiring schematic and or harness drawings.
Reconnect the Connector XCN2B of the UCM and the key switch S1.
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S1 (switched battery) to detect the short circuit (Value: no continuity detected).
S1 (cranking) to detect short circuit (Value: continuity detected).
Once the open circuit is detected, fix the issue by usage of wiring schematic and or harness drawings.
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5203-Cranking line open circuit error

Cause:
Cranking line open circuit error.
1. The UCM has not detected that engine was cranked but input 2B_14 was never high before.
Solution:
Lock the pin 14 and the pin 16 inside the Connector XCN2B harness side.
Perform the short single wire pull-check to verify if pin is fasten enough.
Straight the pins to avoid accidental contact to other pins or replace pins on harness side.
Disconnect the connector from the key switch S1.
Lock wires at the pins 1 and 6 and the pin 8 inside the key switch S1 connector harness side.
Perform the short single wire pull-check to verify if the pin is fasten enough.
Reconnect the connector at the key switch S1. If the fault is present and active, continue with Step 4.
Turn key switch in OFF position and verify functionality of the key switch S1 in the following mode:
detected).
detected).
Verify if the error code is not existing anymore.
Turn key switch in ON position and verify functionality of the key switch S1 in the following mode:
detected).
detected).
Turn key switch in crank position and verify functionality of the key switch S1 in the following mode:
detected).
detected).
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In case of the open circuit detection between the pins at the key switch, replace the key switch by a new part.
S1 (unswitched battery) to detect short circuit (Value: no continuity detected).
Once the short circuit is detected, fix the issue by usage of the wiring schematic and or harness drawings.
Perform continuity test between the pin 14 of the Connector XCN2B of the UCM and pin 6 of the key switch S1
(switched battery) to detect short circuit (Value: no continuity detected).
S1 (cranking) to detect short circuit (Value: continuity detected).
Once the open circuit is detected, fix the issue by usage of the wiring schematic and or the harness drawings.
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5204-Timeout of first cycling message C6_9_Status

Cause:
Error in communication on the UCM_CAN2 system bus between the UCM and the C6.9 during normal operation.
1. Connectors loosen or disconnected (UCAM_CAN2 interrupted, missing power and ground connections).
2. C6.9 is failed (SOFTWARE or HW).
3. Resistor close to the C6.9 failed.
Solution:

Turn key switch ON.
If the LED not flashing up on the C6.9 module during initialization continue with Step 2.
Make sure that the connector is locked to the UCM.
5. Reconnect the Connector CM6-9.
Make sure that the connector is locked. If the fault is present and active, continue with Step 6.
Disconnect the Connector XCN1A.
Lock the pin 1 inside the Connector XCN1A harness side.
Reconnect the Connector XCN1A. If the fault is present and active, continue with Step 7.
Straight the pin 1 to avoid accidental contact to other pins or replace the pin 1 on harness side.
Reconnect the Connector XCN2B. Reconnect the Connector XCN1A.
Straight the pin 1 and the pin 10 to avoid accidental contact to other pins or replace the pin 1 and/ or the pin 10
on the harness side.
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Straight the pin 8 and the pin 9 to avoid accidental contact to other pins or replace the pin 8 and/ or the pin 9 on
harness side.
Disconnect the Connector XCN2B of the UCM.
Disconnect the Connector CM6-9.
Perform continuity test between the pin 1 of the Connector XCN2B and the pin 7 of the Connector CM6-9 (CAN
high) to detect the open circuit (Value: continuity detected):
- Segment 2: from the pin 5 of the Connector X_UCM2 to the pin 7 of the Connector CM6-9.
Reconnect the Connector XCN2B and the Connector CM6-9.
CM6-9 to detect the open circuit (Value: continuity detected):
Perform continuity between the pin 27 of the Connector XCN3B of the UCM and the pin 9 of the Connector
Disconnect the Connector XCN1A of the UCM.
Perform continuity between the pin 1 of the Connector XCN1A and the pin 10 of the Connector CM6-9 to detect
the open circuit (Value: continuity detected):
Reconnect the Connector XCN1A and the Connector CM6-9.
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Repeat measurement at different locations along the UCM_CAN2 Bus if you do not get 60 Ω to identify root cause
of failure.
- check the Connector XR-021;
- check resistor at C6.9 module, repeat measurement between the pin 7 of the Connector CM6-9 the pin 8 of
the Connector CM6-9.
- more than two resistors installed;
- at least one resistor is wrong (> 120 Ω);
- check the Connector XR-021.
Replace the C6.9 module by a new part.
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5205-Timeout of cycling message C6_9_Status

Cause:
Error in communication on the UCM_CAN2 system Bus between the UCM and the C6.9 during initialization.
1. Connectors loosen or disconnected (UCAM_CAN2 interrupted, missing power and ground connections).
2. C6.9 is failed (SOFTWARE or HW).
3. Resistor close to C6.9 failed.
Solution:

Turn key switch ON. If the LED not flashing up on the C6.9 module during initialization continue with Step 2.
5. Reconnect the Connector CM6-9.
Make sure that the connector is locked.
Lock the pin 1 inside the Connector XCN1A harness side.
Reconnect the Connector XCN1A. If the fault is present and active, continue with Step 7.
Straight the pin 1 to avoid accidental contact to other pins or replace the pin 1 on the harness side.
Disconnect the Connector XCN2B. Lock the pin 1 and the pin 10 inside the Connector XCN2B harness side.
Straight the pin 1 and the pin 10 to avoid accidental contact to other pins or replace the pin 1 and/ or the pin 10
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Straight the pin 8 and the pin 9 to avoid accidental contact to the other pins or replace the pin 8 and/or the pin 9
CM6-9 (CAN high) to detect the open circuit (Value: continuity detected):
Perform continuity between the pin 27 of the Connector XCN3B and the pin 9 of the Connector CM6-9 to detect
Disconnect the Connector XCN1A of the UCM.
Perform continuity between the pin 1 of the Connector XCN1A and the pin 10 of the Connector CM6-9 to detect
Reconnect the Connector XCN1A and the Connector CM6-9.
Repeat measurement at different locations along UCM_CAN2 Bus if you do not get 60 Ω to identify root cause
of failure.
- check Connector XR-021;
- check resistor at C6.9 module, repeat measurement between the pin 7 of the Connector CM6-9 and the pin 8
of the Connector CM6-9.
- more than two resistors installed;
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- at least one resistor is wrong (> 120 Ω);

- check the Connector XR-021.
Replace the C6.9 module by a new part.
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5208-Timeout of first message EEC1 or EEC2

Cause:
Error in communication on the CAN1 system bus between the EDC and the UCM during initialization.
1. Fuse 1F2 fails.

2. The EDC not connected.
3. Power or ground wire to the EDC disconnected.
4. The EDC is not capable to transmit message during expected cycletime.
5. The CAN Bus1 is interrupted by the OC or the SC faults at wiring.
8. The EDC SOFTWARE failure → not capable to initialize.
Solution:
1. Verify the EDC, UCM and the AIC software versions:

Connect service tool (EST) and reprogram the EDC, AIC and the UCM.
of the Connector XCN1 (Value R= 60 Ω).
- check the CAN Bus wiring to the AIC and EDC.
- more than two resistors installed (should be only in the AIC and the EDC)
Try to find out what the CAN node is the source of issue. Disconnect node by node and repeat the CAN check.
When the CAN IDs 0CF00400 and the 0CF00300 are existing + correct SOFTWARE downloaded + all other
tests above and below have been successfully → replace the HW of the:
1. UCM
→ quick check (errors still existing?)
2. EDC
Reconnect the Connector XCN1 and the Connector XCN1B.
Make sure that connectors are locked to the EDC, the UCM and the AIC.
Verify that the Connector XA158 of the is connected and locked.
Repeat the CAN resistance measurement. If the fault is present and active, continue with Step 6.
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Check ground connection to the EDC: verify the ground wires at the ground stud at rear frame.
If necessary connect and fixed the ground wire to the ground stud.
Check ground connection to the EDC.
Perform continuity test between the pins 3, 5, 28, 29, 52, 75, 76 of the Connector XA158 of the EDC and the
ground stud rear frame (Value: continuity detected).
circuit.
Check power connection to the EDC.
Perform continuity test between the Connector XA158 of the EDC and the fuse 1F2 to detect the open circuit:
- Segment 1: from the pins 1, 25, 26, 49, 73 of the Connector XA158 of the EDC to the pin 10, 12 of the
Connector X33-40.
- Segment 2: from the pin 10, 12 of the Connector X33-40 to the pin 1 of the and Connector X104-2.
- Segment 3: from the pin 1 of the Connector X104-2 to the pin 2 of the fuse 1F2.
circuit.
Perform continuity test between the pin 1 of the fuse 1F2 and cab upper power stud - unswitched battery (Value:
continuity detected).
circuit.
Check the CAN wiring. Carefully disconnect the Connector XA158 of the EDC.
Perform continuity test between the pin 34 of the Connector XCN1B of the UCM (CAN_high) and the pin 46 of
the Connector XA158 of the EDC (CAN_high) to detect the open circuit:
- Segment 4: from the pin 14 of the Connector X33-30 to the pin 46 of the Connector XA158of the EDC.
circuit.
Check the CAN wiring.
Perform continuity test between the pin 47 of the Connector XA158 of the EDC(CAN_low) and the pin 25 of the
Connector XCN1B of the UCM (CAN_low) to detect the open circuit:
- Segment 4: from the pin 13 of the Connector X33-30 to the pin 47 of the Connector XA158 of the EDC.
Perform continuity test between the pin 47 of the Connector XA158 of the EDC.
Once the Open Circuit is detected, fix the screws or pins or replace wire or repair splices to eliminate Open Circuit.
sheet 20 (55.100)
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5214-Parking brake error

Cause:
The UCM detects parking brake switch failure transmitted by the AIC via CAN.
Error code should come together with other error codes transmitted by the AIC.
1. Fuse 2F11 blown.

3. Loosen wire connection between the AIC and the parking brake switch.
4. The AIC not capable to refresh variable after initialization.
5. The AIC software failure.
Solution:

Turn key switch ON, crank the engine.
Verify if the parking brake function is available and LED in the AIC is corresponding to function ON/ OFF.
Parking brake engaged = LED ON.
Parking brake disengaged = LED OFF .
Check failure and reaction notes from the AIC according to error codes 1350 and 1352.
Turn key switch ON. Connect service tool (EST) and reprogram the AIC and the UCM.
Turn key switch OFF and wait for power down and disconnect service tool (EST).
Check that fuse 2F11 is not blown, if the fuse 2F11 is blown, replace it.
4. Turn key switch ON.
Engage/disengage parking brake and try to verify if the relay 2k115 is working. If the relay 2k115 is fault, replace
it by a new one.
Reconnect the Connector XCN2.
Make sure that connector is locked to the UCM and the AIC.
Reconnect the Connector XS16.
Make sure that the connector is locked at the rocker switch body.
Disconnect the Connector XS16 (parking brake rocker switch).
Perform continuity test between pin 6 of the Connector XCN2 of the AIC and the pin 1 of the Connector XS16 to
Perform continuity test between the pin 8 of the Connector XCN2 and the pin 3 of the Connector XS16 to detect
the open circuit.
Once the short circuit is detected, fix the screws or pins or replace wire or repair splices to eliminate the short
circuit.
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Pull the fuse 2F11 and disconnect the Connector XS16 (parking brake rocker switch).
Perform continuity test between the pin 2 of the Connector XS16 and the pin 2 of the fuse 2F11 to detect the open
circuit.
circuit.
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19002 (DTC 2461)-Battery voltage is lower than expected

Context:
The Engine Control Unit (ECU) A158 monitors battery voltage. If the ECU determines that the battery voltage is less
than 19.2 V, this fault will occur.
Cause:
Battery voltage is less than 19.2 V.
1. Faulty Battery.
2. Faulty ECU supply wiring.
Solution:
From To Value
A. If there is not approximately 24 V, charge the battery and then perform the load test on the battery. If the battery

The key must be in the ON position for voltage and in the OFF position for continuity.
From To Value
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From To Value
failed conductor.

has been resolved.
operation.
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19006 (DTC 2461)-CAN timeout error from NH3 sensor - NH3Fac

message
Context:
The NH3 module B-057 is required to report information at regular intervals to the Engine Control Unit (ECU) A158
via Controller Area Network (CAN). If the information from the NH3 sensor or the ECU is not communicated within
the allotted time frame, this fault will occur.
Cause:
The B-057 has reported, via CAN, that a NH3 sensor or ECU message timeout has occurred.
1. Faulty NH3 sensor to B-057 harness (cable), damaged connector or wiring.

3. Faulty NH3 sensor, internal damage.
Solution:
2. Verify proper and secure connection to the B-057.
Disconnect and reconnect the NH3 connector sensor and the Connector XB-057 from the B-057.

3. Disconnect the NH3 Connector XB-057 from the B-057.
Determine the condition of the B-057 CAN circuit.
Use a multimeter to measure the resistance of the CAN connection on the vehicle (VE) harness side:
From To Value
NH3 Connector XB-057, pin 2 NH3 Connector XB-057, pin 3 There should be 60 Ω

4. Check for other engine After Treatment System (ATS) CAN faults.
A. If other faults do exist, refer to Controller Area Network (CAN) data bus - Test (55.640) to locate and repair
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B. If no other faults exist, the ATS vehicle harness wiring is damaged between the network harness splice and
the NH3 Connector XB-057, pin 2 and/or NH3 Connector XB-057, pin 3, wire CAN_O_H and/or CAN_O_L
for CAN signal. Locate and repair the damage to the ATS CAN circuit wiring.
5. As there is no method for field testing the NH3 sensor, replace the NH3 sensor.

has been resolved.
operation.
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19007-NH3 sensor open or short in measuring cell circuit

Context:
For information regarding the NH3 module B-057 and the NH3 sensor refer to Ammonia (NH3) sensor - ECU de-
scription (55.988). The NH3 module B-057 is required to report information at regular intervals to the Engine Control
Unit (ECU) A158 via Controller Area Network (CAN). If no signal is sensed on one of the cell signal lines, this fault
will occur.
Cause:
The B-057 has reported a short to ground or open circuit error of one or both of the cell signal lines via CAN to the
ECU.
1. Faulty NH3 sensor, open or shorted or grounded internally.

Solution:
2. As there is no method for field testing the sensing cell portions of the sensor, replace the NH3 sensor.

3. As there is no method of field testing or re-flashing the B-057, replace the B-057.
has been resolved.
operation.
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19008-NH3 sensor open or short in ground circuit

Context:
For information regarding the NH3 electronic control unit and the NH3 sensor refer to Ammonia (NH3) sensor - ECU
description (55.988). The NH3 module B-057 is required to report information at regular intervals to the Engine
Control Unit (ECU) A158 via Controller Area Network (CAN). If no current is sensed on the signal ground line, this
fault will occur.
Cause:
The B-057 has reported a short to ground or open circuit error via CAN to the ECU.
1. Faulty NH3 sensor to B-057 wiring, signal ground line is open or grounded.
Solution:
2. Check for short to ground circuit condition in the B-057 to NH3 sensor harness (cable).
Disconnect the NH3 connector sensor from the B-057.
Use a multimeter to check for the continuity on the harness (cable) from the B-057 to NH3 sensor.
A. If there is continuity on any of the checks, the harness or sensing head is damaged. Replace the NH3 sensor
and its connecting cable.
B. If there is no continuity, leave the NH3 connector sensor disconnected and continue with Step 3.
3. As there is no method for field testing the temperature sensing portion of the sensor, replace the NH3 sensor.

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has been resolved.
operation.
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19009 (DTC 18DE)-NH3 sensor short in heater circuit causing

overheating
Context:
The NH3 module B-057 is required to report information at regular intervals to the Engine Control Unit (ECU) A158 via
Controller Area Network (CAN). If a sensor over heating condition exists, this fault will occur. This fault is considered
a second failure fault because it requires two different failures to activate. The Heater + (positive) and - (negative)
control circuits are shorted to a voltage source and ground, respectively.
Cause:
The B-057 has reported a short to voltage source and short to ground condition in the Heater + (positive) and - (neg-
ative) control circuits.
1. Faulty NH3 sensor to B-057 wiring, heater negative line is shorted to ground.
Solution:
2. Verify the condition of the NH3 sensor.
Use a multimeter to measure the resistance and check for continuity on the harness (cable).
A. If the measured resistance is within the specified range and the harness (cable) wiring is not shorted, continue
with Step 3.
B. If the measured resistance is not within the specified range or the harness (cable) wiring is shorted, replace
the NH3 sensor and continue with Step 3.
3. As there is no method for field testing or re-flashing the sensor controller and the only battery level voltage available
in the B-057 to NH3 sensor harness (cable) is the NH3 sensor heater + (positive) circuit wiring, replace the B-057
and check to see that the fault is resolved.
has been resolved.
operation.
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19010-(DTC 161A)-Downstream SCR catalyst temperature sensor

necessary.
Context:
The Engine Control Unit (ECU) A158 monitors the SCR downstream temperature sensor B-022 circuit. Temperature
signal is converted by the analog to digital converter which converts the raw voltage signal into a physical temperature
value. If the ECU detects a voltage greater than 3.30 V in the SCR downstream temperature sensor signal circuit,
Cause:

Solution:
From To Value
A. If there is no continuity, there is an open circuit condition in the B-022 signal circuit, wire 609 WH. Locate and

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From To Value
A. If there is continuity, there is a short circuit condition in the B-022, signal circuit, wire 609. Locate and repair

4. Check the B-022 signal circuit for a short to key battery power condition.
From To Value
A. If there is voltage, there is a short to key battery power condition in the B-022 signal circuit, wire 609 and wire
610-3 BL. Locate and repair the shorted conductor.

has been resolved.
operation.
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19011-(DTC 271A)-Downstream SCR catalyst temperature sensor

necessary.
Context:
The Engine Control Unit (ECU) A158 monitors the SCR downstream exhaust gas temperature sensor B-022 circuit
voltage. If the ECU detects a voltage less than 500 mV in the SCR downstream exhaust gas temperature sensor
signal circuit, this fault will occur.
Cause:
The ECU has detected a voltage less than 500 mV in the B-022 signal circuit.

Solution:
From To Value
A. If there is continuity, there is a short to ground condition in the B-022 signal circuit, wire 609. Locate and repair

3. Replace the B-022
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has been resolved.
operation.
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19012 (DTC E9DE)-NH3 sensor open in heater circuit causing

underheating
Context:
via Controller Area Network (CAN). If a sensor under heating condition exists, this fault will occur.
Cause:
The B-057 has reported, via CAN, to the ECU that an open circuit condition in either control circuit or a short to ground
or a short to a voltage source condition exists in the Heater + (positive) or - (negative) control circuit, respectively.
1. Faulty NH3 sensor, open, shorted, or grounded heater element.

2. Faulty NH3 sensor control circuit, damaged wiring.
Solution:
2. Verify condition of the NH3 sensor heater circuit.
Use a multimeter to measure the resistance and check for continuity on the harness (cable).
A. If the measured resistance is within the specified range and there is no continuity to any of the other pins or
ground, leave the NH3 connector sensor disconnected and continue with Step 3.
B. If there is zero or infinite resistance or continuity to any another pin or ground, there is either a short, open
or grounded circuit condition in the heater circuit wiring or the NH3 sensor has failed internally. Replace the
sensor and its controller connecting cable.
3. As there is no method for field testing or re-flashing the B-057, replace the B-057.
has been resolved.
operation.
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19013-(DTC EADE)-NH3 sensor open or short in temperature cell

circuit
Context:
via Controller Area Network (CAN). If no signal is sensed on the heater temperature sensing signal line, this fault will
occur.
Cause:
The B-057 has reported a short to ground or open circuit error via CAN to the ECU.

Solution:

has been resolved.
operation.
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19014-(DTC EBDE)-NH3 sensor open or short in trim resistor circuit

Context:
via Controller Area Network (CAN). If the reference trim resistor circuit is affected in any way, this fault will occur.
Cause:
The B-057 has reported, via CAN, to the ECU that an open, or a short to ground, or a short to a voltage source
condition exists in the reference trim resistor control circuit.
1. Faulty NH3 sensor to B-057 cable wiring, open, shorted or grounded trim resistor.
Solution:
2. Verify the condition of the trim resistor in the NH3 sensor to B-057 cable.
Use a multimeter to measure the resistance and check for continuity on the B-057 to NH3 sensor harness side.
A. If the measured resistance is within the specified range and there is no continuity to any other pin, leave NH3
connector sensor disconnected and continue with Step 3.
B. If the measured resistance is not within the specified range or there is continuity to any of the other pins, the
NH3 sensor trim resistor has failed or the cabling is damaged. Replace the NH3 sensor and attached cabling.
3. As there is no method for field testing or re-flashing the B-057, replace the B-057.
has been resolved.
operation.
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19015-(DTC 4CDE)-NH3 sensor heater control failure

Context:
via Controller Area Network (CAN). This fault is the result of a heater control failure.
Cause:
The B-057 has reported via CAN to the ECU that a heater control failure has occurred.

Solution:

has been resolved.
operation.
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19016-(DTC 37EE)-NH3 sensor heater performance failure

Context:
via Controller Area Network (CAN). Once the dew-point has been reached, the sensor has 120.0 s to reach heat up.
If the sensor heat up is not completed in time, this fault will occur.
Cause:
The B-057 has reported, via CAN, to the ECU that the NH3 sensor did not reach heat up in the allotted time.
1. Faulty NH3 sensor.

Solution:
Use the EST to check for the presence of any of the following faults:
19012 (DTC E9DE) - NH3 sensor open in heater circuit causing underheating
19013 (DTC EADE) - NH3 sensor open or short in temperature cell circuit
19014 (DTC EBDE) - NH3 sensor open or short in trim resistor circuit
19018 (DTC 4DDE) - NH3 sensor power supply failure
A. If any of the faults listed above are present, resolve the relevant fault or faults. Then check to see that this fault
is also resolved.
B. If there are no relevant faults present, continue with Step 3.

3. Replace the NH3 sensor.

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has been resolved.
operation.
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19017-(DTC 38EE)-NH3 sensor signal out of range failure

Context:
via Controller Area Network (CAN). Two sensing plates internal to the NH3 sensor sense the levels of NH3 and NO2.
One plate (EMF1) senses both NH3 and NO2 while the second plate (EMF2) senses only NO2. The filtered signal
difference between the two plates (EMF1 and EMF2) should be 0.025 - 1.000 V. If the filtered signal difference is not
within the range, this fault will occur.
Cause:
The B-057 has reported, via CAN, to the ECU that the filtered sensing plate data is not with in specification.
1. Faulty NH3 sensor.

Solution:
2. As there is no method for field testing the sensing plate portion of the sensor, replace the NH3 sensor.
Check to see that this fault is resolved.

3. As there is no method for field testing or re-flashing the sensor controller, replace the NH3 Control Unit.
Check to see that this fault is resolved.
has been resolved.
operation.
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19018 (DTC 4DDE)-NH3 sensor power supply failure

Context:
via Controller Area Network (CAN). The required supply voltage range, for full functionality, of the NH3 module B-057
is 11.5 - 28.0 V. The NH3 module B-057 can not achieve and/or maintain NH3 sensor temperature if the input voltage
goes below 11.5 V. If the expected voltage is deemed to be too low or out of range, this fault will occur.
Cause:
The B-057 has reported, via CAN, to the ECU that the expected voltage is deemed to be too low or out of range.
1. Faulty supply voltage, sourcing circuit failure.

Solution:
2. Check the level of the B-057 supply voltage.
Disconnect the vehicle harness (VE) from the B-057 at the NH3 Connector XB-057.
Use a multimeter to measure the voltage on the vehicle harness (VE) side:
From To Value
NH3 Connector XB-057, pin 1 NH3 Connector XB-057, pin 4 There should be between 11.5 -
28.0 V
A. If the voltage is not within the specified limits, refer to the appropriate vehicle electrical schematics to locate
and resolve the issue.
B. If the voltage is within the specified limits, continue with Step 3.

3. As there is no method for field testing or re-flashing the B-057, replace the controller.
has been resolved.
operation.
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19019-(DTC 1A1A)-Upstream SCR catalyst temperature sensor

necessary.
Context:
The Engine Control Unit (ECU) A158 monitors the SCR upstream exhaust gas temperature sensor B-021 circuit.
Temperature signal is converted by the analog to digital converter which converts the raw voltage signal into a physical
temperature value. If the ECU detects a voltage greater than 3.30 V in the SCR upstream exhaust gas temperature
sensor B-021 signal circuit, this fault will occur.
Cause:

Solution:
From To Value
A. If there is no continuity, there is an open circuit condition in the B-021 signal circuit, wire 632. Locate and repair

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From To Value
A. If there is continuity, there is a short circuit condition in the B-021, signal circuit, wire 632. Locate and repair

4. Check the B-021 signal circuit for a short to key battery power condition.
From To Value
A. If there is voltage, there is a short to key battery power condition in the B-021 signal circuit, wire 632 and wire
610-1. Locate and repair the shorted conductor.

has been resolved.
operation.
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19020-(DTC 2B1A)-Upstream SCR catalyst temperature sensor

Context:
The Engine Control Unit (ECU) A158 monitors the SCR upstream exhaust gas temperature sensor B-021 circuit volt-
age. If the ECU detects a voltage less than 500 mV in the SCR upstream exhaust gas temperature sensor B-021
signal circuit, this fault will occur.
Cause:
The ECU has detected a voltage less than 500 mV in the B-021 signal circuit.

Solution:
From To Value
A. If there is continuity, there is a short to ground condition in the B-021 signal circuit, wire 632 and wire 610-1.

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has been resolved.
operation.
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19023-(DTC 4EDE)-NH3 sensor controller failure

Context:
via Controller Area Network (CAN). The NH3 module B-057 contains more than one memory type device. If a failure
condition or failure mode is detected or communicated, internally, this fault will occur.
Cause:
The B-057 has reported, via CAN, to the ECU that it has experienced an internal memory failure.

Solution:
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19024-CAN timeout error from NH3 sensor - NH3Sens message

Inducement configuration with the Electronic Service Tool (EST) before you return the machine to service.
Context:
via Controller Area Network (CAN). If this information is not communicated within the allotted time frame, this ECU
timeout fault will occur.
Cause:
The ECU has reported, via the engine sensor CAN bus, that an B-057 timeout of the NH3 sensor message has
occurred.

Solution:
2. Check the B-057 supply voltage.
Disconnect the vehicle (VE) harness from the B-057 at the NH3 Connector XB-057.
Use a multimeter to check for voltage on the vehicle (VE) harness side:
From To Value
NH3 Connector XB-057, pin 1 NH3 Connector XB-057, pin 4 There should be 24.0 V
A. If the voltage is present, leave the NH3 Connector XB-057 disconnected and continue with Step 3.

3. Determine the condition of the B-057 CAN circuit.
Use a multimeter to measure the resistance of the CAN connection on the vehicle (VE) harness side:
From To Value
NH3 Connector XB-057, pin 2 NH3 Connector XB-057, pin 3 There should be 60 Ω

4. Check for other engine After Treatment System (ATS) CAN faults.
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A. If other faults do exist, see Fuse and controller power relay - Testing Auxiliary relay (55.640), for supply
power and ground, or see Controller Area Network (CAN) data bus - Test (55.640), for CAN, to locate and
repair the faulted condition.
B. If no other faults exist, the ATS vehicle (VE) harness wiring is damaged between the harness splice and the
NH3 Connector XB-057, pin 1 and/or NH3 Connector XB-057, pin 4, wires CN42-33 and/or 123-44, for supply
power and ground or NH3 Connector XB-057, pin 2 and/or NH3 Connector XB-057, pin 3, wires CAN_O_H
and/or CAN_O_L for CAN signal. Locate and repair the damage to the ATS supply power and ground or CAN
circuit wiring.
A. If the fault is resolved, use the EST, see Selective Catalytic Reduction (SCR) exhaust treatment - Configure
- Engine restart counter reset (10.500) if necessary. to perform the Engine Restart Counter Reset / Unlock
Inducement configuration. Then return the machine to service.
has been resolved.
operation.
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19026-(DTC 319C)-Exhaust flap sticking or internal failure

Context:
For information regarding the functional operation of the Exhaust flap A-9001 see Exhaust flap actuator - Overview
(55.014). The exhaust flap A-9001 actuator controller sends and receives information at regular intervals to and
from the Engine Control Unit (ECU) A-9000 via Controller Area Network (CAN). If an internal failure is sensed by the
exhaust flap A-9001 actuator controller, this fault will occur.
Cause:
The ECU A-9000 has reported, via the engine sensor CAN bus, that the exhaust flap A-9001 actuator controller has
reported an internal failure.

3. Faulty exhaust flap A-9001 actuator controller, hardware or firmware.
Solution:
2. Check the exhaust flap A-9001 actuator controller supply voltage.
Disconnect the engine (EN) harness from the exhaust flap A-9001 actuator controller at connector X-9025 NEF.
From To Value
X-9025 NEF pin 1 X-9025 NEF pin 2 There should be 24 V .
A. If the voltage is present, leave connector X-9025 NEF disconnected and continue with Step 3.

3. Determine the condition of the exhaust flap A-9001 actuator controller CAN circuit.
From To Value
X-9025 NEF pin 4 X-9025 NEF pin 5 There should be 60 Ω.

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CAN condition.
splice and the exhaust flap A-9001 actuator controller connector X-9025 NEF pin 1 and/or X-9025 NEF pin 2,
wire VE-218 or EN-049 and/or VE-189B or EN-050 for supply power and ground or X-9025 NEF pin 4 and/or
X-9025 NEF pin 5, wire VE-194B or EN-047 and/or VE-201F or EN-048A for CAN signal. Locate and repair
the damage to the CAN circuit wiring.
5. As there is no method for field testing or re-flashing the sensor controller, replace the exhaust flap A-9001 actuator
controller. Check to see that the fault is resolved.
has been resolved.
operation.
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19027-(DTC 329C)-Exhaust flap actuator supply voltage out of range

Context:
For information regarding the functional operation of the exhaust flap A-9001 see Exhaust flap actuator - Overview
(55.014). The exhaust flap A-9001 actuator controller sends and receives information at regular intervals to and from
the Engine Control Unit (ECU) A-9000 via Controller Area Network (CAN). If an electrical problem is sensed by the
exhaust flap A-9001 actuator controller, this fault will occur.
Cause:
reported an electrical problem.

Solution:
From To Value

From To Value

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CAN condition.
has been resolved.
operation.
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19030-(DTC 439C)-Exhaust flap increased friction or high

mechanical load or flap sticking
Context:
(55.014). The exhaust flap A-9001 actuator controller sends and receives information at regular intervals to and
from the Engine Control Unit (ECU) A-9000 via Controller Area Network (CAN). If the exhaust flap exhibits increased
friction, high mechanical load, or is sticking and this is sensed by the Exhaust flap A-9001 actuator controller, this fault
will occur.
Cause:
reported that the exhaust flap is exhibiting increased friction, high mechanical load, or is sticking.

3. Faulty exhaust flap, bound or damaged.
4. Faulty Exhaust flap A-9001 actuator controller, hardware or firmware.
Solution:
2. Check the Exhaust flap A-9001 actuator controller supply voltage.
Disconnect the engine (EN) harness from the Exhaust flap A-9001 actuator controller at connector X-9025 NEF.
From To Value

3. Determine the condition of the Exhaust flap A-9001 actuator controller CAN circuit.
From To Value
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CAN condition.
Remove the exhaust flap assembly, visually check for debris and check ease of operation.
A. If the exhaust flap is free of debris and operates freely, continue with Step 6.
B. If the exhaust flap contains debris or is hard to operate, clean, adjust, repair or replace, as required.
has been resolved.
operation.
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19033-(DTC 469C)-Exhaust flap stuck during power up test

Context:
the Engine Control Unit (ECU) A-9000 via Controller Area Network (CAN). If a system failure is sensed by the exhaust
flap A-9001 actuator controller, this fault will occur.
Cause:
reported that a system failure has occurred.

Solution:
From To Value

From To Value

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CAN condition.
has been resolved.
operation.
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19034-(DTC 879C)-Exhaust flap actuator is over temperature

Context:
the Engine Control Unit (ECU) A-9000 via Controller Area Network (CAN). If an over-current situation is sensed by
the exhaust flap A-9001 actuator controller, this fault will occur.
Cause:
reported that an over-current situation exists.

Solution:
From To Value

From To Value

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CAN condition.
has been resolved.
operation.
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19035-(DTC 91BC)-CAN timeout error from exhaust flap actuator

Context:
For information regarding the functional operation of the Exhaust flap A-9001 see Exhaust flap actuator - Overview
(55.014). The Exhaust flap A-9001 actuator controller is required to report information at regular intervals to the
Engine Control Unit (ECU) A-9000 via Controller Area Network (CAN). If this information is not communicated within
the allotted time frame, this ECU A-9000 timeout fault will occur.
Cause:
The ECU A-9000 has reported, via the engine sensor CAN bus, that an Exhaust flap A-9001 actuator controller timeout
has occurred.

3. Faulty Exhaust flap A-9001 actuator controller, hardware or firmware.
Solution:
2. Check for Exhaust flap A-9001 actuator controller supply voltage.
From To Value

From To Value

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CAN condition.
controller.
B. If this fault is not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
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19036 (DTC 3F1C)-SCR downstream temperature sensor signal

drift at cold start
Context:
The Engine Control Unit (ECU) A158 monitors the SCR downstream exhaust gas temperature sensor B-022 signal.
If the ECU determines that the temperature signal of the SCR downstream exhaust gas temperature sensor B-022
has drifted at cold start, this fault will occur.
Cause:
The ECU determines that the temperature signal of the B-022 has drifted at cold start.

Solution:
19010 (DTC 161A) - Downstream SCR catalyst temperature sensor voltage is higher than expected
19011 (DTC 271A) - Downstream SCR catalyst temperature sensor voltage is lower than expected
19042 (DTC 372C) - Downstream SCR temperature sensor comparison to a calculated temperature value
failure
19067 (DTC 141A) - Downstream SCR catalyst temperature is too high
19068 (DTC 251A) - Downstream SCR catalyst temperature is too low

3. Use the EST to compare the temperature value of the B-049 to the temperature values of the B-021 and B-022.
Monitor for possible signal drift due to a rapid change in ambient temperature. The sensors should have similar
characteristics.
Monitoring must be done after a cold soak condition to avoid any residual heat.
A. If no faults are found, continue to Step 4.
B. If any faults are found, verify that a rapid change in ambient temperature has not occurred that has caused this
fault to occur.
Use the EST to verify that this fault.
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Perform an engine cold start to verify that this fault has been resolved.
has been resolved.
operation.
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19040-(DTC 352C)-Upstream oxidation catalyst temperature sensor

comparison to a calculated temperature value failure
Inducement configuration with the Electronic Service Tool (EST) before you return the machine to service.
Context:
The Engine Control Unit (ECU) A158 monitors the temperature value of the DOC upstream exhaust gas temperature
sensor B-049. If the ECU determines that there is a calculated temperature value failure, this fault will occur.
Cause:
The ECU has detected a calculated temperature value failure.
1. Higher than normal exhaust temperature (engine misfire etc.)

2. Faulty B-049, not installed or incorrectly mounted.
Solution:
19066 (DTC 1899) - Upstream oxidation catalyst temperature sensor voltage is higher than expected
3838 (DTC 2999) - Upstream oxidation catalyst temperature sensor voltage is lower than expected
3686 (DTC 3D1C) - DOC upstream temperature sensor signal drift at cold start
A. If any of the faults are active, diagnose them first and then return to this fault.
B. If none of the faults are active, continue to Step 3.

3. Check the B-049 for proper installation.
A. If the sensor is incorrectly mounted, loose or damaged, repair as necessary.
B. If no faults are found, continue to Step 4.

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has been resolved.
operation.
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19041 (DTC 362C)-Upstream SCR temperature sensor comparison

to a calculated temperature value failure
necessary.
Context:
The Engine Control Unit (ECU) A158 monitors the temperature value of the SCR upstream exhaust gas temperature
sensor B-021. If the ECU determines that there is a calculated temperature value failure, this fault will occur.
Cause:
1. Higher than normal exhaust temperature. (engine misfire etc.)

2. Faulty of the B-021, not installed or incorrectly mounted.
3. Faulty of the B-021, wiring.
Solution:
19020 (DTC 2B1A) - Upstream SCR catalyst temperature sensor voltage is lower than expected
3687 (DTC 3E1C) - SCR upstream temperature sensor signal drift at cold start
19069 (DTC 181A) - Upstream SCR catalyst temperature too high
19070 (DTC 291A) - Upstream SCR catalyst temperature too low


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counter reset (10.500) if necessary. to perform the Engine Restart Counter Reset / Unlock Inducement configu-
ration.
Then perform the SCR Fault Verification Test, see Selective Catalytic Reduction (SCR) exhaust treatment -
Service instruction - SCR fault repair verification test (10.500), if necessary.
has been resolved.
operation.
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19042-(DTC 372C)-Downstream SCR temperature sensor

comparison to a calculated temperature value failure
necessary.
Context:
The Engine Control Unit (ECU) A158 monitors the temperature value of the SCR downstream exhaust gas tempera-
ture sensor B-022. If the ECU determines that there is a calculated temperature value failure, this fault will occur.
Cause:
1. Higher than normal exhaust temperature. (engine misfire etc.)

2. Faulty B-022, not installed or incorrectly mounted.
Solution:
19010 (DTC 161A) - Downstream SCR catalyst temperature sensor voltage is higher than expected
19011 (DTC 271A) - Downstream SCR catalyst temperature sensor voltage is lower than expected
19036 (DTC 3F1C) - SCR downstream temperature sensor signal drift at cold start
19067 (DTC 141A) - Downstream SCR catalyst temperature is too high
19068 (DTC 251A) - Downstream SCR catalyst temperature is too low


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has been resolved.
operation.
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19043-(DTC 2D54)-Intake air humidity sensor voltage is lower than

expected
Context:
The Engine Control Unit (ECU) A158 monitors the humidity and temperature sensor B-055 signal circuit. If the ECU
determines that the humidity signal circuit voltage of the humidity and temperature sensor is lower than expected, this
fault will occur.
Cause:
The ECU has detected a voltage less than 200 mV for a period greater than 500 ms in the humidity signal circuit of
the B-055.
1. Faulty humidity and temperature sensor, internal failure.

2. Faulty humidity signal circuit of the B-055, short to ground condition.
Solution:
2. Check the humidity signal circuit of the B-055 for a short to ground condition.
From To Value
A. If there is continuity, there is a short to ground in the humidity signal circuit of the B-055, wire 615. Locate and

B. If the fault has been not been resolved, check the ECU for the appropriate software and re-flash, if necessary.
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has been resolved.
operation.
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19047-(DTC 195A)-DEF/AdBlue supply module pump motor

pressure sensor voltage is higher than expected
necessary.
Context:
For information regarding the functional operation of the Diesel Exhaust Fluid DEF/ADBLUE® system refer to Se-
lective Catalytic Reduction (SCR) exhaust treatment - Dynamic description (10.500). If during DEF/ADBLUE®
system normal operation, the raw voltage signal of the supply module A-037 (pressure sensor) exceeds 4.75 V, this
fault will occur.
Cause:
The Engine Control Unit (ECU) A158 has sensed that the raw voltage signal of the supply module A-037 (pressure
sensor) is greater than 4.75 V.
1. Faulty the signal circuit wiring of the supply module A-037 (pressure sensor), shorted to a voltage source.
2. Faulty DEF/ADBLUE® system supply module, internally shorted to a voltage source.
Solution:
2. Check the signal circuit wiring of the supply module pressure sensor for a short to a voltage source.
Disconnect the Connector XA-037 from the A-037.
Use a multimeter to check for voltage on the vehicle (VE) harness side:
From To Value
Connector XA-037, pin 4 Chassis ground Due to the internal ECU input sensing
circuit configuration, there should be
4.5 - 5.5 V
A. If there is greater than 5.5 V, there is a short to a voltage source condition in the vehicle (VE) harness Con-
nector XA-037, pin 3 and the Connector XA158, pin 7, wire 607. Locate and repair the damaged conductors.
B. If there is no voltage, there is an open circuit condition in the vehicle (VE) harness between the Connector
XA-037, pin 3 and the Connector XA158, pin 7, wire 607. Locate and repair the broken conductor.
C. If there is between 4.5 - 5.5 V, continue with Step 3.

3. As the components internal to the supply module are not serviceable, replace the supply module.
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- Engine restart counter reset (10.500) if necessary, to perform the Engine Restart Counter Reset / Unlock
has been resolved.
operation.
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19048-(DTC 2A5A)-DEF/AdBlue supply module pump motor

pressure sensor voltage is lower than expected
Context:
For information regarding the functional operation of the Diesel Exhaust Fluid DEF/ADBLUE® system refer to Selec-
tive Catalytic Reduction (SCR) exhaust treatment - Dynamic description (10.500). If during normal operation
raw voltage signal supply module A-037 (pressure sensor) drops below 0.25 V, this fault will occur.
Cause:
The Engine Control Unit (ECU) A158 has sensed that the raw voltage signal of the supply module A-037 (pressure
sensor) is less than 0.25 V.
1. Faulty signal circuit wiring of the supply module A-037 (pressure sensor), shorted to ground.
2. Faulty supply module, internally shorted to ground.
Solution:
1. Verify fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault.
2. Check signal circuit wiring of the supply module pressure sensor for short to ground.
Disconnect the Connector XA-037 from the A-037.
Use a multimeter to check for continuity on the vehicle (VE) harness side:
From To Value
A. If there is continuity, there is a short to a ground condition in the vehicle (VE) harness between the Connector
XA-037, pin 3 and the Connector XA158, pin 7, wire 607. Locate and repair the grounded conductor.

3. As the components internal to the DEF/ADBLUE® system supply module are not serviceable, replace the supply
module.
Then check to see if this fault is resolved.
has been resolved.
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operation.
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19050-(DTC 478E)-Downstream NOx sensor supply voltage is out

of range
necessary.
Context:
The SCR downstream NOx sensor B-054 has internal monitoring for operating conditions and reports status along
with sensed data. The normal operating range of the battery power supply voltage to the SCR downstream NOx
sensor B-054 should be 10.0 - 16.0 V. If the expected voltage is deemed to be too low or out of range, by the SCR
downstream NOx sensor B-054, this fault will occur.
Cause:
The B-054 has reported, via CAN, to the Engine Control Unit (ECU) A158 that the expected voltage is deemed to be
too low or out of range.
1. Faulty supply voltage, out of range.

Solution:
2. Check supply voltage.
Disconnect the vehicle (VE) harness from the SCR downstream NOx sensor at the Connector XB-054.
Use a multimeter to measure the voltage on the vehicle (VE) harness side:
From To Value
Connector XB-054, pin 1 Connector XB-054, pin 2 There should be between 10.0 -
16.0 V
A. If the supply voltage is not within the specified range, continue with Step 3.
B. If the supply voltage is within the specified range, continue with Step 4.
3. Check for related supply voltage faults.
Use EST to determine the presence of 19063 (DTC 4A8E) - Upstream NOx sensor supply voltage is out of
range.
A. If fault 19063 (DTC 4A8E) - Upstream NOx sensor supply voltage is out of range is present locate and
repair faulted condition.
B. If this fault is not present, the faulted condition is between Connector XB-054, pin 1 or Connector XB-054,
pin 2 and the vehicle (VE) harness splice SPL_3F26 or SPL_07EN, wire 123-31 or 123-41. Locate and repair
the conductor failure.
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4. As there is no method for field testing the SCR downstream NOx sensor, replace the SCR downstream NOx sensor.
A. If this fault is resolved, use EST, see Selective Catalytic Reduction (SCR) exhaust treatment - Configure
Inducement configuration then return the machine to service.
has been resolved.
operation.
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19051-(DTC E46E)-Upstream NOx sensor internal failure (Heater

Open Circuit Error)
necessary.
Context:
For information regarding the functional operation of the smart Diesel Oxidation Catalyst (DOC) upstream NOx sensor
see Nitrogen Oxide (NOx) sensor - Dynamic description (55.988). The DOC upstream NOx sensor B-056 has
internal monitoring for open wire or short circuit and sends an error status in case of a detected failure. This failure is
the result of an open circuit error in the sensor heater circuit.
Cause:
The B-056 has reported, via CAN, to the ECU that an open circuit condition exists in the heater control circuit.

Solution:
Then use the EST, see Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data (Upstream sensor) (55.988)
if necessary, to perform the Replacement of the Nox Upstream Sensor - Reset ECU Data configuration.
has been resolved.
operation.
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19052-(DTC 256E)-Upstream NOx sensor internal failure (Heater

Short Circuit Error)
necessary.
Context:
the result of a short circuit error in the sensor heater circuit.
Cause:
The B-056 has reported, via CAN, to the ECU that a short circuit condition exists in the heater control circuit.

Solution:
Then use the EST, refer to Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data (Upstream sensor)
(55.988) if necessary, to perform the Replacement of Nox Upstream Sensor - Reset ECU Data configuration.
has been resolved.
operation.
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19053-(DTC A66E)-Upstream NOx sensor internal failure (Heater

Performance Plausibility Error)
Context:
internal monitoring and delivers information about its error status and the results of self diagnosis procedure, via
CAN, to the Engine Control Unit (ECU). One of the monitored conditions is whether or not the DOC upstream NOx
sensor B-056 reached the appropriate operating temperature within the allotted time. Once the dew point has been
reached, the sensor has 120.0 s to reach heat up. If the sensor heat up is not completed in time, this fault will occur.
Cause:
The DOC upstream NOx sensor has reported, via CAN, to the ECU that the sensor failed to reach heater working
temperature in the allotted time.

Solution:
Use the EST to check for the presence of fault 19063 (DTC 4A8E) - Upstream NOx sensor supply voltage is
out of range.
A. If fault 19063 (DTC 4A8E) - Upstream NOx sensor supply voltage is out of range is present, resolve fault
19063 (DTC 4A8E) - Upstream NOx sensor supply voltage is out of range. Then check to see that this
B. If the fault 19063 (DTC 4A8E) - Upstream NOx sensor supply voltage is out of range is not present, continue
with Step 3.
3. As there is no method for field testing or re-flashing the sensor controller, replace the DOC upstream NOx sensor.
Then use EST, see Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data (Upstream sensor) (55.988)
Run the machine and use the EST capability to view parameters to verify that the sensor has reached dew point.
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has been resolved.
operation.
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19054-(DTC E48E)-Upstream NOx sensor internal failure (Open

Circuit Error)
necessary.
Context:
the result of an open circuit error in the sensor NOx and/or oxygen level circuit.
Cause:
The B-056 has reported, via CAN, to the ECU that an open circuit condition exists in the NOx and/or Oxygen level
circuit.

Solution:
has been resolved.
operation.
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19059 (DTC 258E)-Upstream NOx sensor internal failure (short

circuit error)
necessary.
Context:
the result of a short circuit error in the sensor NOx and/or Oxygen level circuit.
Cause:
The B-056 has reported, via CAN, to the ECU that a short circuit condition exists in the NOx and/or Oxygen level
circuit.

Solution:
Then use the EST, refer to Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data (Upstream sensor)
(55.988) if necessary, to perform the Replacement of Nox Upstream Sensor - Reset ECU Data configuration.
has been resolved.
operation.
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19060-(DTC 9E6E)-CAN timeout error from upstream NOx sensor

necessary.
Context:
For information regarding the functional operation of the smart Diesel Oxidation Catalyst (DOC) upstream NOx sen-
sor see Nitrogen Oxide (NOx) sensor - Dynamic description (55.988). The DOC upstream NOx sensor B-056 is
required to report information at regular intervals to the Engine Control Unit (ECU) via CAN. If this information is not
communicated within the allotted time frame, this ECU timeout fault will occur.
Cause:
The ECU has reported, via CAN, that a DOC upstream NOx sensor message timeout has occurred.

Solution:
2. Check for the presence of supply voltage fault.
Use EST to determine the presence of fault 19063 (DTC 4A8E) - Upstream NOx sensor supply voltage is out
of range.
A. If fault 19063 (DTC 4A8E) - Upstream NOx sensor supply voltage is out of range is present, resolve the
19063 (DTC 4A8E) - Upstream NOx sensor supply voltage is out of range fault. Then determine if this fault
is also resolved.
B. If fault 19063 (DTC 4A8E) - Upstream NOx sensor supply voltage is out of range is not present, continue
with Step 3.
3. Determine the condition of the CAN circuit of B-056.
Disconnect the After Treatment System (ATS) vehicle (VE) harness from the DOC upstream NOx sensor at the
Connector XB-056.
Use a multimeter to measure the resistance of the CAN circuit on the ATS vehicle (VE) harness side:
From To Value
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if necessary, to perform the Replacement of Nox Upstream Sensor - Reset ECU Data configuration.
5. Check for other engine ATS CAN faults.
A. If other faults do exist, see Controller Area Network (CAN) data bus - Test (55.640) to locate and repair the
faulted condition.
B. If no other faults exist, the ATS vehicle (VE) harness wiring is damaged between the network harness splice
and the Connector XB-056, pin 3 and/or Connector XB-056, pin 4, wire CAN_O_H and/or CAN_O_L. Locate
and repair the damage to the ATS CAN circuit wiring.
has been resolved.
operation.
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19061-(DTC 32BE)-Upstream NOx sensor lambda signal deviation -

NOx sensor possible removal detected
necessary.
Context:
internal monitoring for operating conditions and reports status along with sensed data. If the sensor lambda data
value is outside the values established by the minimum/maximum curves specified in the Engine Control Unit (ECU)
A158, dependent on the lambda value itself, this fault will occur.
Cause:
The ECU has determined that the B-056 is not measuring correct lambda values.

Solution:
A. If the fault is resolved, use EST see Selective Catalytic Reduction (SCR) exhaust treatment - Configure
- Engine restart counter reset (10.500), if necessary, to perform the Engine Restart Counter Reset / Unlock
Inducement configuration. Then perform the SCR Fault Repair Verification Test if necessary. Then return the
machine to service.

Then use the EST, see Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data (Upstream sensor)
(55.988), if necessary, to perform the Replacement of Nox Upstream Sensor - Reset ECU Data configuration.
A. If the fault is resolved, use EST to perform the SCR Fault Repair Verification Test, see Selective Catalytic
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19062-(DTC E98E)-Upstream NOx sensor values are not plausible

Context:
see Nitrogen Oxide (NOx) sensor - Dynamic description (55.988). The smart DOC upstream NOx sensor B-056
delivers information about its error status and the results of self diagnosis procedure, via CAN, to the Engine Control
Unit (ECU) A158. If the DOC upstream NOx sensor B-056 sends the message Lambda or NOx signal not plausible,
Cause:
The B-056 has reported, via CAN, to the ECU that the Lambda or NOx signal is not plausible.
1. Faulty DOC upstream NOx sensor, hardware or firmware.
Solution:
1. Check for related fault.
Use the Electronic Service Tool (EST) to check for fault 19071 (DTC 2DDA) - SCR catalyst efficiency lower than
first NOx production threshold level.
A. If fault 19071 (DTC 2DDA) - SCR catalyst efficiency lower than first NOx production threshold level is
present, the DOC upstream NOx sensor is poisoned. Replace the DOC upstream NOx sensor. Then use EST,
to perform the Replacement of Nox Upstream Sensor - Reset ECU Data configuration.
B. If fault 19071 (DTC 2DDA) - SCR catalyst efficiency lower than first NOx production threshold level is
not present, ignore this fault.
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19063-(DTC 4A8E)-Upstream NOx sensor supply voltage is out of

range
necessary.
Context:
internal monitoring for operating conditions and reports status along with sensed data. The expected normal operating
range of the battery power supply voltage to the DOC upstream NOx sensor is 10.0 - 16.0 V. If the expected voltage
is deemed to be too low or out of range, by the DOC upstream NOx sensor this fault will occur.
Cause:
The B-056 has reported, via CAN, to the Engine Control Unit (ECU) that the expected voltage is deemed to be too
low or out of range.
1. Faulty supply voltage, out of range.

Solution:
2. Check supply voltage.
Disconnect the After Treatment System (ATS) vehicle (VE) harness from the B-056 at the Connector XB-056.
Use a multimeter to measure the voltage on the vehicle (VE) harness side:
From To Value
16.0 V
A. If the supply voltage is not within the specified range, continue with Step 3.
B. If the supply voltage is within the specified range, continue with Step 4.
3. Check for related supply voltage faults.
Use EST to determine the presence of 19050 (DTC 478E) - Downstream NOx sensor supply voltage is out of
range.
A. If fault 19050 (DTC 478E) - Downstream NOx sensor supply voltage is out of range is present, locate and
repair faulted condition.
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B. If fault 19050 (DTC 478E) - Downstream NOx sensor supply voltage is out of range is not present, the
faulted condition is between the Connector XB-056, pin 1 or Connector XB-056, pin 2 and the ATS vehicle
(VE) harness splice SPL_3F26 or SPL_07EN, wire 123-32 or 123-43. Locate and repair the conductor failure.
4. As there is no method for field testing the DOC upstream NOx sensor, replace the DOC upstream NOx sensor.
Then use EST, see Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data (Upstream sensor) (55.988),
A. If this fault is resolved, use EST, see Selective Catalytic Reduction (SCR) exhaust treatment - Configure
has been resolved.
operation.
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19066-(DTC 1899)-Upstream oxidation catalyst temperature sensor

necessary.
Context:
The Engine Control Unit (ECU) A158 monitors the circuit of the DOC upstream exhaust gas temperature sensor
B-049. If the ECU determines that the signal circuit voltage of the B-049 is greater than 3.60 V, this fault will occur.
The temperature value is will be frozen at the last valid value for a preliminary failure and jumps to a fixed replacement
value of 575.0 °C (1066.9 °F) if the failure is validated.
Cause:
The ECU has detected a voltage greater than 3.30 V in the signal circuit of the B-049.

Solution:
2. Check the signal circuit of the B-049 for an open circuit condition.
From To Value
A. If there is no continuity, there is an open circuit condition in the signal circuit of the B-049, wire 616. Locate
and repair the broken conductor.

3. Check the signal circuit of the B-049 for a short to high source condition.
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From To Value
A. If there is continuity, there is a short circuit condition in the signal circuit of the B-049, wire 616. Locate and

4. Check the signal circuit of the B-049 for a short to key battery power condition.
From To Value
A. If there is voltage, there is a short to key battery power condition in the signal circuit of the B-049, wire 616.

has been resolved.
operation.
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19067 (DTC 141A)-Downstream SCR catalyst temperature is too

high
Context:
The Engine Control Unit (ECU) A158 monitors the SCR downstream exhaust gas temperature sensor B-022. If the
ECU determines that the temperature value is greater than 890.0 °C (1633.9 °F), this fault will occur.
Cause:
Downstream SCR temperature is too high.

2. Catalyst efficiency low.
3. Excessive exhaust back pressure.
4. Over fueling condition.
5. Stuck Electronic Variable Geometric Turbocharger (EVGT) actuator (if equipped).
6. High intake air temperature.
7. Engine valve lash too tight.
8. Faulty injection timing.
9. Faulty camshaft timing.
Solution:
1. Use the EST to check for the following related faults that may have caused this fault to occur.
19010 - (DTC 161A)-Downstream SCR catalyst temperature sensor voltage is higher than expected
19042 (DTC 372C) - Downstream SCR temperature sensor comparison to a calculated temperature value
failure
19036 (DTC 3F1C) - SCR downstream temperature sensor signal drift at cold start
3985 (DTC 1758) - Exhaust gas pressure sensor voltage is higher than expected
3986 (DTC 2858) - Exhaust gas pressure sensor voltage is lower than expected
3450 (DTC 3398) - eVGT actuator blocked
3861 (DTC 3498) - eVGT power supply electrical failure
3457 (DTC 1374) - Intake manifold temperature sensor voltage is higher than expected
3517 (DTC 19C4) - Ambient temperature sensor voltage is higher than expected
3493
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2. Use an in-fared type temperature gun to check the physical temperature of the B-022 at the sensor base.
Run the engine until operating temperature is reached.
A. If the temperature exceeds 537.8 °C (1000 °F), refer to the possible failure modes listed above and repair as
necessary.
B. If the temperature does not exceed 537.8 °C (1000 °F), continue to Step 3.
From To Value
B. If the specified values have not been measured, there is a fault in the wiring of the B-022. Locate and repair
B. If the fault has been not resolved, check the ECU for the appropriate software and re-flash, if necessary.
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19068 (DTC 251A)-Downstream SCR catalyst temperature is too low

Context:
For information regarding the functional operation of the Selective Catalytic Reduction (SCR) system refer to Se-
lective Catalytic Reduction (SCR) exhaust treatment - Dynamic description (10.500). The Engine Control Unit
(ECU) A158 monitors the SCR downstream exhaust gas temperature sensor B-022. If the SCR downstream exhaust
gas temperature sensor B-022 measure a temperature lower than -40.04 °C (-40.07 °F), this fault will occur.
Cause:
The ECU is sensing that the B-022 is below the lower threshold limit.
1. Ambient air temperature, below -40.04 °C (-40.07 °F).

3. Faulty B-022, installation.
Solution:
2. Determine ambient temperature.
Establish if ambient temperature is appreciably greater or less than -40.04 °C (-40.07 °F).
A. If the ambient temperature is less than -40.04 °C (-40.07 °F), this fault will be present and active. The machine
will need to be started or moved to a warmer environment, ignore this fault and return the machine to service.
B. If the ambient temperature is greater than -40.04 °C (-40.07 °F), continue with Step 3.
3. Check the condition of the B-022.
Disconnect the vehicle (VE) harness from the SCR downstream exhaust gas temperature sensor at the Connector
XB-022.
With the key switch in the OFF position, use a multimeter to measure the resistance on the sensor:
From To Value
Connector XB-022, pin 1 Connector XB-022, pin 2 There should be greater than
169.7 Ω
NOTE: to determine actual resistance values for various temperatures see Selective Catalytic Reduction (SCR)
temperature sensors - General specification (55.988).
A. If there is greater than 169.7 Ω, continue with Step 4.
B. If there is less than 169.7 Ω, the B-022 has failed internally. Replace the B-022.
4. Verify proper sensor installation.
Check the B-022 for correct mounting and the electrical connection.
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A. If the sensor is not properly mounted or electrical connector integrity is questionable, remove and re-install,
adjust, and/or replace, as required.
B. If the sensor is properly mounted and electrically connected, check the ECU for the appropriate software and
has been resolved.
operation.
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19069 (DTC 181A)-Upstream SCR catalyst temperature too high

Context:
The Engine Control Unit (ECU) A158 monitors SCR upstream exhaust gas temperature sensor B-021. If the ECU
determines that the temperature is greater than 890 °C (1634 °F), this fault will occur.
Cause:
Upstream SCR temperature is too high.

2. Low catalyst efficiency.
3. Excessive exhaust back pressure.
4. Over fueling condition.
5. Stuck Electronic Variable Geometric Turbocharger (EVGT) actuator.
6. High intake air temperature.
7. Engine valve lash too tight.
8. Faulty injection timing.
9. Faulty camshaft timing.
Solution:
19041 (DTC 362C) - Upstream SCR temperature sensor comparison to a calculated temperature value fail-
ure
3687 (DTC 3E1C) - SCR upstream temperature sensor signal drift at cold start
3985 (DTC 1758) - Exhaust gas pressure sensor voltage is higher than expected
3986 (DTC 2858) - Exhaust gas pressure sensor voltage is lower than expected
3450 (DTC 3398) - eVGT actuator blocked
3861 (DTC 3498) - eVGT power supply electrical failure
3457 (DTC 1374) - Intake manifold temperature sensor voltage is higher than expected
3517 (DTC 19C4) - Ambient temperature sensor voltage is higher than expected
3093 (DTC 3312) - Compared camshaft and crankshaft speed sensor values are not plausible
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2. Use an in-fared type temperature gun to check the physical temperature of the B-021 at the sensor base.
Run the engine until operating temperature is reached.
A. If the temperature exceeds 537.8 °C (1000 °F), refer to the possible failure modes listed above and repair as
necessary.
B. If the temperature does not exceed 537.8 °C (1000 °F), continue to Step 3.
3. Check the wiring of the B-021.
From To Value
B. If the specified values have not been measured, there is a fault in the wiring of the B-021. Locate and repair
B. If the fault has been not resolved, check the ECU for the appropriate software and re-flash, if necessary.
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19070 (DTC 291A)-Upstream SCR catalyst temperature too low

Context:
(ECU) A158 monitors the SCR upstream exhaust gas temperature sensor B-021. If the temperature upstream of he
SCR catalyst is below -40.04 °C (-40.07 °F), this fault will occur.
Cause:
The ECU is sensing that the upstream SCR catalyst temperature is below the lower threshold limit.
1. Ambient air temperature, below -40 °C (-40 °F).

3. Faulty B-021, installation.
Solution:
2. Determine ambient temperature.
Establish if ambient temperature is appreciably greater or less than -40 °C (-40 °F).
A. If the ambient temperature is less than -40 °C (-40 °F), this fault will be present and active. The machine will
need to be started or moved to a warmer environment, ignore this fault and return the machine to service.
B. If the ambient temperature is greater than -40 °C (-40 °F), continue with Step 3.
3. Check the condition of the B-021.
Disconnect the vehicle (VE) harness from the B-021 at the Connector XB-021.
With the key switch in the OFF position, use a multimeter to measure the resistance on the sensor:
From To Value
169.7 Ω
NOTE: to determine actual resistance values for various temperatures see Selective Catalytic Reduction (SCR)
temperature sensors - General specification (55.988).
A. If there is greater than 169.7 Ω, continue with Step 4.
B. If there is less than 169.7 Ω, the B-021 has failed internally. Replace the B-021.
4. Verify proper sensor installation.
Check the B-021 for correct mounting and the electrical connection.
A. If the sensor is not properly mounted or electrical connector integrity is questionable, remove and re-install,
adjust, and/or replace, as required.
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B. If the sensor is properly mounted and electrically connected, check the ECU for the appropriate software and
has been resolved.
operation.
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19071-(DTC 2DDA)-SCR catalyst efficiency lower than first Nox

production threshold level
NOTE: before troubleshooting, download the ‘Data Stored’ information from the Engine Control Unit (ECU). See Elec-
tronic module - Download (55.640).
necessary.
Context:
lective Catalytic Reduction (SCR) exhaust treatment - Dynamic description (10.500). The instantaneous SCR
catalyst efficiency is obtained from the Diesel Oxidation Catalyst (DOC) upstream NOx sensor B-056 and the SCR
downstream NOx sensor B-054. When the Engine Control Unit (ECU) A158 determines that the SCR catalyst effi-
ciency is lower than expected, this fault occurs.
Cause:
The ECU calculated that the SCR catalyst efficiency is lower than expected.
1. Faulty B-054, measures too high values.

2. Faulty B-056, measures too high values.
3. Faulty NH3 sensor, measures too high values.
4. Faulty B-050, 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. Verify that the fault is present and active.
2. Check for related faults.
Use the Electronic Service Tool (EST) to check for the presence of SCR Downstream NOx sensor fault 3528 (DTC
319E) - Downstream NOx sensor values are not plausible or DOC upstream NOx sensor 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
this fault is also resolved.
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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 3.
Use the EST to check for the presence of SCR downstream NOx sensor fault 19422 (DTC 43CE) - Downstream
NOx sensor signal is stuck at a constant value or NH3 sensor 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 this
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 4.
Use the EST to check for the presence of DEF/ADBLUE® quality sensor fault 19140 (DTC 4BCA) - DEF/AdBlue
concentration is out of range or 19159 (DTC 144E) - DEF/AdBlue quality sensor internal failure (concen-
tration 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/Ad-
Blue 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 this fault is also resolved.
B. If neither 19140 (DTC 4BCA) - DEF/AdBlue concentration is out of range nor 19159 (DTC 144E) - DEF/Ad-
Blue 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,
5. Check the DEF/ADBLUE® level and the DEF/ADBLUE® mixture concentration.
Visually determine that the B-050 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 or if
the DEF/ADBLUE® mixture concentration is not between 28.75 - 36.25 %, drain the DEF/ADBLUE®. Then
remove, inspect and clean, if necessary, the DEF/ADBLUE® quality sensor to assure the cover holes of the
DEF/ADBLUE® quality sensor 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 and the
DEF/ADBLUE® mixture concentration is between 28.75 - 36.25 %, continue with Step 6.
6. Check the SCR exhaust system.
Check the exhaust pipes, and connections for external soot or DEF/ADBLUE® leakage.
There should be no leakage.
A. If leakage does exist, repair or replace the component.
B. If there is no visible signs of external leakage, continue with Step 7.

7. Check the dosing module, and the flange interface for deposits.
Remove the dosing module and check for large deposits that would inhibit injection.
There should be no blockage or leakages.
A. If significant blockage does exist, repair or replace the dosing module, as required.
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B. If significant blockage is not visible, do not install the dosing module and continue with Step 8.
8. Check DEF/ADBLUE® system for pressure, leaks and quantity.
Orient the dosing module 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 5.00 - 7.00 bar (72.50 - 101.50 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.
B. If the pressure is within specification, the spray pattern is uniform, and leakage is not seen, do not install the
dosing module and continue with Step 9.
9. Check the condition of the DEF/ADBLUE® mixing chamber.
Visually inspect the DEF/ADBLUE® and exhaust gas mixing chamber, through the dosing module mounting hole,
for large deposits (at least 25.0 % of the surface is blocked) or damage.
A. If large deposits are discovered, clean the DOC assembly. Clean the mixing chamber manually, if possible.
Use EST to run the ‘Desulfurization / Thermal Conditioning Procedure’, see Selective Catalytic Reduction
(SCR) exhaust treatment - Test (10.500). If damage is discovered, repair or replace the DOC assembly as
required. See Selective Catalytic Reduction (SCR) muffler and catalyst - Configure - Reset ECU data
(10.500), if necessary, to perform the Replacement of Catalyst - Reset ECU Data configuration.
B. If large deposits or damage is not discovered, install the dosing module. Continue with Step 10.
10. Check the condition of the DOC catalyst.
Remove the B-049.
Visually inspect the catalyst, through the mounting hole of the DOC upstream temperature sensor, 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, see Selective
Catalytic Reduction (SCR) muffler and catalyst - Configure - Reset ECU data (10.500), if necessary, to
perform the Replacement of Catalyst - Reset ECU Data configuration.
B. If substrate contamination or damage does not exist, continue with Step 11.
11. Check the condition of the SCR catalyst.
Remove the B-021.
Visually inspect the catalyst, through the mounting hole of the SCR upstream temperature sensor, 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, see Selective Cat-
alytic Reduction (SCR) muffler and catalyst - Configure - Reset ECU data (10.500), if necessary, to
perform the Replacement of Catalyst - Reset ECU Data configuration.
B. If substrate contamination or damage does not exist, continue with Step 12.
12. Check the ECU software.
Use the EST to check for the appropriate ECU software.
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A. If the ECU is not running appropriate software, use the EST to re-flash the ECU.
B. If the ECU is currently running appropriate software, use the EST to retrieve stored engine data, then use
ASIST to escalate a concern.
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19077-(DTC 334A)-DEF/AdBlue pressure stabilization failure

necessary.
Context:
For information regarding the functional operation of the Diesel Exhaust Fluid ( DEF/ADBLUE®) system see Selective
Catalytic Reduction (SCR) exhaust treatment - Dynamic description (10.500). After pressure build up attempt
has exceeded 50.0 s and the DEF/ADBLUE®pressure provided by the supply module is still outside the range of
8.5 - 9.5 bar (123.2 - 137.8 psi), the DEF/ADBLUE® system will be placed in evacuation mode to remove any DEF/
ADBLUE® and this fault will then occur.
Cause:
The Engine Control Unit (ECU) A158 has determined that a DEF/ADBLUE® system pressure line failure exists.
1. Faulty DEF/ADBLUE® system, pre-filter in suction line restricted.

2. Faulty DEF/ADBLUE® system, filter in inlet connector of the supply module restricted.
3. Faulty DEF/ADBLUE® system, filter in back-flow connector of the supply module restricted.
4. Faulty DEF/ADBLUE® system, tank ventilation line restricted.
5. Faulty DEF/ADBLUE® system, suction line frozen, blocked or leaking (tubing, hydraulic connector, O-ring).
6. Faulty DEF/ADBLUE® system, back-flow line frozen or blocked (tubing, hydraulic connector).
7. Faulty DEF/ADBLUE® system, leakage on suction pipe inside DEF/ADBLUE® tank unit.
8. Faulty DEF/ADBLUE® system, supply module pump motor or pressure sensor defective.
Solution:
1. Check for freezing, blockage, or damage to DEF/ADBLUE® system.
Visually and tactually inspect the DEF/ADBLUE® system filters and tank ventilation line, items 1 through 4 in the
list above, for blockage.
There should be no blockage,
A. If blockage is found, repair or replace the affected component.
B. If no blockage is found, continue with Step 2.

2. Check for freezing, blockage, damage or leakage to DEF/ADBLUE® system.
Visually and tactually inspect the DEF/ADBLUE® system, items 5 through 7 in the list above, lines, hydraulic con-
nectors and O-rings for blockage, damage or leakage.
There should be no blockage, damage or leakage.
A. If blockage, damage or leakage is found, repair or replace the affected component.
B. If no blockage, damage or leakage is found, continue with Step 3.

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Use the Electronic Service Tool (EST) to check for the presence of fault 19550 (DTC 4B8A) - DEF/AdBlue system
unable to build sufficient pressure for dosing.
A. If fault 19550 (DTC 4B8A) - DEF/AdBlue system unable to build sufficient pressure for dosing is present,
resolve fault 19550 (DTC 4B8A) - DEF/AdBlue system unable to build sufficient pressure for dosing.
Then determine if this fault is also resolved.
B. If fault 19550 (DTC 4B8A) - DEF/AdBlue system unable to build sufficient pressure for dosing is not
present, continue with Step 4.
4. Test the DEF/ADBLUE® system.
Use the EST to perform the Urea Dosing System Test (UDST) and follow the one screen instructions.
Use the UDST Trouble Shooting Guideline, as required, to identify and resolve the problem.
Then use EST to perform the Engine Restart Counter Reset / Unlock Inducement configuration. See Selective
Catalytic Reduction (SCR) exhaust treatment - Configure - Engine restart counter reset (10.500), if neces-
sary.
Then perform the SCR Fault Repair Verification Test. See Selective Catalytic Reduction (SCR) exhaust treat-
Then verify that this fault has been resolved.

5. Replace the DEF/ADBLUE® system supply module.
sary.
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19079-(DTC 1A4A)-DEF/AdBlue over pressure failure

necessary.
Context:
For information regarding the functional operation of the DEF/ADBLUE® system refer to Selective Catalytic Reduc-
tion (SCR) exhaust treatment - Dynamic description (10.500). If during DEF/ADBLUE® system normal operation
the pressure exceeds 11.00 bar (159.50 psi) the Engine Control Unit (ECU) A158 will monitor the pressure until it
falls below 10.75 bar (155.88 psi). If the pressure does not fall below 10.75 bar (155.88 psi) within 60 s, this fault
will be set.
Cause:
The ECU has determined that an excessive pressure condition exists in the DEF/ADBLUE® system.
1. Faulty DEF/ADBLUE® system pressure or back flow line (tube), restricted.

2. Faulty DEF/ADBLUE® system filter in supply module back flow connector, restricted.
3. Faulty DEF/ADBLUE® system throttle in supply module back flow connector, restricted.
4. Faulty DEF/ADBLUE® system non-return-valve in supply module back flow connector, does not open.
5. Faulty supply module, motor pump defective.
6. Faulty supply module, pressure sensor defective.
Solution:
2. Check for blockage or damage in the DEF/ADBLUE® system pressure or back flow line (tube).
Visually and tactually inspect the system pressure and back flow lines for restrictions and/or damage.
There should be no blockage or damage.
A. If blockage or damage is found, repair or replace the line (tube).
B. If no blockage or damage is found, continue with Step 3.

3. Check the DEF/ADBLUE® system supply module back flow connector contents.
Visually and tactually inspect the filter, throttle, and non-return-valve internal to the supply module back flow con-
nector for restrictions and/or damage.
A. If blockage or damage is found, repair or replace as needed.
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4. Check for related DEF/AdBlue® system faults.
Use EST to determine if fault 19047 (DTC 195A) - DEF/AdBlue supply module pump motor pressure sensor
voltage is higher than expected or 19111 (DTC 723A) - DEF/AdBlue supply module pump motor short circuit
to ground failure is currently active.
A. If either fault 19047 (DTC 195A) - DEF/AdBlue supply module pump motor pressure sensor voltage is
higher than expected or fault 19111 (DTC 723A) - DEF/AdBlue supply module pump motor short circuit
to ground failure is present, resolve fault 19047 (DTC 195A) - DEF/AdBlue supply module pump motor
pressure sensor voltage is higher than expected and/or fault 19111 (DTC 723A) - DEF/AdBlue supply
module pump motor short circuit to ground failure. Then determine if this fault is also resolved.
B. If neither fault 19047 (DTC 195A) - DEF/AdBlue supply module pump motor pressure sensor voltage is
higher than expected nor fault 19111 (DTC 723A) - DEF/AdBlue supply module pump motor short circuit
to ground failure is present, continue with Step 5.
Then use EST to perform the Engine Restart Counter Reset / Unlock Inducement configuration.
Then perform the SCR Fault Repair Verification Test.
Then verify that the fault has been resolved.

6. As the components internal to the DEF/AdBlue® system supply module are not serviceable, replace the supply
module.
sary.
has been resolved.
operation.
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19080-(DTC 294A)-DEF/AdBlue under pressure failure

necessary.
Context:
For information regarding the functional operation of the Diesel Exhaust Fluid ( DEF/ADBLUE®) system see Selective
Catalytic Reduction (SCR) exhaust treatment - Dynamic description (10.500). If during DEF/ADBLUE® system
normal operation the pressure drops below 5.50 bar (79.75 psi), but not below 0.55 bar (7.98 psi), and does not
exceed 5.75 bar (83.38 psi) within 10.0 s, this fault will occur.
Cause:
The Engine Control Unit (ECU) has determined that a low pressure condition exists in the DEF/ADBLUE® system.
1. Faulty DEF/ADBLUE® tank level, too low a fluid level.

2. Faulty DEF/ADBLUE® system, leakage.
3. Faulty DEF/ADBLUE® tank suction (inlet) line (tube), restricted.
4. Faulty supply module, pump not delivering or pressure sensor values too low.
Solution:
2. Check fluid level in DEF/ADBLUE® system supply tank.
As air in the DEF/ADBLUE® system will cause the pressure level to decrease, visually check the fluid level in the
supply tank.
There should be an adequate level of fluid.
A. If a less than adequate level is found, fill the DEF/ADBLUE® system supply tank to an acceptable level.
B. If an adequate level is found, continue with Step 3.

3. Check for external leakage in DEF/ADBLUE® system.
Visually and tactually inspect the system pressure and back flow lines (tubes) and connections for leakage and/or
damage.
There should be no leakage or damage.
A. If leakage or damage is found, repair or replace the line (tube) and/or connector, as required.
B. If no leakage or damage is found, continue with Step 4.

4. Check for related DEF/ADBLUE® system pump faults.
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Use EST to determine if any of the following faults are currently active:
19156 (DTC 335A) - DEF/AdBlue supply module pump motor severe speed deviation
19107 (DTC 515A) - DEF/AdBlue supply module pump motor open load failure
19108 (DTC 613A) - DEF/AdBlue supply module pump motor short circuit to battery failure
19111 (DTC 723A) - DEF/AdBlue supply module pump motor short circuit to ground failure
19748 (DTC 833A) - DEF/AdBlue supply module pump motor over temperature failure
A. If any of the related faults, listed above, are present, resolve those faults. Then determine if this fault is also
resolved.
B. If none of the related faults, listed above, are present, continue with Step 5.
5. Check for blockage in the DEF/ADBLUE® system filters.
Visually and tactually inspect the DEF/ADBLUE® supply module suction (inlet) line (tube) and filters and connec-
tions for blockage and/or damage.
A. If blockage or damage is found, repair or replace the line (tube), filter and/or connector, as required.

6. Check for restriction in the DEF/ADBLUE® system suction (inlet) line (tube).
Provide an alternate DEF/ADBLUE® source and suction (inlet) line (tube) to the DEF/ADBLUE® supply module.
Use the EST to perform the Urea Dosing System Test (UDST) and follow the on screen instructions.
Use the UDST Troubleshooting Guideline, as required, to identify and resolve the problem.
A. If a problem is identified and resolved, use the EST, see Selective Catalytic Reduction (SCR) exhaust treat-
ment - Configure - Engine restart counter reset (10.500) if necessary. to perform the Engine Restart Counter
B. If a problem is not identified, continue with Step 7.

module.
sary.
has been resolved.
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operation.
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19081-(DTC 717A)-DEF/AdBlue dosing valve actuator short circuit

to ground in high side failure
Context:
The Engine Control Unit (ECU) A158 monitors the circuit of the dosing module Y-007. The dosing is valve is actuated
by a high side and low side driver to achieve the best possible control over the valve. If the ECU detects a short circuit
to ground in the high side driver circuit, this fault will occur.
Cause:
The ECU has detected a short to ground in the high side driver circuit of the Y-007.

2. Faulty Y-007 wiring, short to ground condition.
Solution:
Disconnect the Connector XY-007.
From To Value
Connector XY-007, pin 1 Connector XY-007, pin 2 There should be between 11 - 13 Ω
A. If the value is not within the specified range, the Y-007 has failed internally. Replace the DEF/ADBLUE® dosing
valve actuator.
B. If the value is within the specified range, leave the connector disconnected and continue to Step 3.
3. Check the high side driver circuit of the Y-007 for a short to ground condition.
From To Value
A. If there is continuity, there is short to ground condition in the Y-007 high side driver circuit, wire 623. Locate
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has been resolved.
operation.
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19082-(DTC 6C5A)-DEF/AdBlue reverting valve driver circuit short

to battery failure
Context:
The Engine Control Unit (ECU) A158 monitors the DEF/ADBLUE® reverting valve circuit for a short to battery power
condition. If the ECU detects a short to battery power, this fault will occur.
Cause:
The ECU has detected a short to battery power condition in the supply module A-037 (reverting valve) circuit.
1. Faulty supply module A-037 (reverting valve), wiring.

2. Faulty supply module A-037 (reverting valve), internal failure.
Solution:
2. Check the supply module A-037 (reverting valve) wiring for short to battery power condition.
Disconnect the Connector XA-037.
From To Value
A. If there is continuity, there is a short circuit condition in the supply module A-037 (reverting valve) circuit, wire

3. Check the supply module A-037 (reverting valve) wiring for short to key battery power condition.
From To Value
A. If there is voltage, there is a short to key battery power in the supply module A-037 (reverting valve) circuit,
wire 685. Locate and repair the shorted conductor.
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4. Replace the supply module.
has been resolved.
operation.
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19083-(DTC 7D5A)-DEF/AdBlue reverting valve driver circuit short

to ground failure
Context:
The Engine Control Unit (ECU) A158 monitors the supply module A-037 (reverting valve) circuit for a short to ground
condition. If the ECU detects a short to ground condition, this fault will occur.
Cause:
The ECU has detected a short to ground condition in the supply module A-037 (reverting valve) circuit.
1. Faulty supply module A-037 (reverting valve), wiring.

Solution:
2. Check the supply module A-037 (reverting valve) wiring for a short to ground condition.
From To Value
A. If there is continuity, there is a short circuit condition in the supply module A-037 (reverting valve) circuit, wire

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has been resolved.
operation.
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19084-(DTC 5E5A)-DEF/AdBlue reverting valve driver circuit open

failure
Context:
The Engine Control Unit (ECU) A158 monitors the supply module A-037 (reverting valve) circuit. If the ECU detects
an open load failure in the supply module A-037 (reverting valve) circuit, this fault will occur.
Cause:
The ECU has detected an open load failure in the supply module A-037 (reverting valve) circuit.
1. Faulty supply module A-037 (reverting valve) wiring, open circuit condition.
Solution:
2. Check the supply module A-037 (reverting valve) wiring for an open circuit condition.
From To Value
Connector XA158, pin 85 Connector XA-037, pin 12 There should be continuity
A. If there is no continuity, there is an open circuit condition in the DEF/ADBLUE® reverting valve circuit, wire 685.

3. Replace the A-037.
has been resolved.
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operation.
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19096 (DTC 436A)-DEF/AdBlue supply module temperature not

available
necessary.
Context:
For information regarding the functional operation of the Diesel Exhaust Fluid DEF/ADBLUE® system see Selective
Catalytic Reduction (SCR) exhaust treatment - Dynamic description (10.500). At the beginning of each driving
cycle (key cycle) the Engine Control Unit (ECU) A158 requests a temperature read-out from the control board of the
supply module (pump motor) A-037. If the control board of the supply module (pump motor) does not respond with a
temperature measurement after the maximum calibrated number of times, this fault will occur.
Cause:
The Engine Control Unit (ECU) did not receive the temperature read-out from the control board of the supply module
(pump motor) A-037.
1. Faulty driver control circuit wiring (low side) of the supply module (pump motor) A-037, damaged.
2. Faulty of the supply module (pump motor) A-037, internal failure.
Solution:
2. Check the driver control circuit wiring (low side) of the supply module (pump motor) A-037.
Disconnect the vehicle (VE) harness from the DEF/ADBLUE® system supply module at the Connector XA-037.
With the key switch in the OFF position, use a multimeter to check the condition of the driver control circuit wire
(low side) of the supply module pump motor:
From To Value
With the key switch in the ON position, use a multimeter to check the condition of the driver control circuit wire
(low side) of the supply module (pump motor) A-037:
From To Value
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A. If the low side driver control circuit wire is continuous and not grounded or shorted to a voltage source, continue
with Step 3.
B. If the driver control circuit wire (low side) is not continuous or is grounded or is shorted to a voltage source, use
the appropriate machine electrical schematics to locate and repair the broken or damaged conductor.
3. As there is no method for field testing the DEF/ADBLUE® system supply module temperature sensor or control
board, replace the DEF/ADBLUE® system supply module.
counter reset (10.500) if necessary, to perform the Engine Restart Counter Reset / Unlock Inducement configu-
ration.
has been resolved.
operation.
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19105-(DTC 879A)-DEF/AdBlue tank heater actuator over

temperature
Context:
The Engine Control Unit (ECU) A158 monitors the circuit of the DEF/ADBLUE® tank heating valve. If the ECU detects
an over temperature/current condition in the circuit of the SCR tank heating valve Y-063, this fault will occur.
Cause:
The ECU has detected an over temperature/current condition in the Y-063 circuit.

2. Faulty Y-063 wiring.
Solution:
From To Value
A. If the value is within the specified range, leave the connector disconnected and continue to Step 3.
3. Check the Y-063 for a short to battery power condition.
From To Value
A. If there is continuity, there is a short circuit condition in the Y-063 circuit, wire WH 0.75. Locate and repair the
shorted conductor.

4. Check the Y-063 for a short to key battery power condition.
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From To Value
A. If there is voltage, there is a short to key battery power in the Y-063 circuit, wire WH 0.75. Locate and repair
has been resolved.
operation.
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19106-(DTC 759A)-DEF/AdBlue tank heater actuator short circuit to

ground failure
Context:
The Engine Control Unit (ECU) A158 monitors the circuit of the DEF/ADBLUE® tank heating valve. If the ECU detects
a short to ground condition in the circuit of the SCR tank heating valve Y-063, this fault will occur.
Cause:
The ECU has detected a short to ground condition in the Y-063 circuit.

2. Faulty Y-063 wiring.
Solution:
From To Value
3. Check the Y-063 for a short to ground condition.
From To Value
A. If there is continuity, there is a short circuit condition in the Y-063 circuit, wire WH 0.75. Locate and repair the
shorted conductor.
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has been resolved.
operation.
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19107-(DTC 515A)-DEF/AdBlue supply module pump motor open

load failure
Context:
The Engine Control Unit (ECU) A158 monitors the circuit of the supply module (pump motor) A-037. If the ECU detects
an open load failure in the circuit of the supply module (pump motor) A-037, this fault will occur.
Cause:
The ECU has detected an open load failure in the the circuit of the supply module (pump motor) A-037.
1. Faulty supply module (pump motor) A-037 wiring, open circuit condition.
2. Faulty supply module (pump motor) A-037, internal failure.
Solution:
2. Check the supply module (pump motor) A-037 wiring for an open circuit condition.
From To Value
A. If there is no continuity, there is an open circuit condition in the supply module (pump motor) A-037 wiring.

has been resolved.
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operation.
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19108-(DTC 613A)-DEF/AdBlue supply module pump motor short

circuit to battery failure
Context:
The Engine Control Unit (ECU) A158 monitors the circuit of the supply module (pump motor) A-037 for a short to
battery power condition. If the ECU detects a short to battery power, this fault will occur.
Cause:
The ECU has detected a short to battery power condition in the circuit of the supply module (pump motor) A-037.
1. Faulty the supply module (pump motor) A-037, wiring.

2. Faulty the supply module (pump motor) A-037, internal failure.
Solution:
2. Check the wiring for short to battery power condition.
From To Value
A. If there is continuity, there is a short circuit condition in the supply module (pump motor) A-037 wiring. Locate

3. Check the supply module (pump motor) A-037 wiring for short to key battery power condition.
From To Value
A. If there is voltage, there is a short to key battery power in the supply module (pump motor) A-037 circuit, wire
WH 0.75. Locate and repair the shorted conductor.
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has been resolved.
operation.
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19111-(DTC 723A)-DEF/AdBlue supply module pump motor short

circuit to ground failure
Context:
The Engine Control Unit (ECU) A158 monitors the circuit of the supply module (pump motor) A-037 for a short to
ground condition. If the ECU detects a short to ground condition, this fault will occur.
Cause:
The ECU has detected a short to ground condition in the circuit of the supply module (pump motor) A-037.
1. Faulty supply module (pump motor) A-037, wiring.

Solution:
2. Check the wiring of the supply module (pump motor) A-037 for a short to ground condition.
From To Value
A. If there is continuity, there is a short circuit condition in the wiring of the supply module (pump motor) A-037.

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has been resolved.
operation.
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19113-(DTC 8F5A)-DEF/AdBlue reverting driver circuit over

temperature failure
Context:
The Engine Control Unit (ECU) A158 monitors the circuit of the supply module (reversing valve) A-037 for an over
temperature/current condition. If the ECU detects an over temperature/current condition, this fault will occur.
Cause:
The ECU has detected an over temperature/current condition in the circuit of the DEF/ADBLUE® reverting valve.
1. Faulty supply module (reversing valve) A-037, wiring.

2. Faulty supply module (reversing valve) A-037, internal failure.
Solution:
19082 (DTC 6C5A) - DEF/AdBlue reverting valve driver circuit short to battery failure
A. If the listed fault is active, diagnose it first and then return to this fault.

3. Check the supply module (reversing valve) A-037 wiring for a short to battery power condition.
From To Value
A. If there is continuity, there is a short circuit condition in the supply module (reversing valve) A-037 circuit, wire
WH 0.75. Locate and repair the shorted conductor.

4. Check the supply module (reversing valve) A-037 wiring for short to key battery power condition.
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From To Value
A. If there is voltage, there is a short to key battery power in the supply module (reversing valve) A-037 circuit,
wire WH 0.75. Locate and repair the shorted conductor.

Use the Electronic Service Tool (EST) to perform the Urea Dosing System Test (UDST) and follow the on screen
instructions.
has been resolved.
operation.
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19126 (DTC FF9F)-SCR Inducement: Warning, triggered by

tampering fault
Context:
this fault to occur. Any one of many Selective Catalytic Reduction (SCR) DEF/ADBLUE® technical failure tampering
detection faults will cause this fault to occur. The active fault causing this fault needs to be identified and resolved
within the next 36 h of operation to avoid engine de-rate.
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19140-(DTC 4BCA)-DEF/AdBlue concentration is out of range

necessary.
Context:
For information regarding the functional operation of the DEF/ADBLUE® quality sensor B-050 see Diesel Exhaust
Fluid (DEF)/AdBlue® quality sensor - Overview (55.988). The B-050 has internal monitoring for operating con-
ditions and reports status along with sensed data to the Engine Control Unit (ECU) A158. The normal range for
concentration of DEF/ADBLUE® fluid is 28.75 - 36.25 %. If the concentration value is outside these limits, this fault
will occur.
Cause:
The B-050 has reported to the ECU that the DEF/ADBLUE® fluid concentration level is out of range.
1. Faulty DEF/ADBLUE® fluid concentration level, too high or too low.

Solution:
1. Determine the DEF/ADBLUE® fluid concentration level.
Use a refractometer to check the concentration level of the DEF/ADBLUE® fluid.
There should be between 28.75 - 36.25 %.
A. If the concentration is not within range, replace the DEF/ADBLUE® fluid.
B. If the concentration is within range, continue with Step 2.

2. As there is no method for field testing, replace the B-050.
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19141-(DTC 4CCA)-DEF/AdBlue quality sensor detects diesel fuel

in DEF/AdBlue tank
Context:
Fluid (DEF)/AdBlue® quality sensor - Overview (55.988). The B-050 has internal monitoring for operating condi-
tions and reports status along with sensed data to the Engine Control Unit (ECU) A158. If a contaminant, such as
diesel fuel, is sensed, this fault will occur.
Cause:
The B-050 has reported to the ECU that diesel fuel has been sensed in the DEF/ADBLUE® fluid.
1. Faulty DEF/ADBLUE® fluid, contaminated with diesel fuel.

Solution:
1. Check for DEF/ADBLUE® fluid contamination.
Secure a sample of the DEF/ADBLUE® fluid from the tank to determine if diesel fuel exists in the tank.
There should be no diesel fuel.
A. If there is diesel fuel contamination, flush the DEF/ADBLUE® tank and replace the DEF/ADBLUE® fluid. See
Diesel Exhaust Fluid (DEF)/AdBlue® tank - Cleaning (10.500), if necessary.
B. If there is no contamination, continue with Step 2.

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19142 (DTC 4DCA)-DEF/AdBlue quality sensor temperature failure

(different from DEF/AdBlue level temperature)
necessary.
Context:
tions and reports status along with sensed data to the Engine Control Unit (ECU). The ECU compares the reported
temperature data to temperature data from the Selective Catalytic Reduction (SCR) DEF/ADBLUE® tank level and
temperature sensor. If this temperature difference is greater than 20 °C (68 °F), this fault will occur.
Cause:
The ECU has determined that the B-050 temperature data is not plausible.
1. Faulty B-050, improperly mounted.

Solution:
1. Check the B-050 for proper mounting.
Visually check the B-050 to determine that it is properly installed.
A. If the sensor is not properly installed, reinstall as required.
B. If the sensor is properly installed, continue with Step 2.

2. Check for related tank temperature failures.
Use the Electronic Service Tool (EST) to check for the presence of 19095 (DTC 2F3A) - DEF/AdBlue tank tem-
perature sensor plausibility failure.
A. If fault 19095 (DTC 2F3A) - DEF/AdBlue tank temperature sensor plausibility failure is present, resolve
fault 19095 (DTC 2F3A) - DEF/AdBlue tank temperature sensor plausibility failure. Then determine if this
B. If fault 19095 (DTC 2F3A) - DEF/AdBlue tank temperature sensor plausibility failure is not present, con-
tinue with Step 3.
3. As there is no method for field testing, replace the DEF/ADBLUE® quality sensor.
counter reset (10.500) if necessary, to perform the Engine Restart Counter Reset / Unlock Inducement configu-
ration.
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19144 (DTC 9AEA)-CAN timeout error from DEF/AdBlue quality

sensor
necessary.
Context:
The DEF/ADBLUE® quality sensor B-050 is required to report information at regular intervals to the Engine Control
Unit (ECU) A158 via CAN. If this information is not communicated within the allotted time frame, this ECU timeout
fault will occur.
Cause:
The ECU has reported, via the engine sensor CAN bus, that a B-050 timeout of the B-050 message has occurred.

Solution:
2. Check the B-050 controller supply voltage.
Disconnect the Connector XB-050 from the DEF/ADBLUE® quality sensor.
Use a multimeter to check for voltage on the VE harness side:
From To Value
Connector XB-050, pin 3 Connector XB-050, pin 6 There should be 24 V
A. If the voltage is present, leave the Connector XB-050 disconnected and continue with Step 3.

3. Determine the condition of the B-050 controller CAN circuit.
Use a multimeter to measure the resistance of the CAN connection on the VE harness side:
From To Value

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A. If other faults do exist, see Fuse and controller power relay - Testing Auxiliary relay (55.640), for supply
power and ground, or see Controller Area Network (CAN) data bus - Test (55.640), for CAN, to locate and
repair the faulted condition.
B. If no other faults exist, the vehicle (VE) harness wiring is damaged between the ATS devices harness splice
and the B-050 controller the Connector XB-050, pin 3 and/or Connector XB-050, pin 6, wire OR 1.0 and/or
BK 1.0, for supply power and ground or Connector XB-050, pin 5 and/or Connector XB-050, pin 4, wire GN
0.75 and/or YE 0.75 for CAN signal. Locate and repair the damage to the ATS supply power and ground or
CAN circuit wiring.
- Engine restart counter reset (10.500), if necessary to perform the Engine Restart Counter Reset / Unlock
has been resolved.
operation.
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to battery failure
necessary.
Context:
For information regarding the functional operation of the Selective Catalytic Reduction (SCR) system see Selective
Catalytic Reduction (SCR) exhaust treatment - Dynamic description (10.500). The Engine Control Unit (ECU)
A158 monitors the electrical current used to energize the dosing module Y-007. In the event of an excessive current
requirement, due to a short circuit, the ECU interrupts current flow to prevent damage and this fault occurs.
Cause:
The ECU detects an over current condition (short circuit to battery) in the Y-007 solenoid low side control circuit.
1. Faulty Y-007 solenoid coil, shorted.

2. Faulty Y-007 low side control circuit wiring, shorted to a voltage source.
Solution:
2. Verify the condition of the Y-007.
Disconnect the vehicle (VE) harness from the Y-007 at the Connector XY-007.
Use a multimeter to measure the resistance of the Y-007 solenoid coil of the DEF/ADBLUE® dosing module:
From To Value
Connector XY-007, pin 1 Connector XY-007, pin 2 There should be between 11.4 -
12.6 Ω
A. If the measured resistance is within the specified range, leave the Connector XY-007 disconnected and con-
tinue with Step 3.
B. If there is no resistance, the Y-007 solenoid coil is shorted, replace the Y-007.
3. Check low side driver control wiring for a short to voltage source condition.
With the key switch in the ON position, use a multimeter to check for voltage on the vehicle (VE) harness side
from:
From To Value
Connector XY-007, pin 1 Chassis ground There should be no voltage
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A. If there is voltage, there is a short to a voltage source condition in the vehicle (VE) harness between the Con-
nector XY-007, pin 1 and the Connector XY-007, pin 96, wire WH 0.75. Locate and repair the damaged
conductor.
has been resolved.
operation.
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to ground failure
Context:
The Engine Control Unit (ECU) A158 monitors the dosing module Y-007 low side driver circuit. If the ECU detects a
short to ground or open circuit condition in the low side driver circuit, this fault will occur.
Cause:
The ECU has detected a short to ground or open circuit condition in the Y-007 low side driver circuit.

2. Faulty Y-007 wiring, short to ground or open circuit condition.
Solution:
From To Value
A. If the value is not within the specified range, the Y-007 has failed internally. Replace the Y-007.
3. Check the Y-007 low side driver circuit for an open circuit condition.
From To Value
Connector XA158, pin 96 Connector XY-007, pin 1 There should be continuity
A. If there is no continuity, there is an open circuit condition in the Y-007 low side driver circuit , wire WH 0.75.

4. Check the Y-007 low side driver circuit for a short to ground condition.
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From To Value
A. If there is continuity, there is a short to ground condition in the Y-007 low side driver circuit, wire WH 0.75.
has been resolved.
operation.
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19153-(DTC 624E)-DEF/AdBlue quality sensor internal failure (Short

circuit to battery error)
necessary.
Context:
tions and reports status along with sensed data to the Engine Control Unit (ECU) A158. If the sensor determines that
an internal failure such as a short to source voltage exists, this fault will occur.
Cause:
The B-050 has reported to the ECU that a short to source voltage exists internally in the quality sensing circuitry.

Solution:
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19154-(DTC 325A)-DEF/AdBlue supply module pump temperature

is too low to activate pump
necessary.
Context:
Catalytic Reduction (SCR) exhaust treatment - Dynamic description (10.500). The supply module (pump motor)
A-037 control board works initially in temperature measurement mode (to determine if unfreezing/heat-up is neces-
sary) then switches to pump actuation mode (to build up pressure and prepare to inject). If the supply module (pump
motor) A-037 control board does not switch to pump actuation mode after temperature measurement has been carried
out, this fault will occur.
Cause:
The Engine Control Unit (ECU) A158 has determined that the supply module (pump motor) A-037 control board did
not switch to pump actuation mode.
1. Faulty supply module A-037, internal failure.

Solution:
1. Check the supply module A-037 operation.
Use the EST and follow the on-screen instructions to perform the Urea Dosing System Test (UDST).
Follow the UDST-Troubleshooting Guideline to determine the problem.
A. If the UDST identifies a problem, follow the UDST-Troubleshooting Guideline to locate and repair the failure.
B. If the UDST does not identify a problem, check the ECU for the appropriate software and re-flash, if necessary.
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19156-(DTC 335A)-DEF/AdBlue supply module pump motor severe

speed deviation
Context:
Catalytic Reduction (SCR) exhaust treatment - Dynamic description (10.500). The supply module (pump motor)
A-037 control board monitors pump speed according to Pulse Width Modulated (PWM) request. If an excessive
current situation occurs and the supply module (pump motor) A-037 is restarted more than five times in the same
driving cycle (key cycle), this fault will occur.
Cause:
The Engine Control Unit (ECU) A158 has restarted the supply module (pump motor) A-037 more than five times due
to an over-current condition.
1. Faulty supply module A-037, internal failure.
Solution:
1. Check the supply module A-037 operation.
Use the Electronic Service Tool (EST) and follow the on-screen instructions to perform the Urea Dosing System
Test (UDST).
Follow the UDST-Trouble-shooting Guideline to determine the problem.
A. If the UDST identifies a problem, follow the UDST-Trouble-shooting Guideline to repair the failure.
B. If the UDST does not identify a problem, check the ECU for the appropriate software and re-flash, if necessary.
NOTE: cold ambient (frozen DEF/ADBLUE®) or extended period of non-use (crystalization) condition may be pre-
venting pump motor operation.
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19158-(DTC 734E)-DEF/AdBlue quality sensor internal failure (Short

circuit to ground error)
necessary.
Context:
tions and reports status along with sensed data to the Engine Control Unit (ECU) A158. If the sensor determines that
an internal failure such as a short to ground exists, this fault will occur.
Cause:
The B-050 has reported to the ECU that a short to ground exists internally in the quality sensing circuitry.

Solution:
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19159-(DTC 144E)-DEF/AdBlue quality sensor internal failure

(Concentration value is higher than expected)
Context:
concentration of DEF/ADBLUE® fluid is 28.75 - 36.25 %. If the concentration value is significantly outside the high
limit, this fault will occur.
Cause:
The B-050 has reported to the ECU that the DEF/ADBLUE® fluid concentration level is higher than expected.
1. Faulty B-050, too high.

3. Faulty software of ECU.
Solution:
1. Determine DEF/ADBLUE® fluid concentration level.

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(Concentration value is lower than expected)
Context:
concentration of DEF/ADBLUE® fluid is 28.75 - 36.25 %. If the concentration value is significantly outside the low
limit, this fault will occur.
Cause:
The B-050 has reported to the ECU that the DEF/ADBLUE® fluid concentration level is lower than expected.
1. Faulty B-050, too low.

Solution:
1. Determine DEF/ADBLUE® fluid concentration level.

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(Internal fault)
Context:
tions and reports status along with sensed data to the Engine Control Unit (ECU) A158. If an internal sensor system
error is detected, this fault will occur.
Cause:
The B-050 has reported to the ECU that it has an internal sensor system error.

Solution:
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(Temperature sensor circuit short to battery)
Context:
tions and reports status along with sensed data to the Engine Control Unit (ECU) A158. If an internal sensor failure,
temperature sensing circuitry short to source voltage, is detected, this fault will occur.
Cause:
The B-050 has reported to the ECU that it has an internal sensor failure.

Solution:
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(Temperature sensor circuit short to ground)
Context:
tions and reports status along with sensed data to the Engine Control Unit (ECU) A158. If an internal sensor failure,
temperature sensing circuitry short to ground, is detected, this fault will occur.
Cause:
The B-050 has reported to the ECU that it has an internal sensor failure.

Solution:
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19167-(DTC 1A4E)-DEF/AdBlue quality sensor internal failure

(Temperature sensor value is higher than expected)
Context:
tions and reports status along with sensed data to the Engine Control Unit (ECU) A158. If a self-diagnostic fault check
indicates the temperature signal to be out of range (maximum threshold), this fault will occur.
Cause:
The B-050 has reported to the ECU that the DEF/ADBLUE® fluid temperature is higher than expected.

Solution:
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19168-(DTC 1B4E)-DEF/AdBlue quality sensor internal failure

(Temperature sensor value is lower than expected)
Context:
tions and reports status along with sensed data to the Engine Control Unit (ECU) A158. If the temperature value is
significantly outside the low limit, this fault will occur.
Cause:
The B-050 has reported to the ECU that the DEF/ADBLUE® fluid temperature is lower than expected.

Solution:
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19169-(DTC 4C4E)-DEF/AdBlue quality sensor internal failure

(Temperature sensor failure)
Context:
tions and reports status along with sensed data to the Engine Control Unit (ECU) A158. If an internal sensor system
error is detected, this fault will occur.
Cause:
The B-050 has reported to the ECU that it has an internal sensor system error.

Solution:
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to battery in high side failure
necessary.
Context:
A158 monitors the electrical current used to energize the dosing module Y-007. If the ECU internal sensing circuit
does not sense current flow when it is requested, the ECU interrupts the current flow circuit and this fault occurs.
Cause:
The ECU detects a short to high source (battery voltage) or open circuit condition in the Y-007 high side driver control
circuit.
1. Faulty Y-007 solenoid coil, open.

2. Faulty Y-007 high side control circuit wiring, shorted to a voltage source or open.
Solution:
2. Verify the condition of the DEF/ADBLUE® dosing module.
Use a multimeter to measure the resistance of the Y-007 solenoid coil:
From To Value
Connector XY-007, pin 1 Connector XY-007, pin 2 There should be between 11.4 -
12.6 Ω
A. If the measured resistance is within the specified range, leave the Connector XY-007 disconnected and con-
tinue with Step 3.
B. If there is infinite resistance, the Y-007 solenoid coil is open, replace the Y-007.
3. Check high side driver control wiring for a short to voltage source condition.
With the key switch in the ON position, use a multimeter to check for voltage on the vehicle (VE) harness side
from:
From To Value
Connector XY-007, pin 2 Chassis ground There should be no voltage
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nector XY-007, pin 2 and the Connector XA158, pin 23, wire WH 0.75. Locate and repair the damaged
conductors.
B. If there is no voltage, continue with Step 4.

4. Check high side driver control wiring for an open circuit condition.
Install a jumper wire from the vehicle (VE) harness side of the ECU the Connector XA158, pin 23 to chassis
ground.
Use a multimeter to check for continuity on the vehicle (VE) harness side from:
From To Value
Connector XY-007, pin 2 Chassis ground There should be continuity
A. If there is no continuity, there is an open condition in the vehicle (VE) harness between the Connector XY-007,
pin 2 and the Connector XA158, pin 23, wire WH 0.75. Locate and repair the broken conductor.
has been resolved.
operation.
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in high side failure
Context:
The Engine Control Unit (ECU) A158 monitors the dosing module Y-007 circuit. The Y-007 is actuated by a high side
and low side driver to achieve the best possible control over the valve. If the ECU detects a short circuit in the high
side driver circuit, this fault will occur.
Cause:
The ECU has detected a short circuit in the Y-007 high side driver circuit.

2. Faulty Y-007 wiring, short circuit condition.
Solution:
19081 (DTC 717A) - DEF/AdBlue dosing valve actuator short circuit to ground in high side failure
B. If the listed fault is not active, continue to Step 3.

From To Value
A. If the value is not within the specified range, the Y-007 has failed internally. Replace the Y-007.
4. Check the Y-007 high side driver circuit for a circuit condition.
From To Value
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A. If there is continuity, there is short circuit condition in the Y-007 high side driver circuit, wire WH 0.75. Locate

5. Check the Y-007 high side driver circuit for a short to key battery power condition.
From To Value
A. If there is voltage, there is a short circuit condition in the Y-007 high side driver circuit, wire WH 0.75. Locate
has been resolved.
operation.
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19179-(DTC 1CBE)-Downstream NOx sensor self-diagnosis result

is higher than the limit
Context:
Self diagnosis is requested and performed during Engine Control Unit (ECU) A158 afterrun, as long as the Selec-
tive Catalytic Reduction (SCR) downstream NOx sensor B-054 reached dew point, the engine is stopped, and self
diagnosis is not inhibited by another failure. If the value resulting from self diagnosis is above high limit (greater than
140 %), this fault will occur. For information regarding the functional operation of the smart B-054 refer to Nitrogen
Oxide (NOx) sensor - Dynamic description (55.988).
Cause:
The B-054 has too high positive drift.
Solution:
Then use the Electronic Service Tool (EST), refer to Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data
(Downstream sensor) (55.988) if necessary, to perform the Replacement of Nox Downstream Sensor - Reset
ECU Data configuration.
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19180-(DTC 2DBE)-Downstream NOx sensor self-diagnosis result

is lower than the limit
Context:
sensor B-054 refer to Nitrogen Oxide (NOx) sensor - Dynamic description (55.988). Self diagnosis is requested
and performed during Engine Control Unit (ECU) A158 afterrun, as long as the B-054 reached dew point, the engine
is stopped, and self diagnosis is not inhibited by another failure. If the value resulting from self diagnosis is below low
limit (less than 75 %), this fault will occur.
Cause:
The B-054 has too high negative drift.
Solution:
Then use the Electronic Service Tool (EST), refer to Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data
(Downstream sensor) (55.988) if necessary, to perform the Replacement of Nox Downstream Sensor - Reset
A. If the fault is resolved, use the EST, refer to Selective Catalytic Reduction (SCR) exhaust treatment - Con-
Unlock Inducement configuration, then return the machine to service.
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19187-(DTC 11CE) - Upstream NOx sensor self-diagnosis result is

higher than the limit
Context:
B-056 refer to Nitrogen Oxide (NOx) sensor - Dynamic description (55.988). Self diagnosis is requested and
performed during Engine Control Module (ECU) A158 afterrun, as long as the B-056 reached dew point, the engine is
stopped, and self diagnosis is not inhibited by another failure. If the value resulting from self diagnosis is above high
limit (greater than 140 %), this fault will occur.
Cause:
The B-056 has too high positive drift.
Solution:
Then use the Electronic Service Tool (EST), refer to Nitrogen Oxide (NOx) sensor - Configure - Reset ECU
data (Upstream sensor) (55.988) if necessary, to perform the Replacement of Nox Upstream Sensor - Reset
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19188 (DTC 22CE)-Upstream NOx sensor self-diagnosis result is

lower than the limit
Context:
B-056 refer to Nitrogen Oxide (NOx) sensor - Dynamic description (55.988). Self diagnosis is requested and
performed during Engine Control Unit (ECU) A158 afterrun, as long as the B-056 reached dew point, the engine is
stopped, and self diagnosis is not inhibited by another failure. If the value resulting from self diagnosis is below low
limit (less than 75 %), this fault will occur.
Cause:
The B-056 has too high negative drift.
Solution:
Then use the Electronic Service Tool (EST), refer to Nitrogen Oxide (NOx) sensor - Configure - Reset ECU
data (Upstream sensor) (55.988) if necessary, to perform the Replacement of Nox Upstream Sensor - Reset
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19225-(DTC 931B)-CAN C Bus off passive failure

necessary.
Context:
of the ECU. CAN Node C Bus is the main engine interface bus. The ECU provides a CAN termination resistor for the
CAN Node C Bus, internal to the ECU. If the ECU senses that CAN Node C Bus is not functioning properly, this fault
will occur.
Cause:
ECU has sensed a “Bus Off” state to be present at CAN Node C.

2. Faulty engine auxiliary relay 1KAUX, loose connection or internal failure.
Solution:
Use the EST to determine if other engine CAN faults exist.
A. If other engine CAN faults do exist, resolve the engine CAN faults, then check to see that 3263 (DTC 971B) -
CAN C Bus off failure is also resolved.
B. If other engine CAN faults do not exist, continue with Step 3.

With the key switch in the ON position, use a multimeter to check for voltage on the vehicle (VE) harness side:
From To Value
Connector XA158, pin 1 Chassis ground There should be 24.0 V
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4.
With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle (VE) harness side:
From To Value
A. If there is continuity on all of the checks, continue with Step 5.
5. Determine the condition of the ECU CAN C circuit.
Disconnect the engine (EN) harness from the ECU at connector X-9002.
From To Value
Use a multimeter to measure the resistance of the CAN C termination resistor, internal to the ECU:
From To Value
circuit.
has been resolved.
operation.
Harnesses and connectors - Electrical schematic sheet 05 (55.100) Wiring harnesses - Electrical schematic
sheet 04 (55.100)
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19262 (DTC 659A)-DEF/AdBlue tank heater actuator short circuit to

battery failure
Context:
The Engine Control Unit (ECU) A158 monitors the SCR tank heating valve Y-063 circuit. If the ECU detects a short
to battery power condition in the Y-063 circuit, this fault will occur.
Cause:
The ECU has detected a short to battery power condition in the Y-063 circuit.

2. Faulty Y-063, wiring.
Solution:
From To Value
3. Check the Y-063 for a short to battery power condition.
From To Value
A. If there is continuity, there is a short circuit condition in the Y-063 circuit, wire WH-075. Locate and repair the
shorted conductor.

4. Check the Y-063 for a short to key battery power condition.
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From To Value
A. If there is voltage, there is a short to key battery power in the Y-063 circuit, wire WH-075. Locate and repair
has been resolved.
operation.
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19264-(DTC 569A)-DEF/AdBlue tank heater actuator open load

failure
Context:
The Engine Control Unit (ECU) monitors the SCR tank heating valve Y-063 circuit. If the ECU detects an open circuit
condition in the Y-063 circuit, this fault will occur.
Cause:
The ECU has detected an open circuit condition in the Y-063 circuit.

2. Faulty Y-063, wiring.
Solution:
From To Value
3. Check the Y-063 for an open circuit condition.
From To Value
Connector XA158, pin 72 Connector XY-063, pin 3 There should be continuity
A. If there is no continuity, there is an open circuit condition in the Y-063 circuit, wire WH 0.75. Locate and repair
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has been resolved.
operation.
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19323-(DTC 94FB)-External engine shutdown request received

Context:
This fault is for informational purposes and requires no action. This fault is the result of a request for engine shutdown
via Controller Area Network (CAN) to the Engine Control Unit (ECU) A158.
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19336-(DTC 354A)-DEF/AdBlue general pressure check failure

necessary.
Context:
Catalytic Reduction (SCR) exhaust treatment - Dynamic description (10.500). After the DEF/ADBLUE® pressure
has stabilized 8.5 - 9.5 bar (123.2 - 137.8 psi) the dosing module Y-007 is energized for 1.0 s. If the sensed pressure
provided by the supply module pressure sensor exceeds 8.5 bar (123.2 psi) while the Y-007 solenoid is energized
(valve open) and the maximum number of heating cycles has been reached, this fault will occur. If the maximum
number of heating cycles has not been reached, an additional heating cycle will be performed.
Cause:
The Engine Control Unit (ECU) A158 is sensing a pressure greater than 8.5 bar (123.2 psi) while the Y-007 solenoid
is energized.
1. Faulty DEF/ADBLUE® system pressure lines (tubing), restricted.

2. Faulty DEF/ADBLUE® heating system, ineffective.
3. Faulty Y-007 solenoid valve, restricted or damaged.
4. Faulty supply module, restricted or damaged.
Solution:
1. Check for freezing, blockage, or damage to DEF/ADBLUE® system pressure lines (tubing).
Visually and tactually inspect the system pressure lines for blockage and damage.
A. If blockage or damage is found, repair or replace the affected line (tube).

2. Check operation of the engine coolant heating system lines (tubing).
Visually and tactually inspect the heating system lines to determine that the system is providing sufficient heating.
There should be adequate heating.
A. If ineffective heating is found, locate and repair the heating problem.
B. If adequate heating is found, continue with Step 3.

instructions.
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sary.

4. Check for Y-007 fault.
Use the EST to determine the status of fault 19817 - (DTC 377A)-DEF/AdBlue dosing valve is blocked.
A. If the fault is present and/or active, resolve fault 19817 - (DTC 377A)-DEF/AdBlue dosing valve is blocked.
Then check to see that this fault is also resolved.
B. If the fault is not present and inactive, continue with Step 5.

sary.

module.
sary.
Then check to see if this is resolved.
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19337-(DTC 344A)-DEF/AdBlue dosing system backflow line

pressure too high plausibility failure
necessary.
Context:
A158 checks the back-flow line and back-flow connector for blockages. If a frozen or otherwise blocked back-flow
line or back-flow connector is detected, this fault will occur.
Cause:
The ECU has determined that a high pressure condition exists in the back-flow line (tube) portion of the DEF/ADBLUE®
system.
1. Faulty DEF/ADBLUE® back-flow line (tube), restricted.

2. Faulty DEF/ADBLUE® connector (throttle), restricted.
3. Faulty DEF/ADBLUE® system heater, ineffective.
Solution:
1. Check the DEF/ADBLUE® system back-flow line (tube).
Visually and tactually inspect the supply module to tank back-flow line for blockage or damage.
A. If any blockage or damage is found, replace or repair as required.

2. Check the DEF/ADBLUE® supply module back-flow connector (throttle).
Visually inspect the supply module back-flow connector (throttle) for blockage or damage.
A. If any blockage or damage is found, replace or repair as required.

3. Check the DEF/ADBLUE® supply module back-flow line (tube) and the connector (throttle) for freezing.
Visually and tactually inspect the supply module back-flow line (tube) and connector (throttle) for blockage due to
freezing.
There should be no blockage.
A. If any blockage due to freezing is found, the DEF/ADBLUE® heating system is deficient, locate and repair or
replace, as required, the heating system deficiency.
B. If no blockage due to freezing is found, continue with Step 4.
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4. Replace the DEF/ADBLUE® supply module.
Check to see that this fault has been resolved.
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19356-(DTC 3FDE)-Downstream NOx sensor signal and NH3 sensor

signal plausibility check failure
Context:
For information regarding the functional operation of the NH3 sensor and the NH3 module B-057 see Ammonia (NH3)
sensor - Dynamic description (55.988). The B-057 is required to report information at regular intervals to the Engine
Control Unit (ECU) A158 via Controller Area Network (CAN). The NH3 sensor senses both NH3 and NOx. If the NOx
signal is smaller than the NH3 signal, this fault will occur.
Cause:
The B-057 has reported via CAN to the ECU that the NOx and/or NH3 signal is not plausible.
1. Faulty NH3 sensor, drifted or defective.

Solution:

has been resolved.
operation.
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19409 (DTC 2D93)-High pressure intercooler outlet pressure sensor

plausibility check low failure
Context:
The Engine Control Unit (ECU) A158 monitors the High Pressure Intercooler (HPI) outlet pressure sensor B-9012
value for plausibility. If the ECU determines that the pressure value is too low based on engine speed and air tem-
perature, this fault will occur.
Cause:
The ECU determined that the pressure value is too low based on engine speed and air temperature.

2. Faulty cooling system, low coolant or low pressure.
Solution:
B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Go
to Step 6.
DTC 2B93 - High pressure intercooler outlet pressure sensor voltage lower than expected
A. If the fault is active, diagnose it first and then return to this fault, DTC 2D93 - High pressure intercooler outlet
pressure sensor plausibility check low failure.

3. Check the B-9012 pressure signal wire for a short to ground condition.
Disconnect connector X-9002 from the ECU.
From To Value
A. If there is continuity, there is a short to ground condition in the temperature signal circuit, wire EN-609. Locate

4. Check the cooling system for proper operation.
Check coolant for the appropriate level.
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Check the secondary cooling system cap pressure.
Pressure test the secondary cooling system to identify any leakage.

Use the EST to verify that DTC 2D93 - High pressure intercooler outlet pressure sensor plausibility check
low failure has been resolved.
B. If the fault has not been resolved, inspect the engine cooling system for appropriate functioning and the appro-
priate coolant level and repair as necessary. If no faults are found, check the ECU for the appropriate software
and re-flash, if necessary.
has been resolved.
operation.
Wiring harnesses - Electrical schematic sheet 05 (55.100) Harnesses and connectors - Electrical schematic
sheet 05 (55.100)
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19415 (DTC FABF)-Remaining DEF/AdBlue is below the empty

threshold
necessary.
Context:
(ECU) A158 monitors the level and temperature of the DEF/ADBLUE® fluid. If the level of the fluid becomes 0.0 % of
full (empty), this fault will occur.
Cause:
The DEF/ADBLUE® tank level and temperature sensor B-020 level signal to the ECU is 0.0 % of full.
1. DEF/ADBLUE® tank fluid level, too low.

2. Faulty B-020, failed internally.
Solution:
1. Fill the DEF/ADBLUE® tank to the appropriate level.
Then check to see that this fault has been resolved.
A. If this fault is resolved, use the Electronic Service Tool (EST), see Selective Catalytic Reduction (SCR) ex-
haust treatment - Configure - Engine restart counter reset (10.500) if necessary, to perform the Engine
Restart Counter Reset / Unlock Inducement configuration. Then return the machine to service.
B. If this fault is not resolved, continue with Step 2.

2. Verify the condition of the B-020.
Use a multimeter to measure the resistance of the B-020:
From To Value
12000 Ω
A. If the measured resistance is greater than 12000 Ω, check the ECU for the appropriate software and re-flash,
if necessary.
B. If the measured resistance is less than 12000 Ω, the B-020 has failed internally. Replace the B-020 unit.
NOTE: once the B-020 has been removed, inspect the apparatus to determine if the filler spout magnet broke free
of its mounting and became lodged causing a false reading.
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19422-(DTC 43CE)-Downstream NOx sensor signal is stuck at a

constant value
Context:
sensor B-054 see Nitrogen Oxide (NOx) sensor - Dynamic description (55.988). The B-054 is required to report
information at regular intervals to the Engine Control Unit (ECU) A158 via Controller Area Network (CAN). If the B-054
signal, during engine operation, does not vary sufficiently, this fault will occur.
Cause:
The B-054 has reported, via CAN, to the ECU that the expected signal dynamic is not being sensed.
1. Faulty B-054, incorrectly / improperly installed (signal is not changing).
Solution:

3. As there is no method for flashing or field testing the B-054, replace the sensor.
Then use EST, see Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data (Downstream sensor) (55.988),
if necessary, to perform the Replacement of the Nox Downstream Sensor - Reset ECU Data configuration.
has been resolved.
operation.
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19434 (DTC E26D)-ECU internal failure - EEPROM erase error

Context:
The Engine Control Unit (ECU) A158 has the capability of reading and writing values to flash or Electrically Erasable
Programmable Read Only Memory (EEPROM). The ECU monitors the reading and writing capability of this function.
If the ECU 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

Context:
If the ECU 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

Context:
If the ECU 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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19496 (DTC 184A)-Monitoring of over pressure

necessary.
Context:
Catalytic Reduction (SCR) exhaust treatment - Dynamic description (10.500). If during DEF/ADBLUE® system
normal operation or purging the pressure exceeds 12.50 bar (181.25 psi) this fault will occur.
Cause:
The Engine Control Unit (ECU) A158 has determined that the pressure in the DEF/ADBLUE® system is too high.
1. Faulty DEF/ADBLUE® system pressure or back flow line (tube), restricted.

2. Faulty DEF/ADBLUE® system filter in supply module back flow connector, restricted.
3. Faulty DEF/ADBLUE® system throttle in supply module back flow connector, restricted.
4. Faulty DEF/ADBLUE® system non-return-valve in supply module back flow connector, does not open.
5. Faulty supply module, pump defective.
6. Faulty supply module, pressure sensor defective.
Solution:
2. Check for blockage or damage in the DEF/ADBLUE® system pressure or back flow line (tube).
Visually and tactually inspect the system pressure and back flow lines for restrictions and/or damage.

3. Check the DEF/ADBLUE® system supply module back flow connector contents.
Visually and tactually inspect the filter, throttle, and non-return-valve internal to the supply module back flow con-
nector for restrictions and/or damage.
A. If blockage or damage is found, repair or replace as needed.

4. Check for related DEF/ADBLUE® system faults.
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Use EST to determine if fault 19047 (DTC 195A) - DEF/AdBlue supply module pump motor pressure sensor
voltage is higher than expected or 19111 (DTC 723A) - DEF/AdBlue supply module pump motor short circuit
to ground failure is currently active.
A. If either fault 19047 (DTC 195A) - DEF/AdBlue supply module pump motor pressure sensor voltage is
higher than expected or fault 19111 (DTC 723A) - DEF/AdBlue supply module pump motor short circuit
to ground failure is present, resolve fault 19047 (DTC 195A) - DEF/AdBlue supply module pump motor
pressure sensor voltage is higher than expected and/or fault 19111 (DTC 723A) - DEF/AdBlue supply
module pump motor short circuit to ground failure. Then determine if this fault is also resolved.
B. If neither fault 19047 (DTC 195A) - DEF/AdBlue supply module pump motor pressure sensor voltage is
higher than expected nor fault 19111 (DTC 723A) - DEF/AdBlue supply module pump motor short circuit
to ground failure is present, continue with Step 5.
Then verify that the fault has been resolved.
A. If the fault is resolved, use EST to perform the Engine Restart Counter Reset / Unlock Inducement configura-
tion. See Selective Catalytic Reduction (SCR) exhaust treatment - Configure - Engine restart counter
reset (10.500), if necessary. Then return the machine to service.

module.
sary.
has been resolved.
operation.
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19524-(DTC 15AA)-DEF/AdBlue temperature sensor voltage is

necessary.
Context:
A158 monitors the level and temperature of the DEF/ADBLUE® fluid. If the DEF/ADBLUE® tank level and temperature
sensor B-020 temperature sensing signal is greater than 4.70 V, this fault will occur.
Cause:
The B-020 temperature signal to the ECU is greater than 4.70 V.
1. Faulty B-020, damaged internally.

2. Faulty B-020 level signal wiring, open or shorted to a high source.
Solution:
Use a multimeter to measure the resistance of the DEF/ADBLUE® tank level and temperature sensor:
From To Value
Connector XB-020, pin 3 Connector XB-020, pin 2 There should be 25.56 - 23342 Ω
A. If the resistance is within the specified range, leave the Connector XB-020 disconnected and continue with
Step 3.
B. If the resistance outside the specified range, the B-020 has failed internally. Replace the B-020 unit.
3. Check the B-020 temperature signal circuit wiring for an open circuit condition.
Use a multimeter to check for continuity on the vehicle (VE) harness from:
From To Value
Connector XB-020, pin 3 Connector XA158, pin 8 There should be continuity
A. If there is no continuity, there is an open circuit condition in the vehicle (VE) harness between the Connector
XA158, pin 8 and the Connector XB-020, pin 3, wire 608. Locate and repair the broken conductor.
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B. If there is continuity, leave the Connector XA158 and the Connector XB-020 disconnected and continue with
Step 4.
4. Check the B-020 temperature signal circuit wiring for a short to high source condition.
Use a multimeter to check for voltage on the vehicle (VE) harness side from:
From To Value
nector XA158, pin 8 and the Connector XB-020, pin 3, wire 608. Locate and repair the damaged conductors.
has been resolved.
operation.
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19525-(DTC 26AA)-DEF/AdBlue temperature sensor voltage is

lower than expected
necessary.
Context:
(ECU) A158 monitors the level and temperature of the DEF/ADBLUE® fluid. If the ECU senses that the temperature
signal from the DEF/ADBLUE® tank level and temperature sensor B-020 is less than 0.35 V, this fault will occur.
Cause:
The B-020 temperature signal to the ECU is less than 0.35 V.

2. Faulty B-020 signal wiring, grounded.
Solution:
2. Verify the condition of the DEF/ADBLUE® tank level and temperature sensor.
From To Value
23342 Ω
A. If the resistance is within the specified range, leave the Connector XB-020 disconnected and continue with
Step 3.
B. If the resistance is not within the specified range, the B-020 has failed internally. Replace the B-020 unit.
3. Check the B-020 temperature signal circuit wiring for a short to ground condition.
From To Value
Connector XA158, pin 8 All other pins on the Connector There should be no continuity
XA158
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A. If there is continuity, there is a short to ground condition in the vehicle (VE) harness between the Connector
XA158, pin 8 and the Connector XB-020, pin 3, wire 608. Locate and repair the grounded conductor.
has been resolved.
operation.
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19532-(DTC 374A)-DEF/AdBlue pressure did not drop when system

was evacuated
necessary.
Context:
Catalytic Reduction (SCR) exhaust treatment - Dynamic description (10.500). Once the DEF/ADBLUE® system
evacuation has begun, if the pressure does not drop down to 0.25 bar (3.62 psi) within 40 s, this fault will occur.
Cause:
The Engine Control Unit (ECU) A158 has determined that the DEF/ADBLUE® system was not evacuated properly, as
system pressure remained above 0.25 bar (3.62 psi).
1. Faulty DEF/ADBLUE® system back flow line (tube), restriction.

2. Faulty supply module (reversing valve) A-037, blocked (stuck) closed.
3. Faulty supply module (pressure sensor) A-037, values too high.
Solution:
2. Check for blockage in DEF/ADBLUE® system.
Visually and tactually inspect the system back flow line (tube) for blockage and/or damage.

module.
sary.
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has been resolved.
operation.
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19550-(DTC 4B8A)-DEF/AdBlue system unable to build sufficient

pressure for dosing
necessary.
Context:
Catalytic Reduction (SCR) exhaust treatment - Dynamic description (10.500). If the DEF/ADBLUE® system pres-
sure does not reach 6.50 bar (94.25 psi) within 60.0 s after ten pressure build up cycles, this fault will occur.
Cause:
The Engine Control Unit (ECU) A158 has determined that a low pressure condition exists in the DEF/ADBLUE® sys-
tem.
1. Faulty DEF/ADBLUE® tank level, too low a fluid level (suction of air).
2. Faulty DEF/ADBLUE® system, leakage (external and/or internal).
3. Faulty DEF/ADBLUE® system filters or lines (tubes), restricted.
4. Faulty dosing module Y-007, blocked (stuck) open.
5. Faulty supply module (pump motor) A-037 not delivering enough, supply module (reversing valve) A-037 blocked
(stuck) open, or supply module (pressure sensor) A-037 values too low.
Solution:
2. Check fluid level in DEF/ADBLUE® system supply tank.
As air in the DEF/ADBLUE® system will cause the pressure level to decrease, visually check the fluid level in the
supply tank.
There should be an adequate level of fluid.
A. If a less than adequate level is found, fill the DEF/ADBLUE® system supply tank to an acceptable level.
B. If an adequate level is found, continue with Step 3.

3. Check for leakage or damage and/or blockage in DEF/ADBLUE® system.
Visually and tactually inspect the system filters and suction, pressure and back flow lines (tubes) for leakage and/or
damage.
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A. If leakage or damage is found, repair or replace the filter and/or line (tube).

4. Check for internal tank leakage and air introduction.
Use a separate DEF/ADBLUE® source and clear tubing for testing purposes.
sary.
During normal operation determine if pressure builds and watch for air being introduced into system.
A. If pressure builds and no air is being introduced, the DEF/ADBLUE® tank has failed internally. Locate and repair
or replace the tank.
B. If pressure does not build or air is visible in system, continue with Step 5.
5. Check for leakage in the Y-007.
Visually inspect or test the Y-007 for external or internal leakage and/or internal leak-through damage.
A. If leakage or damage is found, repair or replace the Y-007.

instructions.
sary.
Then verify that fault 19336 (DTC 354A) - DEF/AdBlue general pressure check failure has been resolved.
B. If the fault is not resolved, continue with 7.

module.
sary.
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has been resolved.
operation.
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19559 (DTC F18F)-DEF/AdBlue level too low warning is active -

Stage 1
necessary.
Context:
(ECU) A158 monitors the level and temperature of the DEF/ADBLUE® fluid. If the level of the fluid falls below 10 % of
full, this fault will occur.
Cause:
The DEF/ADBLUE® tank level and temperature sensor B-020 level signal to the ECU is less than 10 % of full.

Solution:

From To Value
12000 Ω
if necessary.
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19568 (DTC F28F)-DEF/AdBlue level too low warning is active -

Stage 2
necessary.
Context:
(ECU) A158 monitors the level and temperature of the DEF/ADBLUE® fluid. If the level of the fluid falls below 5 % of
full, this fault will occur.
Cause:
The DEF/ADBLUE® tank level and temperature sensor B-020 level signal to the ECU is less than 5 % of full.

Solution:

From To Value
12000 Ω
if necessary.
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19650-(DTC 119A)-DEF/AdBlue tank level sensor voltage too high

necessary.
Context:
(ECU) A158 monitors the level and temperature of the DEF/ADBLUE® fluid. If the DEF/ADBLUE® tank level and tem-
perature sensor B-020 level sensing signal is greater than 4.65 V for 0.5 s, this fault will occur.
Cause:
The B-020 level signal to the ECU is greater than 4.65 V.

2. Faulty B-020 level signal wiring, open or shorted to a high source.
Solution:
From To Value
Connector XB-020, pin 1 Connector XB-020, pin 2 There should be less than infinite
resistance, typically less than
17000 Ω which is greater than full
tank resistance
A. If there is less than infinite resistance, leave the Connector XB-020 disconnected and continue with Step 3.
B. If there is infinite resistance, the B-020 has failed internally. Replace the B-020 unit.
3. Check the B-020 temperature signal circuit wiring for an open circuit condition.
Use a multimeter to check for continuity on the vehicle (VE) harness from:
From To Value
Connector XB-020, pin 1 Connector XA158, pin 31 There should be continuity
A. If there is no continuity, there is an open circuit condition in the vehicle (VE) harness between the Connector
XA158, pin 31 and the Connector XB-020, pin 1, wire 631. Locate and repair the broken conductor.
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B. If there is continuity, leave the Connector XA158 and the Connector XB-020 disconnected and continue with
Step 4.
4. Check the B-020 temperature signal circuit wiring for a short to high source condition.
Use a multimeter to check for voltage on the vehicle (VE) harness side from:
From To Value
nector XA158, pin 31 and the Connector XB-020, pin 1, wire 631. Locate and repair the damaged conductors.
has been resolved.
operation.
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19651-(DTC 229A)-DEF/AdBlue tank level sensor voltage too low

necessary.
Context:
(ECU) A158 monitors the level and temperature of the DEF/ADBLUE® fluid. If the ECU senses that the signal from
the DEF/ADBLUE® tank level and temperature sensor B-020 is less than 0.27 V for 0.5 s, this fault will occur.
Cause:
The B-020 temperature signal to the ECU is less than 0.27 V.

2. Faulty B-020 signal wiring, grounded.
Solution:
Fill the DEF/ADBLUE® tank.
From To Value
Connector XB-020, pin 1 Connector XB-020, pin 2 There should be a measurable
amount of resistance, typically
between 12000 - 16100 Ω
A. If there is a measurable amount of resistance, leave the Connector XB-020 disconnected and continue with
Step 3.
B. If there is no measurable amount of resistance ( 0.0 Ω), the B-020 has failed internally. Replace the B-020 unit.
.
3. Check the B-020 temperature signal circuit wiring for a short to ground condition.
From To Value
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A. If there is continuity, there is a short to ground condition in the vehicle (VE) harness between the Connector
XA158, pin 31 and the Connector XB-020, pin 1, wire 631. Locate and repair the grounded conductor.
has been resolved.
operation.
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19708 (DTC 3995)-Monitoring for pressure loss in the high pressure

accumulator (rail test)
WARNING
Pressurized system!
If the after run process is interrupted and unable to be completed, the fuel system may remain pres-
surized. DO NOT open the high pressure fuel system until this fault is corrected and the after run
process is able to be completed.
W1317A
Context:
The Engine Control Unit (ECU) A158 performs a fuel rail pressure loss test during after-run to monitor for possible
fuel leakage. If the ECU determines that fuel rail pressure can not stay pressurized between 200 - 1000 bar (29000
- 14500 psi) during the rail test, leakage is assumed and this fault will occur.
Cause:
The ECU has detected leakage in the fuel rail during the after-run rail test.
1. Faulty rail pressure sensor, wiring or internal failure.

3. Faulty rail pressure sensor, leakage.
4. Faulty Pressure Relief Valve (PRV), leakage.
5. Faulty high pressure fuel lines, leakage.
6. Faulty cylinder head, leakage.
7. Engine oil level full, fuel contamination.
8. Fuel leakage under valve cover.
9. Faulty cylinder head, fuel supply/return passage leakage.
Solution:
3764 (DTC F561) - ECU after run power interruption
3968 (DTC 5171) - After run relay high side driver circuit open failure
3981 (DTC 5971) - After run relay low side driver circuit open or short to ground failure
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19748 (DTC 833A)-DEF/AdBlue supply module pump motor over

temperature failure
necessary.
Context:
The Engine Control Unit (ECU) A158 monitors the supply module (pump motor) A-037 circuit for an over temperature/
current condition. If the ECU detects an over temperature/current condition, this fault will occur.
Cause:
The ECU has detected an over temperature/current condition in the A-037 circuit.
1. Faulty supply module (pump motor) A-037, wiring.

Solution:
19108 (DTC 613A) - DEF/AdBlue supply module pump motor short circuit to battery failure

3. Check the supply module (pump motor) A-037 wiring for a short to battery power condition.
From To Value
A. If there is continuity, there is a short circuit condition in the supply module (pump motor) A-037 wiring. Locate
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4. Check the supply module (pump motor) A-037 wiring for short to key battery power condition.
From To Value
A. If there is voltage, there is a short to key battery power in the supply module (pump motor) A-037 circuit, wire

instructions.
counter reset (10.500) if necessary to perform the Engine Restart Counter Reset / Unlock Inducement configu-
ration.
has been resolved.
operation.
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19787 (DTC F49F)-SCR Inducement: Level 1 (torque reduction),

triggered by DEF/AdBlue dosing interruption fault
Context:
this fault to occur. Any one of many Selective Catalytic Reduction (SCR) DEF/ADBLUE® fluid injection interruption
faults that remains active for more than 10 h will cause this fault to occur.
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19788-(DTC F59F)-SCR Inducement: Level 3 (creep mode),

triggered by DEF/AdBlue dosing interruption fault
Context:
faults that remains active for more than 20 h will cause this fault to occur.
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19789 (DTC F69F)-SCR Inducement: Warning, triggered by

DEF/AdBlue dosing interruption fault
Context:
faults will cause this fault to occur. The active fault causing this fault needs to be identified and resolved within the
next 10 h of operation to avoid engine de-rate.
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19797 (DTC FA9F)-SCR Inducement: Level 1 (torque reduction),

triggered by DEF/AdBlue quality fault
Context:
(DTC 4BCA) - DEF/AdBlue concentration is out of range and/or 19142 (DTC 4DCA) - DEF/AdBlue quality sensor
temperature failure (different from DEF/AdBlue level temperature) , which after being active for more than 10 h
will cause this fault to occur.
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19798 (DTC FB9F)-SCR Inducement: Level 3 (creep mode),

triggered by DEF/AdBlue quality fault
Context:
temperature failure (different from DEF/AdBlue level temperature), which after being active for more than 20 h
will cause this fault to occur.
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19799 (DTC FC9F)-SCR Inducement: Warning, triggered by

DEF/AdBlue quality fault
Context:
temperature failure (different from DEF/AdBlue level temperature), either of which will cause this fault to occur.
The active fault causing this fault needs to be identified and resolved within the next 10 h of operation to avoid engine
de-rate.
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19800 (DTC FD9F)-SCR Inducement: Level 1 (torque reduction),

triggered by tampering fault
Context:
detection faults that remains active for more than 36 h will cause this fault to occur.
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19801 (DTC FE9F)-SCR Inducement: Level 3 (creep mode),

triggered by tampering fault
Context:
detection faults that remains active for more than 100 h will cause this fault to occur.
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19817-(DTC 377A)-DEF/AdBlue dosing valve is blocked

necessary.
Context:
A158 detects operation of the dosing module Y-007 by the detection of needle movement, called BIP detection (Begin
of Injection Period). If the current variation (negative peak) result of the needle reaching the rear stop does not occur,
Cause:
The ECU is not sensing full needle movement when the Y-007 solenoid is energized.
1. Faulty Y-007 solenoid valve, damaged or restricted.

Solution:
1. Check for physical damage.
Visually and tactually inspect the Y-007 for thermal or other physical damage.
There should be no damage.
A. If damage is found, replace the dosing module.
B. If no damage is found, continue with Step 2.

2. Check the electrical integrity of the Y-007 solenoid coil.
Use a multimeter to measure the resistance of the Y-007 solenoid coil:
From To Value
Connector XY-007, pin 1 Connector XY-007, pin 2 There should be 11.4 - 12.6 Ω
A. If the measured resistance is within specification, continue with Step 3.
B. If the measured resistance is not within specification, replace the Y-007.

instructions.
sary.
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19889-(DTC 45E1)-Vehicle speed CAN message not received

Context:
The Engine Control Unit (ECU) A158 acquires a vehicle and cardan shaft speed via Controller Area Network (CAN)
from the vehicle controller. If the data message is erroneous, the vehicle speed measuring device is deemed to be
defective or not functioning correctly and this fault will occur. See the appropriate vehicle service manual to determine
how to restore the speed signal.
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Index
FAULT CODES - DTC

0000-Retrieving fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
19002 (DTC 2461)-Battery voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599
19006 (DTC 2461)-CAN timeout error from NH3 sensor - NH3Fac message . . . . . . . . . . . . . . . . . . . 601
19007-NH3 sensor open or short in measuring cell circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
19008-NH3 sensor open or short in ground circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
19009 (DTC 18DE)-NH3 sensor short in heater circuit causing overheating . . . . . . . . . . . . . . . . . . . . 606
19010-(DTC 161A)-Downstream SCR catalyst temperature sensor voltage is higher than expected 608
19011-(DTC 271A)-Downstream SCR catalyst temperature sensor voltage is lower than expected 610
19012 (DTC E9DE)-NH3 sensor open in heater circuit causing underheating . . . . . . . . . . . . . . . . . . 612
19013-(DTC EADE)-NH3 sensor open or short in temperature cell circuit . . . . . . . . . . . . . . . . . . . . . . 614
19014-(DTC EBDE)-NH3 sensor open or short in trim resistor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 615
19015-(DTC 4CDE)-NH3 sensor heater control failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
19016-(DTC 37EE)-NH3 sensor heater performance failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
19017-(DTC 38EE)-NH3 sensor signal out of range failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
19018 (DTC 4DDE)-NH3 sensor power supply failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
19019-(DTC 1A1A)-Upstream SCR catalyst temperature sensor voltage is higher than expected . 622
19020-(DTC 2B1A)-Upstream SCR catalyst temperature sensor voltage is lower than expected . . 624
19023-(DTC 4EDE)-NH3 sensor controller failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626
19024-CAN timeout error from NH3 sensor - NH3Sens message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627
19026-(DTC 319C)-Exhaust flap sticking or internal failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
19027-(DTC 329C)-Exhaust flap actuator supply voltage out of range . . . . . . . . . . . . . . . . . . . . . . . . . 631
19030-(DTC 439C)-Exhaust flap increased friction or high mechanical load or flap sticking . . . . . . 633
19033-(DTC 469C)-Exhaust flap stuck during power up test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635
19034-(DTC 879C)-Exhaust flap actuator is over temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 637
19035-(DTC 91BC)-CAN timeout error from exhaust flap actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 639
19036 (DTC 3F1C)-SCR downstream temperature sensor signal drift at cold start . . . . . . . . . . . . . . 641
19040-(DTC 352C)-Upstream oxidation catalyst temperature sensor comparison to a calculated
temperature value failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643
19041 (DTC 362C)-Upstream SCR temperature sensor comparison to a calculated temperature
value failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645
19042-(DTC 372C)-Downstream SCR temperature sensor comparison to a calculated temperature
value failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 647
19043-(DTC 2D54)-Intake air humidity sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . 649
19047-(DTC 195A)-DEF/AdBlue supply module pump motor pressure sensor voltage is higher than
expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651
47829048B 15/06/2016
55.10 [55.DTC] / 794
19048-(DTC 2A5A)-DEF/AdBlue supply module pump motor pressure sensor voltage is lower than
expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 653
19050-(DTC 478E)-Downstream NOx sensor supply voltage is out of range . . . . . . . . . . . . . . . . . . . 655
19051-(DTC E46E)-Upstream NOx sensor internal failure (Heater Open Circuit Error) . . . . . . . . . . 657
19052-(DTC 256E)-Upstream NOx sensor internal failure (Heater Short Circuit Error) . . . . . . . . . . . 658
19053-(DTC A66E)-Upstream NOx sensor internal failure (Heater Performance Plausibility Error) 659
19054-(DTC E48E)-Upstream NOx sensor internal failure (Open Circuit Error) . . . . . . . . . . . . . . . . . 661
19059 (DTC 258E)-Upstream NOx sensor internal failure (short circuit error) . . . . . . . . . . . . . . . . . . 662
19060-(DTC 9E6E)-CAN timeout error from upstream NOx sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 663
19061-(DTC 32BE)-Upstream NOx sensor lambda signal deviation - NOx sensor possible removal
detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 665
19062-(DTC E98E)-Upstream NOx sensor values are not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . 666
19063-(DTC 4A8E)-Upstream NOx sensor supply voltage is out of range . . . . . . . . . . . . . . . . . . . . . . 667
19066-(DTC 1899)-Upstream oxidation catalyst temperature sensor voltage is higher than expected
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 669
19067 (DTC 141A)-Downstream SCR catalyst temperature is too high . . . . . . . . . . . . . . . . . . . . . . . . 671
19068 (DTC 251A)-Downstream SCR catalyst temperature is too low . . . . . . . . . . . . . . . . . . . . . . . . . 673
19069 (DTC 181A)-Upstream SCR catalyst temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675
19070 (DTC 291A)-Upstream SCR catalyst temperature too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677
19071-(DTC 2DDA)-SCR catalyst efficiency lower than first Nox production threshold level . . . . . . 679
19077-(DTC 334A)-DEF/AdBlue pressure stabilization failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 683
19079-(DTC 1A4A)-DEF/AdBlue over pressure failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 685
19080-(DTC 294A)-DEF/AdBlue under pressure failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 687
19081-(DTC 717A)-DEF/AdBlue dosing valve actuator short circuit to ground in high side failure . 690
19082-(DTC 6C5A)-DEF/AdBlue reverting valve driver circuit short to battery failure . . . . . . . . . . . . 692
19083-(DTC 7D5A)-DEF/AdBlue reverting valve driver circuit short to ground failure . . . . . . . . . . . . 694
19084-(DTC 5E5A)-DEF/AdBlue reverting valve driver circuit open failure . . . . . . . . . . . . . . . . . . . . . 696
19096 (DTC 436A)-DEF/AdBlue supply module temperature not available . . . . . . . . . . . . . . . . . . . . . 698
19105-(DTC 879A)-DEF/AdBlue tank heater actuator over temperature . . . . . . . . . . . . . . . . . . . . . . . 700
19106-(DTC 759A)-DEF/AdBlue tank heater actuator short circuit to ground failure . . . . . . . . . . . . . 702
19107-(DTC 515A)-DEF/AdBlue supply module pump motor open load failure . . . . . . . . . . . . . . . . . 704
19108-(DTC 613A)-DEF/AdBlue supply module pump motor short circuit to battery failure . . . . . . . 706
19111-(DTC 723A)-DEF/AdBlue supply module pump motor short circuit to ground failure . . . . . . . 708
19113-(DTC 8F5A)-DEF/AdBlue reverting driver circuit over temperature failure . . . . . . . . . . . . . . . . 710
19126 (DTC FF9F)-SCR Inducement: Warning, triggered by tampering fault . . . . . . . . . . . . . . . . . . . 712
19140-(DTC 4BCA)-DEF/AdBlue concentration is out of range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713
19141-(DTC 4CCA)-DEF/AdBlue quality sensor detects diesel fuel in DEF/AdBlue tank . . . . . . . . . 714
19142 (DTC 4DCA)-DEF/AdBlue quality sensor temperature failure (different from DEF/AdBlue level
temperature) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715
19144 (DTC 9AEA)-CAN timeout error from DEF/AdBlue quality sensor . . . . . . . . . . . . . . . . . . . . . . . 717
19145-(DTC 647A)-DEF/AdBlue dosing valve actuator short circuit to battery failure . . . . . . . . . . . . 719
19149-(DTC 737A)-DEF/AdBlue dosing valve actuator short circuit to ground failure . . . . . . . . . . . . 721
19153-(DTC 624E)-DEF/AdBlue quality sensor internal failure (Short circuit to battery error) . . . . . 723
47829048B 15/06/2016
55.10 [55.DTC] / 795
19154-(DTC 325A)-DEF/AdBlue supply module pump temperature is too low to activate pump . . . 724
19156-(DTC 335A)-DEF/AdBlue supply module pump motor severe speed deviation . . . . . . . . . . . 725
19158-(DTC 734E)-DEF/AdBlue quality sensor internal failure (Short circuit to ground error) . . . . . 726
19159-(DTC 144E)-DEF/AdBlue quality sensor internal failure (Concentration value is higher than
expected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 727
19160-(DTC 254E)-DEF/AdBlue quality sensor internal failure (Concentration value is lower than
expected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 728
19161-(DTC 464E)-DEF/AdBlue quality sensor internal failure (Internal fault) . . . . . . . . . . . . . . . . . . 729
19165-(DTC 684E)-DEF/AdBlue quality sensor internal failure (Temperature sensor circuit short to
battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 730
19166-(DTC 794E)-DEF/AdBlue quality sensor internal failure (Temperature sensor circuit short to
ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 731
19167-(DTC 1A4E)-DEF/AdBlue quality sensor internal failure (Temperature sensor value is higher
than expected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 732
19168-(DTC 1B4E)-DEF/AdBlue quality sensor internal failure (Temperature sensor value is lower
than expected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 733
19169-(DTC 4C4E)-DEF/AdBlue quality sensor internal failure (Temperature sensor failure) . . . . . 734
19173-(DTC 627A)-DEF/AdBlue dosing valve actuator short circuit to battery in high side failure . 735
19174-(DTC 467A)-DEF/AdBlue dosing valve actuator short circuit in high side failure . . . . . . . . . . 737
19179-(DTC 1CBE)-Downstream NOx sensor self-diagnosis result is higher than the limit . . . . . . . 739
19180-(DTC 2DBE)-Downstream NOx sensor self-diagnosis result is lower than the limit . . . . . . . . 740
19187-(DTC 11CE) - Upstream NOx sensor self-diagnosis result is higher than the limit . . . . . . . . . 741
19188 (DTC 22CE)-Upstream NOx sensor self-diagnosis result is lower than the limit . . . . . . . . . . . 742
19225-(DTC 931B)-CAN C Bus off passive failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 743
19262 (DTC 659A)-DEF/AdBlue tank heater actuator short circuit to battery failure . . . . . . . . . . . . . 745
19264-(DTC 569A)-DEF/AdBlue tank heater actuator open load failure . . . . . . . . . . . . . . . . . . . . . . . 747
19323-(DTC 94FB)-External engine shutdown request received . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 749
19336-(DTC 354A)-DEF/AdBlue general pressure check failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750
19337-(DTC 344A)-DEF/AdBlue dosing system backflow line pressure too high plausibility failure 752
19356-(DTC 3FDE)-Downstream NOx sensor signal and NH3 sensor signal plausibility check failure
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 754
19409 (DTC 2D93)-High pressure intercooler outlet pressure sensor plausibility check low failure 755
19415 (DTC FABF)-Remaining DEF/AdBlue is below the empty threshold . . . . . . . . . . . . . . . . . . . . . 757
19422-(DTC 43CE)-Downstream NOx sensor signal is stuck at a constant value . . . . . . . . . . . . . . . 758
19434 (DTC E26D)-ECU internal failure - EEPROM erase error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 759
19435 (DTC E36D)-ECU internal failure - EEPROM read error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 760
19436 (DTC E46D)-ECU internal failure - EEPROM write error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 761
19496 (DTC 184A)-Monitoring of over pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 762
19524-(DTC 15AA)-DEF/AdBlue temperature sensor voltage is higher than expected . . . . . . . . . . . 764
19525-(DTC 26AA)-DEF/AdBlue temperature sensor voltage is lower than expected . . . . . . . . . . . . 766
19532-(DTC 374A)-DEF/AdBlue pressure did not drop when system was evacuated . . . . . . . . . . . . 768
19550-(DTC 4B8A)-DEF/AdBlue system unable to build sufficient pressure for dosing . . . . . . . . . . 770
19559 (DTC F18F)-DEF/AdBlue level too low warning is active - Stage 1 . . . . . . . . . . . . . . . . . . . . . . 773
19568 (DTC F28F)-DEF/AdBlue level too low warning is active - Stage 2 . . . . . . . . . . . . . . . . . . . . . . 774
47829048B 15/06/2016
55.10 [55.DTC] / 796
19650-(DTC 119A)-DEF/AdBlue tank level sensor voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . 775
19651-(DTC 229A)-DEF/AdBlue tank level sensor voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . 777
19708 (DTC 3995)-Monitoring for pressure loss in the high pressure accumulator (rail test) . . . . . . 779
19748 (DTC 833A)-DEF/AdBlue supply module pump motor over temperature failure . . . . . . . . . . . 781
19787 (DTC F49F)-SCR Inducement: Level 1 (torque reduction), triggered by DEF/AdBlue dosing
interruption fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 783
19788-(DTC F59F)-SCR Inducement: Level 3 (creep mode), triggered by DEF/AdBlue dosing inter-
ruption fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 784
19789 (DTC F69F)-SCR Inducement: Warning, triggered by DEF/AdBlue dosing interruption fault 785
19797 (DTC FA9F)-SCR Inducement: Level 1 (torque reduction), triggered by DEF/AdBlue quality
fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 786
19798 (DTC FB9F)-SCR Inducement: Level 3 (creep mode), triggered by DEF/AdBlue quality fault 787
19799 (DTC FC9F)-SCR Inducement: Warning, triggered by DEF/AdBlue quality fault . . . . . . . . . . 788
19800 (DTC FD9F)-SCR Inducement: Level 1 (torque reduction), triggered by tampering fault . . . 789
19801 (DTC FE9F)-SCR Inducement: Level 3 (creep mode), triggered by tampering fault . . . . . . . 790
19817-(DTC 377A)-DEF/AdBlue dosing valve is blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 791
19889-(DTC 45E1)-Vehicle speed CAN message not received . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 793
3001 (DTC 3AB1)-Diagnostic fault check of synchronism for double potentiometer and Low Idle
Switch (LIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3002 (DTC 16B1)-Signal range check high for acceleration pedal position device driver sensor 1 . 20
3005-(DTC 4B84)-Air filter clog or circuit failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3007-(DTC 1113)-Engine coolant temperature sensor voltage is higher than expected . . . . . . . . . . 24
3008 (DTC 2213)-Engine coolant temperature sensor voltage is lower than expected . . . . . . . . . . . 26
3010-(DTC 2474)-Intake manifold temperature sensor voltage is lower than expected . . . . . . . . . . . 28
3014-(DTC 4C84)-Air filter clog or circuit failure present for a long time . . . . . . . . . . . . . . . . . . . . . . . . 30
3015-(DTC 1C15)-Fuel temperature sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . 32
3016-(DTC 2D15)-Fuel temperature sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . 34
3019-(DTC 1D64)-Intake manifold pressure sensor voltage is higher than expected . . . . . . . . . . . . 36
3024-(DTC 13C4)-ECU internal failure - Ambient pressure sensor voltage is higher than expected 38
3025-(DTC 24C4)-ECU internal failure - Ambient pressure sensor voltage is lower than expected 39
3028-(DTC 26D3)-Oil pressure is too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3029-(DTC 18D3)-Oil pressure sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . 41
3030-(DTC 29D3)-Oil pressure sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . 43
3034-(DTC 11E3)-Oil temperature sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . 45
3035-(DTC 22E3)-Oil temperature sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . 47
3037-(DTC 2E64)-Intake manifold pressure sensor voltage is lower than expected . . . . . . . . . . . . . 49
3051 (DTC 1161)-Battery voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3052 (DTC 2261)-Battery voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3063 (DTC 6226)-Short circuit error of injector in cylinder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3067-(DTC 6726)-Short circuit error of injector in cylinder 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
47829048B 15/06/2016
55.10 [55.DTC] / 797
3083-(DTC 6326)-Short circuit in injector 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3088-(DTC 4512)-Crankshaft speed sensor values are not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3089-(DTC 4412)-Crankshaft speed sensor pattern is not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3090-(DTC 4212)-Camshaft speed sensor values are not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3091-(DTC 4112)-Camshaft speed sensor pattern is not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3093-(DTC 3312)-Compared camshaft and crankshaft speed sensor values are not plausible . . . . 80
3096-(DTC 951B)-CAN A Bus off failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3102-(DTC 2525)-Fuel rail pressure sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . 83
3104-(DTC F445)-Fuel pressure relief valve is open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3105-(DTC F245)-Fuel pressure relief valve is forced to open, perform pressure increase . . . . . . . 86
3106-(DTC 1145)-Fuel pressure relief valve reached maximum allowed opening count . . . . . . . . . . 87
3107-(DTC 6655)-Fuel metering unit is shorted to battery voltage at the low side . . . . . . . . . . . . . . . 88
3108-(DTC 7755)-Fuel metering unit is shorted to ground at the low side . . . . . . . . . . . . . . . . . . . . . . 90
3110-(DTC 1225)-Rail pressure sensor value is above maximum offset . . . . . . . . . . . . . . . . . . . . . . . 92
3111-(DTC 2325)-Rail pressure sensor value is below minimum offset . . . . . . . . . . . . . . . . . . . . . . . . 94
3112-(DTC 1425)-Fuel rail pressure sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . 96
3118 (DTC E82D)-Internal supply voltage is too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3119 (DTC E92D)-Internal supply voltage is too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3137 (DTC 5255)-Fuel metering unit has an open load error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3141 (DTC 4465)-Fuel pump pressure has exceeded desired pressure limits . . . . . . . . . . . . . . . . . . 102
3146 (DTC 4415)-Water in fuel detected or water in fuel circuit failure . . . . . . . . . . . . . . . . . . . . . . . . . 103
3154-(DTC 6A14)-Intake air heater actuator is shorted to battery voltage . . . . . . . . . . . . . . . . . . . . . . 106
3155-(DTC 7C14)-Intake air heater actuator is shorted to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3156-(DTC 5614)-Intake air heater actuator has an open load error . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3160 (DTC 6733)-Fan clutch solenoid short circuit to battery failure . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3161 (DTC 7833)-Fan clutch solenoid short circuit to ground failure . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3162 (DTC 5533)-Fan clutch solenoid open load failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3163 (DTC 8633)-Fan clutch solenoid ECU driver over temperature failure . . . . . . . . . . . . . . . . . . . . 118
3164 (DTC 1A33)-Fan speed above maximum threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3165 (DTC 2B33)-Fan speed below minimum threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3166-(DTC 63B5)-Fuel filter heater actuator is shorted to battery voltage . . . . . . . . . . . . . . . . . . . . . . 124
3167-(DTC 74B5)-Fuel filter heater actuator is shorted to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3168-(DTC 51B5)-Fuel filter heater actuator has an open load error . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3169-(DTC 82B5)-Fuel filter heater ECU driver has an over temperature error . . . . . . . . . . . . . . . . . 130
3170-(DTC 38CB)-NH3 sensor signal is not changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3172-(DTC F523)-Engine coolant temperature has exceeded the pre-warning threshold . . . . . . . . . 133
3173-(DTC F623)-Engine coolant temperature has exceeded the warning threshold . . . . . . . . . . . . 135
3175-(DTC 4933)-Fan speed signal could not be measured for a period . . . . . . . . . . . . . . . . . . . . . . . 137
3176-(DTC 3B65)-High pressure pump fuel delivery quantity in over run exceeds a maximum thresh-
old . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3177-(DTC F1A2)-Engine over speed condition detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
47829048B 15/06/2016
55.10 [55.DTC] / 798
3179-(DTC 956B)-CAN communication failure between vehicle controller and ECU - BC2ECU2 mes-
sage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3180-(DTC 9B7B)-CAN communication error between vehicle controller to ECU . . . . . . . . . . . . . . . 144
3182-(DTC 9741)-CAN timeout error from cruise control vehicle speed (CCVS) . . . . . . . . . . . . . . . . 146
3183-(DTC 93CB)-CAN communication failure between vehicle controller and ECU controller -
TSC1_VR message (Engine brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
TSC1_VR message (Engine brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3185-(DTC 978B)-Can timeout error from transmission - Transmission fluids (TF) message . . . . . . 152
3188-(DTC 5316)-Open load error of injector in cylinder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3196-Open load error of injector in cylinder 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
3204-Open load error of injector in cylinder 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3226 (DTC 9A98)-CAN timeout error from eVGT Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
3230-(DTC E126)-ECU internal failure - Injector CY33x component . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3233 (DTC E336)-ECU internal failure - Internal SPI injector related timeout error . . . . . . . . . . . . . . 177
3235-(DTC F936)-Exceeded the number of injections for a given engine speed . . . . . . . . . . . . . . . . 178
3236-(DTC F836)-Number of injections is limited by system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
3237 (DTC 1636)-Number of desired injections exceeds threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
3238-(DTC E64D)-ECU internal failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3245-(DTC E51D)-ECU internal failure - Query/response communication errors . . . . . . . . . . . . . . . . 182
3252-(DTC E61D)-ECU internal failure - SPI communication error . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3253-(DTC E41D)-ECU internal failure - Voltage ratio in ADC monitoring . . . . . . . . . . . . . . . . . . . . . . 184
3255-(DTC E31D)-ECU internal failure - ADC test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
3256-(DTC E21D)-ECU internal failure - NTP error in ADC monitoring . . . . . . . . . . . . . . . . . . . . . . . . 186
3258-(DTC 6722)-Starter relay high side driver circuit short to battery failure . . . . . . . . . . . . . . . . . . . 187
3259-(DTC 7822)-Starter relay high side driver circuit short to ground failure . . . . . . . . . . . . . . . . . . . 189
3260-(DTC 5922)-Starter relay low side driver circuit open failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3261-(DTC 6B22)-Starter relay low side driver circuit short to battery failure . . . . . . . . . . . . . . . . . . . 193
3262-(DTC 7C22)-Starter relay low side driver circuit short to ground failure . . . . . . . . . . . . . . . . . . . 195
3263-(DTC 971B)-CAN C Bus off failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3265 (DTC E4DD)-Fuel injection requested during overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
3280 (DTC E62D)-Sensor supply 1 voltage is too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
3281 (DTC E72D)-Sensor supply 1 voltage is too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
3283-(DTC E32D)-ECU internal failure - Sensor 5 volt supply 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3285-(DTC E42D)-ECU internal failure - Sensor 5 Volt supply 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3293-(DTC 2265)-Fuel rail pressure has exceeded maximum positive deviation limits . . . . . . . . . . . 206
47829048B 15/06/2016
55.10 [55.DTC] / 799
3301-(DTC 1565)-Fuel rail pressure has exceeded maximum negative deviation limits . . . . . . . . . . 207
3305 (DTC 2765)-Fuel rail pressure has exceeded minimum limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
3309-(DTC 1865)-Fuel rail pressure has exceeded maximum limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
3334-(DTC 99BB)-CAN communication failure between vehicle controller and ECU controller -
TSC1_PE message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
TSC1_VE message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
3361-(DTC E16D)-ECU internal failure - EEPROM write/read error . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3362-(DTC E1FD)-ECU internal failure - Fuel calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
3368-(DTC F6EF)-Torque limitation caused by performance limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
3370-(DTC F2EF)-Strong torque limitation from engine protection active . . . . . . . . . . . . . . . . . . . . . . 218
3371-(DTC F3EF)-Strong torque limitation from injection system active . . . . . . . . . . . . . . . . . . . . . . . 219
3403-(DTC 8A22)-Starter relay low side ECU driver circuit over temperature failure . . . . . . . . . . . . . 220
3425 (DTC 1438)-Under boost failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
3436-(DTC FBBF)-Inducement system is locked due to 3 detections in 40 hours. The system must
be reset using the dealer service tool screen "Engine Restart Counter Reset" . . . . . . . . . . . . . . . . . . 224
3438-(DTC 7A61)-Auxiliary power relay high side driver circuit short to ground failure . . . . . . . . . . . 225
3439-(DTC 5B61)-Auxiliary power relay low side driver circuit open failure . . . . . . . . . . . . . . . . . . . . . 227
3440-(DTC 8322)-Auxiliary power relay low side ECU driver circuit over temperature failure . . . . . 229
3441 (DTC 6422)-Auxiliary power relay low side driver circuit short to battery failure . . . . . . . . . . . . 231
3442-(DTC 7522)-Auxiliary power relay low side driver circuit short to ground failure . . . . . . . . . . . . 233
3443-(DTC F3A2)-Torque limitation due to excessive coolant temperature . . . . . . . . . . . . . . . . . . . . . 235
3444-(DTC F4A2)-Torque limitation due to excessive exhaust gas temperature . . . . . . . . . . . . . . . . 236
3445-(DTC F5A2)-Torque limitation due to excessive fuel temperature . . . . . . . . . . . . . . . . . . . . . . . . 237
3446-(DTC F6A2)-Torque limitation due to excessive intake air temperature . . . . . . . . . . . . . . . . . . . 238
3447 (DTC F7A2)-Torque limitation due to excessive oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . 239
3448 (DTC F8A2)-Torque limitation due to turbocharger protection after start . . . . . . . . . . . . . . . . . . 240
3449-(DTC E812)-ECU internal failure - Calculated engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
3450 (DTC 3398)-eVGT actuator blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
3457-(DTC 1374)-Intake manifold temperature sensor voltage is higher than expected . . . . . . . . . . 244
3458-(DTC 15E3)-Crankcase pressure too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
3459-(DTC 1BD3)-Oil temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
3460-(DTC 2CD3)-Oil temperature too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
3461-(DTC E69D)-ECU internal failure - Timeout in the shut off path test error . . . . . . . . . . . . . . . . . 250
3462-(DTC E79D)-ECU internal failure - Overvoltage monitoring error . . . . . . . . . . . . . . . . . . . . . . . . 251
3475-(DTC 9D63)-CAN timeout error from coolant water pump actuator . . . . . . . . . . . . . . . . . . . . . . . 252
3501-(DTC E1FD)-ECU internal failure - Software resets in DSM 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
3502 (DTC EE1D)-ECU internal failure - Software resets in DSM 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
3503-(DTC EF1D)-ECU internal failure - software resets in DSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
3507-(DTC 4761)-Engine cranked for too long or key switch failure . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
3508 (DTC FAEF)-Torque limitation active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
3517-(DTC 19C4)-Ambient temperature sensor voltage is higher than expected . . . . . . . . . . . . . . . . 261
3518-(DTC 2AC4)-Ambient temperature sensor voltage is lower than expected . . . . . . . . . . . . . . . . 263
47829048B 15/06/2016
55.10 [55.DTC] / 800
3525-(DTC E18E)-Downstream NOx sensor internal failure (Open Circuit Error) . . . . . . . . . . . . . . . . 265
3526-(DTC E28E)-Downstream Nox sensor internal failure (Short Circuit Error) . . . . . . . . . . . . . . . . 266
3528-(DTC 319E)-Downstream NOx sensor values are not plausible . . . . . . . . . . . . . . . . . . . . . . . . . 267
3529-(DTC E16E)-Downstream NOx sensor internal failure (Heater Open Circuit Error) . . . . . . . . . 268
3530-(DTC E26E)-Downstream NOx sensor internal failure (Heater Short Circuit Error) . . . . . . . . . 269
3531-(DTC A36E)-Downstream NOx sensor internal failure (Heater Performance Plausibility Error) 270
3533 (DTC 9D6E)-CAN timeout error from downstream NOx sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 272
3549 (DTC 1C54)-Intake air humidity sensor voltage is higher than expected for too long . . . . . . . . 274
3557-(DTC FB54)-Intake air humidity sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . 276
3565-(DTC F11F)-SCR inducement warning due to distance/time is active - Level 1 . . . . . . . . . . . . 277
3581-(DTC FD8F)-Torque limitation is active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
3594-(DTC F7EF)-Torque limitation caused by SCR catalyst protection . . . . . . . . . . . . . . . . . . . . . . . 280
3614 (DTC E698)-eVGT motor effort too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
3616-(DTC F1EF)-Torque limitation caused by turbo charger protection . . . . . . . . . . . . . . . . . . . . . . . 283
3617-(DTC FB8F)-SCR inducement warning due to distance/time is active - Level 9 . . . . . . . . . . . . 284
3619-(DTC F5AF)-SCR inducement warning due to distance/time is active - Level 7 . . . . . . . . . . . . 285
3623-(DTC 3CAE)-Downstream NOx sensor lambda signal deviation - NOx sensor possible removal
detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
3624-(DTC 13A3)-Crankcase pressure sensor voltage is higher than expected . . . . . . . . . . . . . . . . . 289
3625-(DTC 24A3)-Crankcase pressure sensor voltage is lower than expected . . . . . . . . . . . . . . . . . 291
3626-(DTC 37B3)-Crankcase pressure has exceeded tolerance limit . . . . . . . . . . . . . . . . . . . . . . . . . 293
3628-(DTC 22A3)-Crankcase pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
3638-(DTC F4EF)-Torque limitation caused by engine brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
3647 (DTC 1338)-Over boost failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
3652-(DTC 911B)-CAN A Bus off passive failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
3680-(DTC E536)-Engine speed limitation via fuel injection cut off is active . . . . . . . . . . . . . . . . . . . . 300
3686 (DTC 3D1C)-DOC upstream temperature sensor signal drift at cold start . . . . . . . . . . . . . . . . . 301
3687-(DTC 3E1C)-SCR upstream temperature sensor signal drift at cold start . . . . . . . . . . . . . . . . . 303
3688 (DTC 4F15)-Water in fuel sensor or sensor circuit failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
3699 (DTC E56D)-ECU EEPROM memory failure - EEPData1 block . . . . . . . . . . . . . . . . . . . . . . . . . 308
3700 (DTC 3754)-Intake air humidity sensor value is not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
3703 (DTC 2B36)-The minimum rail pressure value necessary to allow fuel injection has not been
reached . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
3735-(DTC 8355)-Fuel metering unit has an over-temperature error . . . . . . . . . . . . . . . . . . . . . . . . . . 311
3738-(DTC E71D)-ECU internal failure - ROM error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
3739-(DTC E13D)-ECU internal failure - Loss of synchronization to MM from CPU . . . . . . . . . . . . . 314
3740-(DTC E23D)-ECU internal failure - ECU shutdown test failure . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
3741-(DTC E33D)-ECU internal failure - Wrong set response time . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
47829048B 15/06/2016
55.10 [55.DTC] / 801
3742-(DTC E43D)-ECU internal failure - SPI errors during MoCSOP execution . . . . . . . . . . . . . . . . . 317
3743-(DTC E53D)-ECU internal failure - Undervoltage monitoring error . . . . . . . . . . . . . . . . . . . . . . . 318
3745-(DTC E63D)-ECU internal failure - WDA is not working correctly . . . . . . . . . . . . . . . . . . . . . . . . 319
3746-(DTC E73D)-ECU internal failure - Alarm task period error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
3747-(DTC E83D)-ECU internal failure - Positive test failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
3749 (DTC E5B1)-ECU internal failure - Accelerator pedal position sensor . . . . . . . . . . . . . . . . . . . . 322
3750-(DTC EC36)-ECU internal failure - Fuel injection energizing time is not plausible . . . . . . . . . . 323
3751-(DTC ED36)-ECU internal failure - Fuel injection energizing phase is not plausible . . . . . . . . 324
3752 (DTC EE36)-Fuel injection correction has exceeded a minimum limit . . . . . . . . . . . . . . . . . . . . . 325
3753-(DTC E5DD)-ECU internal failure - Injection quantity correction . . . . . . . . . . . . . . . . . . . . . . . . . 326
3754-(DTC E6DD)-ECU internal failure - Rail pressure plausibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
3755-(DTC E7DD)-ECU internal failure - Torque request comparison . . . . . . . . . . . . . . . . . . . . . . . . . 328
3756-(DTC E1DD)-ECU internal failure - Post injection quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
3757-(DTC E2DD)-ECU internal failure - Post injection shut-off failure . . . . . . . . . . . . . . . . . . . . . . . . 330
3758 (DTC E3DD)-Post injection efficiency failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
3759-(DTC E8DD)-ECU internal failure - Torque request due to fuel pressure exceeds maximum
torque limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
3760-(DTC E9DD)- ECU internal failure - Torque request due to rail control exceeds maximum torque
limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
3761-(DTC EADD)-ECU internal failure - Torque request exceeds maximum torque limit . . . . . . . . 334
3762 (DTC EBDD)-ECU 5 volt supply voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . 335
3763-(DTC ECDD)-ECU 5 volt supply voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . 336
3764-(DTC F561)-ECU after run power interruption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
3767-(DTC E81D)-ECU internal failure - 'WDA active' reported due to errors in query/response com-
munication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
3768-(DTC E91D)-ECU internal failure - 'ABE active' reported due to undervoltage detection . . . . 341
3769-(DTC EA1D)-ECU internal failure - 'ABE active' reported due to overvoltage detection . . . . . 342
3770-(DTC EB1D)-ECU internal failure - 'WDA/ABE active' reported . . . . . . . . . . . . . . . . . . . . . . . . . . 343
3799-(DTC F345)-Fuel pressure relief valve is forced to open, perform pressure shock . . . . . . . . . . 344
3805-(DTC 1D85)-Maximum rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
3808-(DTC 3C65)-High pressure pump fuel delivery quantity at low idle is too high . . . . . . . . . . . . . 346
3810 (DTC 4125)-Rail pressure sensor value is intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
3811-(DTC E22D)-ECU internal failure - Sensor 5 volt supply 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
3812-(DTC 115D)-ECU temperature sensor 1 is too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
3813-(DTC 235D)-ECU temperature sensor 1 is too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
3814-(DTC E55D)-ECU temperature sensor error detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
3838-(DTC 2999)-Upstream oxidation catalyst temperature sensor voltage is lower than expected 354
3858 (DTC 3598)-CAN communication error between ECU and eVGT actuator . . . . . . . . . . . . . . . . 356
3861 (DTC 3498)-eVGT power supply electrical failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
3865 (DTC 4898)-eVGT system failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
3868 (DTC 8998)-eVGT actuator over temperature error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
3870-(DTC 936B)-CAN communication failure between vehicle controller and ECU - BC2ECU1 mes-
sage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
47829048B 15/06/2016
55.10 [55.DTC] / 802
3877-(DTC 647D)-Supply UB1 short to battery failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
3881-(DTC 757D)-Supply UB1 circuit short to ground failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
3882-(DTC 777D)-Supply UB2 short to ground failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
3883-(DTC 797D)-Supply UB3 short to ground failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
3903-(DTC 1A15)-Fuel temperature is too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
3905-(DTC 8814)-Intake air heater ECU driver has an over-temperature . . . . . . . . . . . . . . . . . . . . . . 380
3910-(DTC 4155)-Fuel metering unit intermittent electrical connection . . . . . . . . . . . . . . . . . . . . . . . . 382
3911-(DTC 6455)-Fuel metering unit is shorted to battery voltage at the high side . . . . . . . . . . . . . . 384
3912-(DTC 7555)-Fuel metering unit is shorted to ground at the high side . . . . . . . . . . . . . . . . . . . . . 386
3916-(DTC 1745)-Fuel pressure relief valve has reached maximum allowed open time . . . . . . . . . . 388
3930-(DTC FC8F)-SCR inducement warning due to distance/time is active - Level 10 . . . . . . . . . . . 390
3936 (DTC E52D)-ECU internal: error sensor supplies voltage tracker . . . . . . . . . . . . . . . . . . . . . . . . 391
3961-(DTC ED2D)-CAN communication failure - External torque/speed checksum and counter . . 392
3962 (DTC 49C3)-Crankcase pressure too high for too long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
3963-(DTC 4AC3)-Crankcase pressure too high and oil pressure too low - Fuel in oil suspected . . 395
3964-(DTC 125D)-ECU temperature sensor 2 is too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
3965-(DTC 245D)-ECU temperature sensor 2 is too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
3966-(DTC 165D)-ECU temperature sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . 398
3967-(DTC 275D)-ECU temperature sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . 399
3968-(DTC 5171)-After run relay high side driver circuit open failure . . . . . . . . . . . . . . . . . . . . . . . . . . 400
3969-(DTC 8271)-After run relay high side ECU driver circuit over temperature failure . . . . . . . . . . 402
3970-(DTC 6371)-After run relay high side driver circuit short to battery . . . . . . . . . . . . . . . . . . . . . . . 404
3971-(DTC 6471)-After run relay high side drive circuit short to ground failure . . . . . . . . . . . . . . . . . . 406
3973-(DTC 8671)-After run relay low side ECU drive circuit over temperature failure . . . . . . . . . . . . 408
3974-After run relay low side driver circuit short to battery failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
3977-(DTC 15E5)-Prefilter fuel pressure sensor voltage is higher than expected . . . . . . . . . . . . . . . 412
3978-(DTC 16E5)-Prefilter fuel pressure sensor voltage is lower than expected . . . . . . . . . . . . . . . . 414
3981-After run relay low side driver circuit open or short to ground failure . . . . . . . . . . . . . . . . . . . . . . 416
3985-(DTC 1758)-Exhaust gas pressure sensor voltage is higher than expected . . . . . . . . . . . . . . . 418
3986-(DTC 275D)-Exhaust gas pressure sensor voltage is lower than expected . . . . . . . . . . . . . . . . 420
4113-Logical error at FNR switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
4114-Logical error at direction select signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
4116-Logical error at park brake status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
4117-Logic error at direction select signal 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
4133-Short circuit to battery voltage or open circuit at transmission sump temperature sensor input 431
4134-Short circuit to ground at transmission sump temperature sensor input . . . . . . . . . . . . . . . . . . . 432
4135-Short circuit to battery voltage or open circuit at retarder/ torque converter temperature sensor
input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
4136-Short circuit to ground at retarder/ torque converter temperature sensor input . . . . . . . . . . . . . 434
4137-Short circuit to battery voltage or open circuit at parking brake sensor input . . . . . . . . . . . . . . . 435
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4145-Short circuit to battery voltage or open circuit at engine speed input . . . . . . . . . . . . . . . . . . . . . 438
4146-Short circuit to ground at engine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
4147-Logical error at engine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
4148-Short circuit to battery voltage or open circuit at turbine speed input . . . . . . . . . . . . . . . . . . . . . 444
4149-Short circuit to ground at turbine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
4150-Logical error at turbine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
4151-Short circuit to battery voltage or open circuit at internal speed input . . . . . . . . . . . . . . . . . . . . . 450
4152-Short circuit to ground at internal speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
4153-Logical error at internal speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
4154-Short circuit to battery voltage or open circuit at output speed input . . . . . . . . . . . . . . . . . . . . . . 456
4155-Short circuit to ground at output speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
4156-Logical error at output speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
4158-Output speed zero, doesn't fit to other speed signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
4160-Invalid gear range restriction (CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
4186-Invalid park brake status (CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
4209-Short circuit to battery voltage at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
4210-Short circuit to ground at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
4211-Open circuit at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
4228-Short circuit to battery voltage at clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
4229-Short circuit to ground at clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
4230-Open circuit at clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
4231-Short circuit to battery voltage at clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481
4232-Short circuit to ground at clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
4233-Open circuit at clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
4241-Short circuit to ground at backup alarm relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
4242-Short circuit to battery voltage at backup alarm relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
4243-Open circuit at backup alarm relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488
4273-Slippage at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
4277-Slippage at clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
4278-Slippage at clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
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4279-Overtemp sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
4281-Engine overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
4282-TCM sensed a voltage at oil filter maintenance switch out of the allowed range (dirty filter) . 500
4284-Overspeed output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
4290-Transmission input torque overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
4291-Overtemp converter output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
4292-Short circuit to ground at joystick status indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
4293-Short circuit to battery voltage at joystick status indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
4294-Open circuit at joystick status indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
4305-Short circuit to battery voltage at power supply for sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
4306-Short circuit to ground at power supply for sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
4307-Low voltage at battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
4308-High voltage at battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
4309-Error at valve power supply VPS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
4310-Error valve power supply VPS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
4325-VehicleID#1 timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
4326-Illegal ID request via CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
4337-General EEPROM fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
4338-Configuration error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524
4339-Application error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
4341-Clutch failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
4342-Clutch adjustment data lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
5155-UCM Ground disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528
5159-Error at Fuse 5F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529
5160-Error at Fuse 5F3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
5161-Error at Fuse 5F4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531
5162-Error at Fuse 5F5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
5163-Error at Fuse 5F6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
5164-Open Circuit at Wheel Motor Valve Y8.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534
5165-Open Circuit or Short Circuit to battery at Wheel Motor Valve Y8.2 . . . . . . . . . . . . . . . . . . . . . . 536
5166-Short Circuit to ground at Wheel Motor Valve Y8.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
5167-Short Circuit to power circuit at Wheel Motor Valve Y8.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540
5169-Open Circuit at FWD On/Off Valve Y8.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
5170-Open Circuit or Short Circuit to battery at FWD On/Off Valve Y8.1 . . . . . . . . . . . . . . . . . . . . . . . 543
5171-Short Circuit to ground at FWD On/Off Valve Y8.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
5172-Short Circuit to power circuit at FWD On/Off Valve Y8.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547
5174-Open Circuit at FWD Forward Pump Valve Y8.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549
5175-Open Circuit or Short Circuit to battery at FWD Forward Pump Valve Y8.5 . . . . . . . . . . . . . . . . 551
5176-Short Circuit to ground at FWD Forward Pump Valve Y8.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 553
5177-Short Circuit to power at FWD Forward Pump Valve Y8.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555
5179-Open Circuit at FWD Reverse Pump Valve Y8.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557
5180-Open Circuit or Short Circuit to battery at FWD Reverse Pump Valve Y8.6 . . . . . . . . . . . . . . . 558
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5181-Short Circuit to ground at FWD Reverse Pump Valve Y8.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560
5182-Short Circuit to power at FWD Reverse Pump Valve Y8.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562
5184-Timeout of cycling message AIC2UCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564
5185-Timeout of first cycling message AIC2UCM1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566
5186-Timeout of cycling message EEC1 or EEC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568
5187-Timeout of cycling TCU1 or TCU2 CAN messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570
5188-Actual tire circumference error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
5189-Main Model Info Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574
5194-Gear Restriction Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576
5197-Mismatch AIC CAN message versus brake pressure switch status . . . . . . . . . . . . . . . . . . . . . . 579
5198-Tire circumference out of range error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581
5199-Timeout of first cycling TCU1 or TCU2 messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582
5202-Cranking line short circuit to power error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585
5203-Cranking line open circuit error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587
5204-Timeout of first cycling message C6_9_Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589
5205-Timeout of cycling message C6_9_Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592
5208-Timeout of first message EEC1 or EEC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595
5214-Parking brake error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597
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47829048B 15/06/2016
EN
SERVICE MANUAL
Dozer blade and arm
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
86
Contents
Dozer blade and arm - 86
[86.110] Dozer blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.1
[86.112] Moldboard blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.2
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86
Dozer blade - 110
836C AWD
836C
856C AWD
856C
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86.1 [86.110] / 1
Contents
Dozer blade - 110
TECHNICAL DATA
Dozer blade
FUNCTIONAL DATA
Dozer blade
SERVICE
Dozer blade
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Dozer blade and arm - Dozer blade
Dozer blade - General specification

Plate width 2350 mm (92.5 in) 2450 mm (96.5 in)
Plate height 765 mm (30.1 in) 870 mm (34.3 in)
Scraping depth 136.0 mm (5.4 in) 183.0 mm (7.2 in)
Max. ground clearance 509.0 mm (20.0 in) 547.0 mm (21.5 in)
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Dozer blade - Component identification
SS13G321 1
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1 Ball valve 6 Light bar
2 Hexagon nuts 9 Hydraulic line
3 Cover 10 Hydraulic line
4 Hexagon nut X68 Connector
5 Screw
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SS13G324 2

1 Dozer blade cylinder 7 Bushing
2 Safety bolt 8 Bushing
3 Bolt 9 Dirt scraper
4 Upper rod 10 Bushings
5 Swing arm 11 Dirt scraper
6 Mounting plate
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Dozer blade - Remove

WARNING
Heavy objects!
W0398A
CAUTION
Avoid injury!
Keep hands and feet clear of the machine during raising and lowering operations.
C0079A
WARNING
Escaping fluid!
Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or
other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or per-
forming work on the hydraulic system. Before applying pressure, make sure all connections are tight
and all components are in good condition. Never use your hand to check for suspected leaks under
pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your
doctor immediately.
W0178A
NOTE: Refer also to Dozer blade - Component identification (86.110).

NOTICE: A little amount of hydraulic fluid may flow out when the hydraulic lines are loosened. This should be collected
and properly disposed of.
1. Open the ball valve (1) and lower the front dozer blade.
2. Depressurize the hydraulic system.
3. Close the ball valve (1).
4. Detach the two hydraulic lines (9) and (10) from the
dozer blade cylinder and bind them together.
5. Close off the cylinder connections with stop plugs.
SS13G322 1
6. Unscrew the hexagon nut (2) and disconnect the ball

head of the check rod for the dozer plate position indi-
cator.
SS12F188 2
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7. Remove the cover (3) at the top of the front frame.

8. Remove the cable tie and detach the connector (X68)
of the light bar wiring.
SS13G323 3
9. Loosen the two upper hexagon nuts (4), remove the

screws (5), and take out the light bar (6).
SS12G194 4
10. Secure the dozer plate with suitable lifting gear.

11. Loosen the other screws and nuts and remove the
front equipment using the lifting gear.
SS12F191 5
Next operation:
or
Dozer blade - Disassemble (86.110).
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Dozer blade - Disassemble

WARNING
Heavy objects!
W0398A
Prior operation:
Dozer blade - Remove (86.110).

NOTE: Use suitable drift punches to drive out the bolts.
1. Fasten the front equipment to a support frame and set
the blade on the ground.
2. Secure the dozer blade cylinder (1) with the lifting gear.
3. Remove the safety bolt (2) and pull out the bolt (3).
4. Remove the dozer blade cylinder.
SS12F193 1
5. Secure the dozer plate with the lifting gear.

6. Loosen the safety bolt (2), pull out the bolt (3), and take
out the upper rod (4).
7. Set the bushings (7) aside.
SS13G325 2
8. Loosen the safety bolt (2) and pull out the bolt (3).
9. Remove the dozer plate.
10. Set the bushings (8) and the dirt scraper (9) aside.
SS13J001 3
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11. Secure the swing arm (5) with the lifting gear.
12. Loosen the safety bolt (2), take out the bolt (3), and
remove the swing arm and the upper rod (4).
13. Set the bushings (10) and the dirt scraper (11) aside.
14. Remove the front equipment mounting plate (6) from
the support frame.
SS13J002 4
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Dozer blade - Assemble

WARNING
Heavy objects!
W0398A
CAUTION
Pinch hazard!
C0044A

NOTICE: Check the bolts and bushings for wear or damage.
Check that the lubricating nipple is working.
NOTE: Use a suitable drift punch to drive in the bolts.
1. Fasten the front equipment mounting plate (6) to a sup-
port frame.
2. Bring the swing arm (5) and upper rod (4) into position
with the lifting gear.
3. Insert the bushings (10) in the mounting plate.
4. Insert the dirt scraper (9), insert the bolt (3), and secure
it with safety bolt (2).
SS13J002 1
5. Bring the dozer plate into position with the lifting gear.
6. Insert the bushings (8) in the swing arm (5).
7. Insert the dirt scraper (9), insert the bolt (3), and secure
it with the safety bolt (2).
SS13J003 2
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8. Insert bushing (7) into upper rod (4) and fasten it with
bolt (3) and safety bolt (2) to the dozer plate.
9. Bring the dozer blade cylinder (1) into position with the
lifting gear.
10. Insert the bolt (3) and secure it with the safety bolt (2).
11. Secure the front equipment with the lifting gear and
remove it from the support frame.
SS13J004 3
Next operation:
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Dozer blade - Install

WARNING
Heavy objects!
W0398A
CAUTION
Pinch hazard!
C0044A
WARNING
Escaping fluid!
Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or
other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or per-
forming work on the hydraulic system. Before applying pressure, make sure all connections are tight
and all components are in good condition. Never use your hand to check for suspected leaks under
pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your
doctor immediately.
W0178A

NOTICE: A little amount of hydraulic fluid may flow out when the hydraulic fluid lines are connected. This should be
collected and properly disposed of.
1. Using the lifting gear, bring the dozer blade up to the
assembly plate on the front frame. Pay attention to the
hydraulic lines when doing this.
2. Fasten the dozer plate with bolts and nuts.
3. Leave the two top holes free for mounting the light bar.
4. Tighten the bolts with 540 N·m (398 lb ft).
SS12F191 1
5. Bring the light bar (6) into position and fasten it to the
front frame using the two top screws (5) and hexagon
nuts (4).
6. Tighten the bolts with 540 N·m (398 lb ft).
SS12G194 2
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7. Attach the connector (X68) of the light bar wiring and

fasten the cable with cable tie.
8. Mount the cover (3) at the top of the front frame.
SS13G323 3
9. Remove the stop plugs from the hydraulic cylinder con-

nections.
10. Untie the hydraulic lines (9) and (10) and connect
them to the hydraulic cylinder.
11. Open the ball valve (1).
SS13G322 4
12. Insert the ball head of the check rod for the dozer plate
position indicator in the mounting link, and fasten it
with the hexagon nut (2).
13. Lower the lifting gear and remove any lifting acces-
sories.
14. Start the engine and move the dozer plate several
times to the top and bottom end positions, in order to
vent the hydraulic cylinders.
SS12F188 5
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Index
Dozer blade - 110

Dozer blade - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Dozer blade - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dozer blade - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Dozer blade - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dozer blade - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Dozer blade - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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47829048B 15/06/2016
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Moldboard blade - 112
836C AWD
836C
856C AWD
856C
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Contents
TECHNICAL DATA
Moldboard blade
FUNCTIONAL DATA
Moldboard blade
SERVICE
Moldboard blade
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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Dozer blade and arm - Moldboard blade
Moldboard blade - General specification

Drawbar
A-form weld construction
L-profile 125 mm (4.9 in) x 120 mm (4.7 in) x 140 mm (5.5 in) x 140 mm (5.5 in)
8 mm (0.31 in) 10 mm (0.39 in)
Slewing ring
Internal toothing, sealed roller turntable with zero-clearance bearing, no adjustment necessary
Drive Oil motor and blade turntable Oil motor and blade turntable
Slewing ring diameter 1150 mm (45.28 in) 1350 mm (53.15 in)
Rotating angle 360 ° 360 °
Moldboard blade
made of wear-resistant high-grade steel with hardened circular guide. Changeable separate edge cutter/border
blade.
Blade length 3355 mm (132.1 in) 3660 mm (144.1 in)
Blade height / thickness 526 mm (20.7 in) / 15 mm (0.6 in) 603 mm (23.7 in) / 20 mm (0.8 in)
Edge blade width / thickness 152 mm (6.0 in) / 19 mm (0.7 in) 152 mm (6.0 in) / 19 mm (0.7 in)
Screw diameter 16 mm (0.6 in) 16 mm (0.6 in)
Blade positions
Translational movement
to right 491.0 mm (19.3 in) 645 mm (25.4 in)
to left 708.0 mm (27.9 in) 755 mm (29.7 in)
Range over tires without articulation
right horizontal 1865 mm (73.4 in) 2375.0 mm (93.5 in)
left horizontal 1525 mm (60.0 in) 1685.0 mm (66.3 in)
Range over tires with articulation
right horizontal 2490 mm (98.0 in) 3235.0 mm (127.4 in)
left horizontal 2150 mm (84.6 in) 2545.0 mm (100.2 in)
max. bank angle
right 117 ° 100 °
left 76 ° 112 °
max. lift from ground level 394.0 mm (15.5 in) 480 mm (18.9 in)
max. digging depth 456.0 mm (18.0 in) 500 mm (19.7 in)
Cutting angle adjustment - hydraulic 49.5 ° 50 °
Ripper (optional)
Number of teeth 4 6
Width 900 mm (35.4 in) 1100.0 mm (43.3 in)
Ripper track movable
to left 420 mm (16.5 in) 580 mm (22.8 in)
to right 950 mm (37.4 in) 1200 mm (47.2 in)
Ripping depth 134 mm (5.3 in) 108.0 mm (4.3 in)
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Moldboard blade - Component identification
SS13G300 1
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2 Drawbar 212 Hydraulic line
3 Ball joint 213 Hydraulic line
4 Retaining plate 214 Hydraulic line
6 Screw 215 Hydraulic line
9 Cap 217 Hydraulic line
10 Lift cylinder yoke 220 Hydraulic line
11 Swivel cylinder yoke 221 Hydraulic line
12 Bushing 222 Hydraulic line
13 Detent pin 223 Hydraulic line
15 Saddle upper section 225 Hydraulic line
16 Shim 234 Hydraulic line
17 Shim 235 Hydraulic line
18 Bushing 237 Hydraulic line
19 Saddle lower section
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SS13G305 2
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1 Moldboard blade 23 Screw
2 Nut 24 Pin
3 Blade side shift cylinder 25 Nut
4 Lower slide 26 Spherical washer
5 Cover plate 27 Conical seat
6 Rotary distributor 28 End stop
7 Hydraulic motor 29 Slide bushing
8 Bracket 30 Bushing
9 Worm gear 31 Blade guide plate
10 Pitch adjustment cylinder 32 Slewing ring cover
11 Blade mounting 33 Drawbar
12 Stop spring 34 Slewing ring
13 End stop 37 Lowering control valves
14 Ripper 240 Hydraulic line
15 Bracket 241 Hydraulic line
16 Cotter pin 242 Hydraulic line
17 Pin 243 Hydraulic line
18 Spacer 244 Hydraulic line
19 Cotter pin 245 Hydraulic line
20 Ripper teeth 246 Hydraulic line
21 Pin 247 Hydraulic line
22 Circle
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Moldboard blade - Remove

WARNING
Heavy objects!
W0398A
NOTE:
Mark the hydraulic lines if necessary.
Refer also to Moldboard blade - Component identification (86.112).
NOTICE: A little amount of hydraulic fluid may flow out when the hydraulic lines are loosened. This should be collected
Protect detached hydraulic lines from dirt.
1. Swing the center equipment to the side and set it on
the ground using the related cylinders.
2. Detach the front-frame hydraulic lines (214), (215),
(216), and (217) to the lowering control valves, (224)
and (225) to the rotary distributor, and (237) to the
worm gear.
3. Pull the lines from the guides on the drawbar and place
them outside of the work area.
SS14J044 1
4. Loosen the screws and detach the ball joints (3) of the
lift and swing cylinders from the ball heads on the cen-
ter equipment.
5. Remove the adjusting disks.
SS12F138 2
6. Loosen the 4 screws and move the retaining plate (4)

of the center equipment ball joint.
SS12F139 3
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7. Secure the center equipment with blade and ripper (op-

tional) with lifting gear and place it aside.
SS12F140 4
8. Detach the hydraulic lines (222) and (223) from the

swing cylinder.
Secure the swing cylinder with lifting gear.
9. Remove the 4 screws (6) and take off the swing cylin-
der.
SS13G302 5
10. Detach the hydraulic lines (212) and (213) right and
(220) and (221) left from the lift cylinder.
SS13G303 6
11. Secure the lift cylinder with lifting gear.

12. Remove the 4 screws (8) and take out the swing cylin-
der.
SS12F143 7
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13. Remove the 4 mounting screws of the cap (9) and take
off the cap (9).
14. Pull out the lift cylinder yoke (10) and the swivel cylin-
der yoke (11) and put the bushings (12) aside.
SS12F144 8
15. Detach the hydraulic lines (234) and (235) at the de-
tent pin (13) that locks the saddle.
SS13G304 9
16. Loosen the two screws and take out the detent pin
(13).
17. Secure both parts of the saddle with lifting gear and
take out the six screws (14).
18. Take off the saddle upper section (15) and take off the
shims (16). Remove the screws and take off shim (17)
and bushing (18).
19. Lower the saddle lower section (19).
SS12F146 10
Next operation:
or
Moldboard blade - Disassemble (86.112).
47829048B 15/06/2016
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Moldboard blade - Disassemble

WARNING
Heavy objects!
W0398A
Prior operation:
Moldboard blade - Remove (86.112).
NOTE:
Refer also to Moldboard blade - Component identification (86.112).
NOTE: Use suitable drift punches to drive out the bolts.
NOTICE: Protect detached hydraulic lines from dirt.
1. Fasten the center equipment to a slewing frame with
sufficient load capacity.
2. Push the moldboard blade (1) to the side, so that the
cylinder piston engages.
3. Remove the nut (2) from the blade side shift cylinder
(3) and lift off the disk and the spacer.
SS13G306 1
4. Secure the moldboard blade (1) with lifting gear and

move it sideways out of the mounting.
5. Pay attention to the lower slide (4) when it comes out
of the pilot bushing.
SS13G307 2
6. Remove the cover plates (5) from the hydraulic lines.
SS12F151 3
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7. Detach the hydraulic lines (242) and (243) between the

rotary distributor lower section (6) and the pitch adjust-
ment cylinder (10).
8. Detach the hydraulic lines (244) and (245) between the
rotary distributor lower section (6) and the blade side
shift cylinder (3).
SS12F152 4
9. Detach the hydraulic lines (240), (241), (246), and

(247) from the hydraulic motor (7) of the slewing ring,
and from the rotary distributor upper section (6).
SS12F153 5
10. Loosen the screws and remove the rotary distributor

(6).
To do this, pull out the bracket (8) from the seat in the
mounting.
SS12F154 6
11. Loosen the screws and disconnect the hydraulic mo-

tor (7) of the slewing ring from the worm gear (9).
12. Take off the O-ring.
SS12F155 7
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13. Turn the drawbar through 90 °, and loosen the safety

bolt.
14. Take out the bolt and detach the pitch adjustment
cylinder (10) from the blade mounting (11).
15. Take out the inner seals and bushings.
SS12F156 8
16. Turn the drawbar through another 90 °.

17. If an optional ripper is being installed, remove the stop
springs (12) and the end stop (13).
18. Bring the ripper (14) into operating position and re-
move the bracket (15).
SS13G308 9
19. Remove the cotter pin (16) from the pins and turn the
blade mounting (11) so that the pins (17) can be re-
moved.
20. Remove the spacers (18) and the ripper (14).
SS13G309 10
21. Remove the cotter pins (19) to detach the ripper teeth
(20) from the ripper (14).
SS13G310 11
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22. Secure the blade mounting (11) with the lifting gear.
23. Remove the screws of the pin (21) from the circle (22).
SS13G311 12
24. Insert the two screws (23) (more than 140 mm (5.5 in)
in length) in threaded holes and pry out the pin (21).
SS12F161 13
25. Detach the blade mounting (11) from the circle (22).
26. Remove the spacers and seals.
SS13G312 14
27. Loosen the safety bolt, take out the pin (24), and de-
tach the pitch adjustment cylinder (10) from the circle
(22).
28. Take out the inner seals and the bushings.
SS12F163 15
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29. Loosen the nut (25), remove the spherical washer (26)
and the conical seat (27), and take out the blade side
shift cylinder (3).
SS12F164 16
30. Loosen the screws, remove the end stops (28), and
take out the slide bushings (29).
SS12F165 17
31. Using a suitable puller, remove the bushings (30) from

the holes at the ends of the blade mounting (11).
SS12F166 18
32. Remove the cover, loosen the screws, and remove the
two blade guide plates (31).
SS12F167 19
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33. Loosen the six screws and detach the slewing ring
cover (32) from the drawbar (33).
SS12F168 20
34. Secure the circle (22) with the lifting gear.

35. Loosen the screws and remove the circle (22).
SS12F169 21
36. Insert the two ring bolts at 180 ° from each other, in
order to secure the slewing ring (34) with the lifting
gear.
37. Loosen the screws from the drawbar (33) and remove
the slewing ring.
SS12F170 22
38. Turn the drawbar through 180 °.

39. Loosen the four screws and remove the worm gear
(9).
SS12F171 23
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40. Detach hydraulic lines (240), (241), (246), and (247)

from lowering control valves (37).
41. Loosen the screws and remove the lowering control
valves.
42. Using the lifting gear, hold the drawbar (33) and lift it
away from the slewing frame.
SS13G313 24
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Moldboard blade - Assemble

WARNING
Heavy objects!
W0398A
CAUTION
Pinch hazard!
C0044A
NOTE:
Refer to Moldboard blade - Component identification (86.112).
NOTE: Use a suitable drift punch to drive in the bolts.
NOTICE: Protect detached hydraulic lines from dirt.
1. Fasten the drawbar (33) to a slewing frame with suffi-
cient load capacity.
2. Mount the two lowering control valves (37).
3. Lay out the hydraulic lines (240), (241), (246), and
(247) and connect them to the lowering control valves.
SS13G313 1
4. Mount the worm gear (9) and tighten the four screws.
SS12F171 2
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6. Mount the slewing ring (34) and fasten it with four bolts
offset at 90 °.
7. Rotate the slewing ring through a complete turn. Bring
the color-coded teeth up to the gear wheel, and check
that there is a gap of 0.300 mm (0.012 in) between the
teeth.
SS13G314 3
8. Insert and tighten the other bolts that connect the slew-
ing ring (34) to the drawbar (33).
SS12F174 4
10. Fasten the circle (22) to the slewing ring.

11. First, insert and tighten the four bolts offset at 90 °.
13. Tighten the other bolts in the direction of rotation.
SS12F169 5
14. Mount the slewing ring cover (32).

15. Tighten the bolts on the drawbar (33).
16. Fill it with grease (3 greasing points on the drawbar
and 1 greasing point below the drawbar).
SS12F168 6
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17. Fasten the blade mounting to a support frame.

18. Fasten the two blade guide plates (31).
20. Attach the cover.
SS12F167 7
21. Using a plastic mallet, drive the bushings (30) into the
holes at the ends of the blade mounting (11).
22. Apply grease generously.
SS12F175 8
23. Install the blade slide bushings (29).

24. Attach and tighten the end stops.
SS13G315 9
25. Mount the blade side shift cylinder (3) with one of the
two conical seats (27).
26. Insert the two centering pins in the holes provided.
SS14J043 10
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27. Insert the other conical seat (27), insert the spherical
washer (26), and tighten the nut (25).
SS13G316 11
28. Set the pitch adjustment cylinder (10) with the inner
bushings and the seals on the circle (22).
29. Insert the pin (24) and secure it with the bolt.
SS12F163 12
30. Place the blade mounting (11) and the seals on the
circle (22).
SS13G312 13
31. Insert the spacers (39) as required.
SS12F178 14
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32. WARNING
Avoid injury!
To prevent frostbite, always wear gloves when
you handle frozen parts.
Failure to comply could result in death or seri-
ous injury.
W1218A
Insert the pins (21) after chilling to -55 °C (-67.0 °F).
SS12F179 15
33. Fasten the screws of the pin (21) for the blade mount-
ing (11) to the circle (22).
SS13G311 16
34. For the optional ripper, secure the ripper teeth (20) to
the ripper (14) with the cotter pins (19).
SS13G310 17
35. Turn the blade mounting (11).

36. Insert the pin (17), the spacers (18), and the ripper
(14).
37. Knock the cotter pin (16) into the pin.
SS13G309 18
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38. Insert the bracket (15) for the ripper (14) in rest posi-
tion.
SS13G317 19
39. Bring the ripper (14) into rest position or working po-
sition and block them with the end stop (13).
40. Mount the stop spring (12).
SS13G308 20

42. Fasten the pitch adjustment cylinder (10) with the in-
ner bushings and seals to the blade mounting (11).
SS13G318 21
43. Insert the pin and tighten the safety bolt.
SS13N025 22
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44. Turn the drawbar (33) through another 90 °.

45. Insert the O-ring (40) and install the hydraulic motor
of the slewing ring.
NOTE: Ensure the correct positioning of the hydraulic mo-
tor shaft and adapter relative to the worm gear.
SS13J046 23
46. Tighten the screws of the hydraulic motor (7) of the

slewing ring on the worm gear (9).
SS13J047 24
47. Install the rotary distributor on the bracket (8).

48. Insert the bracket (8) in the seat in the rotating ball
bearing.
SS13G320 25
49. Tighten the screws of the rotary distributor (6) on the

drawbar (33).
SS13J048 26
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50. Attach the hydraulic lines (240) and (241) of the top
lowering control valve to the hydraulic motor (7) of the
slewing ring and the hydraulic lines (246) and (247) of
the bottom lowering control valve to the upper section
of the rotary distributor (6).
SS12F153 27
51. Connect the hydraulic lines (242), (243), (244), and

(245) between the rotary distributor lower section (6),
the pitch adjustment cylinder, and to the blade side
shift cylinder.
SS12F152 28
52. Attach the hydraulic line cover plates (5).
SS12F151 29
53. Lift the blade with lifting gear and bring it from the side
into contact with the blade mounting.
54. Ensure that the lower slide (4) is correctly inserted in
the pilot bushing.
SS13G307 30
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55. Push in the moldboard blade (1) from the side and
insert the upper rail in the guide plates (31) and the
lower slide in the other guide bushing, until the cylin-
der piston enters the hole in the blade.
SS12F185 31
56. Insert the spacer and the disk. Tighten the nut (2) and
move the moldboard blade (1) to the other side, to
bring the piston out of the cylinder.
57. Tighten the nut (2) of the blade side shift cylinder (3)
on the moldboard blade, then loosen slightly.
58. With suitable lifting gear, lift the center equipment
away from the slewing frame.
SS13G306 32
Next operation:
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Moldboard blade - Install

WARNING
Heavy objects!
W0398A
CAUTION
Pinch hazard!
C0044A
NOTE: Refer also to Moldboard blade - Component identification (86.112).

NOTICE: A little amount of hydraulic fluid may flow out when the hydraulic lines are installed. This should be collected
1. Secure the saddle lower section (19) with lifting gear
and raise it till it touches the front frame.
2. Insert the shims (16) and fasten the saddle upper sec-
tion (15) with the screws (14).
3. Insert the bushing (18) and the shim (17) and fasten it.
4. Fasten the detent pin (13) to the saddle upper section
using the two bolts and the lock washers.
SS12F146 1
5. Insert the bushings (12), lift cylinder yoke (10), and the
swivel cylinder yoke (11).
6. Mount the cap (9).
7. Tighten the bolts.
SS12F144 2
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86.2 [86.112] / 27
8. Connect the hydraulic lines (234) and (235) to the de-

tent pin (13).
SS13G304 3
9. Bring the lift cylinder into position with the lifting gear.
10. Mount the bushings and covers.
11. Tighten the screws (8).
SS12F143 4
12. Attach the hydraulic lines (220) and (221) on left and
(212) and (213) on right of the lift cylinder.
SS13G303 5
13. Bring the swing cylinder into position with the lifting
gear.
14. Mount the bushings and covers.
15. Tighten the 4 screws (6).
16. Attach the hydraulic lines (222) and (223) to the swing
cylinder.
SS13G302 6
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17. Lift the center equipment, the moldboard blade, and

the ripper (optional) with the lifting gear.
18. Place the retaining plate (4) and the bushing (20) with
the two O-rings on the center equipment ball joint and
smear generously with grease.
SS12F147 7
19. Move the moldboard blade and the ripper (optional)

with the lifting gear until the ball joint and bushing
comes into the seat in the front frame.
SS12F140 8
20. Fasten the retaining plate (4) to the front frame and
tighten the bolts.
SS12F139 9
22. Connect the ball joints (3) of the lift cylinders and the
swing cylinder to the ball joints of the center equip-
ment.
23. Insert the appropriate adjusting disks and tighten the
bolts.
SS12F138 10
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25. Push the hydraulic lines (214), (215), (216), and (217)
of the front frame through the guides onto the drawbar
and connect them to the lowering control valves, then
hydraulic lines (224) and (225) to the rotary distributor,
and hydraulic line (237) to the turning gear.
SS14J044 11
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Index

Moldboard blade - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Moldboard blade - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Moldboard blade - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Moldboard blade - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Moldboard blade - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Moldboard blade - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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47829048B 15/06/2016
EN
SERVICE MANUAL
Tools
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
89
Contents
Tools - 89
[89.128] Ripper assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.1
47829048B 15/06/2016
89
Tools - 89
Ripper assembly - 128
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
89.1 [89.128] / 1
Contents
Tools - 89
TECHNICAL DATA
Ripper assembly
FUNCTIONAL DATA
Ripper assembly
SERVICE
Ripper assembly
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Tools - Ripper assembly
Ripper assembly - General specification

Ripping width, tooth centre – tooth 2000.0 mm (78.7 in) 2220.0 mm (87.4 in)
centre
Ripping depth 307.0 mm (12.1 in) 328.0 mm (12.9 in)
Number of teeth 3/5 3/5
Tooth gap 1000 mm (39.4 in) / 500 mm (19.7 in) 1110 mm (43.7 in) / 555 mm (21.9 in)
47829048B 15/06/2016
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Ripper assembly - Component identification
SS13J014 1
47829048B 15/06/2016
89.1 [89.128] / 4

3 Bolt 20 Hexagon head bolt
4 Bolt 22 Hexagon nut
5 Hydraulic cylinder 23 Disk
13 Spacer bushing 25 Lock washer
14 Scraper ring 40 Ball valve
19 Cap bolt
47829048B 15/06/2016
89.1 [89.128] / 5
SS13J019 2

1 Spring 7 Ripper
2 Safety bolt 8 Roll pin
3 Cover 9 Bolt
4 Ring 10 Roll pin
5 Folding cotter 11 Tooth
6 Bolt
47829048B 15/06/2016
89.1 [89.128] / 6
Ripper assembly - Remove

WARNING
Heavy objects!
W0398A
CAUTION
Avoid injury!
Keep hands and feet clear of the machine during raising and lowering operations.
C0079A
Prior operation:
Remove the two rear wheels (refer to Rear wheels - Remove (44.520)).
NOTE: Refer also to Ripper assembly - Component identification (89.128).

1. Raise the rear of the grader and place it on a suitable
support frame so that the tandem drive swings out and
the bolt can be removed.
NOTE: View with the rear ripper removed.
SS13J015 1
2. Open the ball valve (40), lower the rear ripper, and de-
pressurize the hydraulic system.
3. Secure the rear ripper with lifting gear.
4. Unscrew the self-locking hexagon nuts (22).
5. Remove the cap bolt (19) and pull out the bolt (4) of the
hydraulic cylinder (5).
6. When doing so, pay attention to the two scraper rings
(14) and the spacer bushings (13).
NOTE: Use a suitable drift punch to drive out the bolt (4).
SS13J016 2
47829048B 15/06/2016
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7. Loosen the hexagon-head bolt (20) and remove it along

with the disk (23) and the lock washer (25).
8. Pull out the bolt (3) using a suitable tool (drift punch or
puller).
SS12F200 3
9. Lift off the rear ripper with lifting gear.

10. Close the ball valve.
11. The hydraulic cylinders can be left on the vehicle with-
out opening the hydraulic lines.
Next operation:
Ripper assembly - Install (89.128).
or
Ripper assembly - Disassemble (89.128).
47829048B 15/06/2016
89.1 [89.128] / 8
Ripper assembly - Disassemble

WARNING
Heavy objects!
W0398A
Prior operation:
Ripper assembly - Remove (89.128).

1. Lift the rear ripper with lifting gear with adequate ca-
pacity.
2. Detach the springs (1).
3. Loosen the safety bolt (2), and remove the cover (3)
from the ripper.
SS13J018 1
4. Swivel the ring (4) upwards and remove the folding cot-
ter (5).
5. Remove the bolt (6) from the ripper (7).
6. Hold the ripper while lowering.
SS12G009 2
7. Hold the ripper (7).

8. Knock out the roll pin (8) with a pin punch.
9. Take out the bolt (9) and remove the ripper.
SS12G010 3
47829048B 15/06/2016
89.1 [89.128] / 9
10. Knock out the roll pin (10) with a pin punch.
11. Disconnect the tooth (11) from the ripper (7).
12. Repeat the steps 4 to 11 to remove the other rippers.
SS12G011 4
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Ripper assembly - Assemble

WARNING
Heavy objects!
W0398A

1. Lift the rear ripper with lifting gear with adequate ca-
pacity.
2. Fasten the tooth (11) to the ripper (7) using the roll pin
(10).
SS12G011 1
3. Hold the ripper (7) and guide it into seat.

4. Insert the pin (9) and secure it with the roll pin (8).
SS12G010 2
5. Bring the ripper (7) into operating position.

6. Insert the pin (6), secure it with the folding cotter (5)
and close the ring (4).
7. Repeat the steps 2 to 6 for the other rippers.
SS12G009 3
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89.1 [89.128] / 11
8. Mount the cover (3) on the ripper.

9. Tighten the mounting bolt (2) and attach the springs (1).
SS13J018 4
Next operation:
Ripper assembly - Install (89.128).
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89.1 [89.128] / 12
Ripper assembly - Install

WARNING
Heavy objects!
W0398A
CAUTION
Pinch hazard!
C0044A

1. Raise the rear of the grader and place it on a suitable
support frame so that the tandem drive swings out and
the bolt can be mounted.
SS13J015 1
2. Lift the rear ripper with lifting gear and bring the holes
into line.
3. Insert the bolt (3).
SS13J017 2
4. Secure the bolt (3) with the disk (23), the lock washer
(25), and the hexagon head bolt (20).
SS12F200 3
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5. Open the ball valve (40).

6. Fasten the hydraulic cylinder (5) to the rear ripper with
the bolt (4).
7. When doing so, pay attention to the two scraper rings
(14) and the spacer bushings (13).
8. Align the bolt (4) and secure it with the cap bolt (19)
and a new self-locking hexagon nut (22).
SS13J016 4
9. Mount the two rear wheels.

10. Lower the lifting gear and remove any lifting acces-
sories.
11. Raise the rear end, remove the supports, and lower
the rear of the grader.
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Index
Tools - 89

Ripper assembly - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Ripper assembly - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Ripper assembly - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ripper assembly - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ripper assembly - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Ripper assembly - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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47829048B 15/06/2016
EN
SERVICE MANUAL
Platform, cab, bodywork, and decals
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
90
Contents
Platform, cab, bodywork, and decals - 90
[90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1
[90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2
[90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3
47829048B 15/06/2016
90
Cab - 150
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
90.1 [90.150] / 1
Contents
Cab - 150
FUNCTIONAL DATA
Cab
SERVICE
Cab
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cab floor
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
47829048B 15/06/2016
90.1 [90.150] / 2
Platform, cab, bodywork, and decals - Cab
Cab - Static description

The noise-insulated driver's cab is mounted on an elastically supported operating platform. Entry/exit to the cab is
through a lockable door on either side. There are sun-blinds and a heater to ensure a comfortable working climate.
Ventilation is by external or recirculated air; the external air is drawn in through a filter system.
Optionally, the cab can be equipped with an air conditioning system.
47829048B 15/06/2016
90.1 [90.150] / 3
Cab - Remove
WARNING
Heavy objects!
W0398A
Prior operation:
Open the hood and bring it into service position 2.
Disconnect the batteries (refer to Battery - Remove (55.302)).
Remove the floor mats.
1. Remove the four wheel cover brackets (2) from the rear
axle.
SS14E236 1
2. Remove the corner panels (3) from the cab floor.
SS12G181 2
3. Remove the side panels (4) from the cab floor.
SS12G182 3
47829048B 15/06/2016
90.1 [90.150] / 4
4. Disconnect the electrical connectors (5) from the un-

derside right or left of the cab floor.
X14 and X15 to cab
E3.9 Left work lamp (optional)
E4.9 Right work lamp (optional)
SS12J009 4
5. Disconnect the ground strap (6) from the rear panel of

the cab.
SS12G184 5
6. Cut the cable tie (7) and loosen the cable clamp (8).
7. Loosen the hexagon-head screw (9) and pull the bow-
den cable wire out of the retainer (10).
SS14H001 6
8. Pull off the hoses (11) from the washer pumps.

NOTE: Mark the two hoses for the windshield washer sys-
tems.
SS14H002 7
9. Disconnect the rearview camera wire harness in the

cab (if machine is equipped with a rearview camera).
47829048B 15/06/2016
90.1 [90.150] / 5
10. Attach four eye bolts (12) to the cab roof and attach
the sling gear to the eye bolts.
11. Secure the cab using suitable lifting gear.
SS12G185 8
12. Remove the right side storage compartment (13).
SS14E222 9
13. After removing the mounting screws, carefully lift the

storage compartment and disconnect the lines from
the optional 12 V power outlet (15).
14. Lift the storage compartment (14) out of the cab, to-
gether with the bowden cable for the hood release.
SS12G187 10
15. Pull off the heating/ventilation hose (16) on left or right

of the B-pillars.
SS12J010 11
47829048B 15/06/2016
90.1 [90.150] / 6
16. Unscrew the six hexagon nuts (17) (three on each

side) and two hexagon nuts (18) (front left and right)
and remove the washers (20).
17. Unscrew the four hexagon-head bolts (19) (two on
each side).
NOTE: The two rear hexagon nuts (left and right) are lo-
cated in the cab.
SS12G189 12
NOTICE: When lifting the cab, take care with the two ca-
bles (5) and hoses (11) for the windshield washer system,
particularly when pulling them through the cab floor.
SS12G190 13
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Cab - Install
WARNING
Heavy objects!
W0398A
CAUTION
Pinch hazard!
C0044A
1. Bring the holes in the cab into line with the holes in the
cab floor.
NOTICE: When setting the cab down, take care with the
two cables (5) and hoses (11) for the windshield washer
system, particularly when pushing them through the cab
floor.
NOTE: Use longer bolts or an assembly lever for aligning
the cab.
SS12G190 1
2. Check that the silent blocks are in place, then check for
damage and replace if necessary.
3. Insert the three right side mounting bolts, from the top
downward.
4. Fasten the cab to the cab floor with the four hexagon-
head bolts (19) (two on each side).
SS12J011 2
5. On the left side, insert the front mounting bolt from the
top downward and the two rear mounting bolts with the
washer (20) from the bottom upward.
6. Mount the washers (20) and tighten the hexagon nuts
(17).
7. At the front left and right, insert the bolts (M16x20),
screw on the hexagon nuts (18) and tighten them.
SS12J012 3
47829048B 15/06/2016
90.1 [90.150] / 8
8. Attach the heating/ventilation hose (16) on the left or

right of the B-pillars.
SS12J010 4
9. Install the right side storage compartment (13).
SS14E222 5
10. Push the bowden cable wire through the rear panel of
the cab.
11. Align the storage compartment and connect the lines
to the optional 12 V power outlet (15).
12. Fasten the storage compartment (14).
SS12G187 6
13. Remove the sling gear and the eye bolts (12).
SS12G195 7
14. Connect the rearview camera wire harness in the cab

(if machine is equipped with a rearview camera).
47829048B 15/06/2016
90.1 [90.150] / 9
15. Lay out the two hoses (11) for the windshield washer
reservoir and follow the markings to attach them to the
washer pumps.
NOTICE: Check that the hoses are free of tension and that
there are no kinks.
SS14H002 8
16. Connect the ground strap (6) to the rear panel of the
cab.
SS12G184 9
17. Reconnect the electrical connectors (5) on the under-

side right or left of the cab floor.
X14 and X15 to cab
E3.9 Left work lamp (optional)
E4.9 Right work lamp (optional)
SS12J009 10
18. Loosen the hexagon-head screw (9) if necessary, and

pass the bowden cable wire through the retainer (10).
19. Using the screw (9) and the additional cable clamp
(8), attach the cable to the release lever of the hood-
locking mechanism.
20. Connect the existing cable to the bowden cable with
the cable tie (7).
SS14H001 11
47829048B 15/06/2016
90.1 [90.150] / 10
21. Mount the cab floor side panels (4).
SS12G182 12
22. Mount the corner panels (3) on the cab floor.
SS12G181 13
23. Fasten the four wheel cover brackets (2) at the rear
axle.
SS14E236 14
24. Mount all four rear wheels.
SS13J041 15
47829048B 15/06/2016
90.1 [90.150] / 11
25. Attach the two rear wheel covers to the previously

mounted brackets using the mounting bolts (1).
SS14E208 16
Next operation:
Connect the batteries (refer to Battery - Install (55.302)).
Place the floor mats in the cab.
Close the hood.
47829048B 15/06/2016
90.1 [90.150] / 12
Cab floor - Remove

WARNING
Heavy objects!
W0398A
WARNING
Chemical hazard!
When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.
Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect
fluids in proper containers. Obey all local and environmental regulations when disposing of chemi-
cals.
W0371A
WARNING
Pressurized system!
Refrigerant under pressure. Service, repair, or recharging must be performed only by trained service
technician.
W1180A
Prior operation:
Cab - Remove (90.150).
Engine hood panel rear support - Remove (90.100).
NOTICE: Hydraulic fluid may flow out when the hydraulic lines are loosened. This should be collected and properly
disposed of.
NOTE: Drain off hydraulic fluid and engine coolant.
If the optional air conditioning system is installed, drain off the refrigerant.
1. Loosen the mounting bolts (1) and take off the cover on
hydraulic lines (2).
SS12G196 1
47829048B 15/06/2016
90.1 [90.150] / 13
2. Disconnect the hydraulic lines from the hydraulic con-

trol block to the front frame, close them off, and raise
them, so that there are no obstructions when you re-
move the platform.
NOTE: Attach identifying markers to these lines before re-
moval, to prevent confusion when reinstalling.
SS12G013 2
3. Detach the cab floor grounding strap (6) from the frame.
4. Screw the four M20 eye bolts (7) into the cab floor.
SS14H004 3

brake pressure reservoirs (7).
6. Loosen the hose clamps (8).
7. Detach the hydraulic lines (282) and (284) from the rear
axle.
SS14F023 4
8. Detach the hydraulic line (291) from the parking brake

pressure reservoir (7).
9. Detach the hydraulic line from the flushing circuit pres-
sure reservoir (9).
10. Loosen the hose clamps (8).
rear axle.
SS14F024 5
47829048B 15/06/2016
90.1 [90.150] / 14
12. Detach the hydraulic hose from the double gear pump
for the brake (10).
SS12J015 6
13. Detach the left cover from the control console.

steering servo.
SS12G200 7
15. Detach the hydraulic line (350) from the left fan motor
(11).
SS14H005 8
16. Detach the hydraulic lines (228), (229), (230), (231),

and (234) from the LS valve block.
SS12J019 9
47829048B 15/06/2016
90.1 [90.150] / 15
17. Detach the hydraulic line (264) from the 12 bar

(174.0 psi) safety valve to the hydraulic fluid tank.
SS12G203 10
18. Detach the coolant line (12) (air conditioner to air

conditioner compressor) from the air conditioner
compressor.
19. Detach the coolant line (13) (air conditioner to filter
drier) from the filter drier (14).
SS14F028 11
SS14F027 12
20. Detach the heater return line (15) from the engine
coolant hose.
SS12G205 13
47829048B 15/06/2016
90.1 [90.150] / 16
21. Detach the heater feed line (16) from the engine block.
SS14H006 14
22. Detach the emergency steering hydraulic line (257)

(steering servo to collector block) from the collector
block (17).
SS12G207 15
23. Detach the two return lines (226) and (227) from the
return collector block (18).
SS12J017 16
24. Secure the cab floor (19) with a suitable lifting gear
and raise it slightly.
SS14H007 17
47829048B 15/06/2016
90.1 [90.150] / 17
25. Pull out the hydraulic lines (254) and (255) (steering
servo to steering cylinder) along the hose bundle.
SS12J018 18
26. Lift the cab floor, checking for any cable ties that may
still be attached.
27. Set the cab floor down on suitable trestles.
SS12G211 19
47829048B 15/06/2016
90.1 [90.150] / 18
Cab floor - Install

WARNING
Heavy objects!
W0398A
WARNING
Chemical hazard!
When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.
Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect
fluids in proper containers. Obey all local and environmental regulations when disposing of chemi-
cals.
W0371A
WARNING
Pressurized system!
Refrigerant under pressure. Service, repair, or recharging must be performed only by trained service
technician.
W1180A
CAUTION
Pinch hazard!
C0044A
1. Check the silent blocks (20) and the sleeves (21) for
damage.
2. Replace the silent blocks if necessary.
SS12G212 1
3. Bring the cab floor over the frame and hold the hy-
draulic and the electrical lines aside.
SS12G211 2
47829048B 15/06/2016
90.1 [90.150] / 19
4. Lower the cab floor (19) so that access is still possible

to the underside.
SS14H007 3
5. Lay out the hydraulic lines (254) and (255) (steering

cylinders to steering servo) along the existing hose
bundle to the steering servo.
6. Check that they are free of tension and that there are
no kinks.
SS12J018 4
7. Lower the cab floor further and align it with the holes
in the frame using mounting bolts and/or an assembly
lever.
SS14H008 5
8. Attach the two return lines (226) and (227) to the return
collector block (18).
SS12J017 6
47829048B 15/06/2016
90.1 [90.150] / 20
9. Attach the hydraulic line (264) ( 12 bar (174.0 psi)

safety valve to hydraulic-fluid tank) to the hydraulic-fluid
tank.
SS12G203 7
10. Attach the heater return line (15) to the engine coolant
hose.
SS12G205 8
11. Attach the heater feed line (16) to the engine block.
SS14H006 9
12. Attach the hydraulic line (291) to the parking brake

pressure reservoir (7).
13. Attach the hydraulic line to the flushing circuit pressure
reservoir (9).
14. Fasten the hose clamps (8).
15. Attach the hydraulic lines (283) and (285) to the rear
axle.
SS14F024 10
47829048B 15/06/2016
90.1 [90.150] / 21
16. Fasten the hydraulic hoses to the frame with the hose
clamp at a distance of (L) = 380 mm (15.0 in).
SS14H009 11
17. Reconnect the two connectors (3) and (4) on the right
under the cab floor.
SS12G231 12
18. Attach the emergency steering hydraulic line (257)

(steering servo to collector block) to the collector block
(17).
SS12G207 13
47829048B 15/06/2016
90.1 [90.150] / 22
19. Attach the coolant line (12) (air conditioner to air condi-
tioner compressor) to the air conditioner compressor.
20. Attach the coolant line (13) (air conditioner to filter
drier) to the filter drier (14).
SS14F028 14
SS14F027 15
21. Attach the hydraulic hose to the double gear pump for
brake (10).
SS12J015 16
22. Attach the hydraulic lines (254) and (255) to the steer-
ing servo.
23. Attach the left cover of the control console.
NOTE: If the hose markings are no longer visible, the hy-
draulic hose with the 90 ° connection is to be connected to
the lower nipple, and the hydraulic hose with the 45 ° con-
nection to the upper nipple of the steering servo.
SS12G200 17
47829048B 15/06/2016
90.1 [90.150] / 23
24. Attach the hydraulic line (350) to the left fan motor
(11).
SS14H005 18
25. Connect the hydraulic lines to the LS valve block as

follows:
• (228) to XV1
• (229) to XV2
• (230) to S1
• (231) to S2
• (234) to N3
SS12J019 19
26. Plug in the connector (5) on the rear left of the cab
floor and lock it.
SS12J020 20
27. Unscrew the four M20 eye bolts (7) from the cab floor.
28. Connect the cab floor grounding strap (6) to the frame.
29. Install the rear panel.
Refer to Engine hood panel rear support - Install
(90.100).
SS14H004 21
47829048B 15/06/2016
90.1 [90.150] / 24
30. Attach the hydraulic lines (277) and (278) to the brake
pressure reservoirs (7).
31. Mount the hose clamps (8).
32. Attach the hydraulic lines (282) and (284) to the rear
axle.
SS14F023 22
33. Fasten the hydraulic hoses to the frame with the hose
clamp at a distance of (L) = 380 mm (15.0 in).
SS12J200 23
34. Connect the hydraulic lines to the hydraulic control

block. (Refer to Distributor and lines - Component
identification (35.310)).
SS12G013 24
35. Mount the cover on the hydraulic lines (2) using the
mounting screws (1).
SS12G196 25
Next operation:
Cab - Install (90.150).
Fill with hydraulic fluid.
47829048B 15/06/2016
90.1 [90.150] / 25
Fill with engine coolant.

Pour in refrigerant if the optional air conditioning system is installed.
47829048B 15/06/2016
90.1 [90.150] / 26
Index
Cab - 150
Cab - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cab - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cab - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cab floor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cab floor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
47829048B 15/06/2016
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Mechanically-adjusted operator seat - 120
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
90.2 [90.120] / 1
Contents
SERVICE
Mechanically-adjusted operator seat

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
47829048B 15/06/2016
90.2 [90.120] / 2
Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat
Mechanically-adjusted operator seat - Remove

Prior operation:
Disconnect the batteries (refer to Battery - Remove (55.302)).
1. If available, carefully pull the driver seat cable out of the

side console and disconnect it (X110).
SS12G214 1
2. Unscrew the four bolts and remove the driver seat.
SS12G215 2
47829048B 15/06/2016
90.2 [90.120] / 3
Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat
Mechanically-adjusted operator seat - Install

1. Fasten the operator seat to the cover with the four bolts.
SS12G215 1
2. If available, connect the operator seat cable to the con-

nector (X110).
3. Push the connector into the side console housing.
SS12G214 2
Next operation:
Connect the batteries (refer to Battery - Install (55.302)).
Carry out a function test.
47829048B 15/06/2016
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Index

Mechanically-adjusted operator seat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Mechanically-adjusted operator seat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47829048B 15/06/2016
90.2 [90.120] / 5
47829048B 15/06/2016
90.2 [90.120] / 6
Engine hood and panels - 100
836C AWD
836C
856C AWD
856C
47829048B 15/06/2016
90.3 [90.100] / 1
Contents
SERVICE
Hood
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine hood panel rear support
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
47829048B 15/06/2016
90.3 [90.100] / 2
Platform, cab, bodywork, and decals - Engine hood and panels
Hood - Remove
WARNING
Heavy objects!
W0398A
1. From the cab, release the engine hood, and open it.
NOTE: If the bowden cable is faulty, the hood can be re-
leased on the left of the vehicle using a hook.
SS12D526 1
2. Secure the hood with suitable lifting gear and open it.
3. Disconnect the rearview camera wire harness (if ma-
chine is equipped with a rearview camera).
SS14E235 2
3. Loosen the screw (1) on the sliding rod and the

hexagon nut (2) on the gas-operated strut.
4. Loosen the two screws (3) that fix the hood to the rear
frame and put the plate (4) aside.
SS14H011 3
47829048B 15/06/2016
90.3 [90.100] / 3
4. Loosen the screw (1) on the sliding rod and the

hexagon nut (2) on the gas-operated strut.
5. Loosen the two screws (3) that fix the hood to the rear
frame and put the plate (4) aside.
SS14H010 4
47829048B 15/06/2016
90.3 [90.100] / 4
Hood - Install
WARNING
Heavy objects!
W0398A
1. Using suitable lifting gear, lift the engine hood onto the
frame, and align it.
SS14E235 1
2. Place the plate (4) and fasten the hood to the frame
using the two bolts (3).
3. Fasten the screw (1) of the sliding rod and the hexagon
nut (2) of the gas-operated strut to the bracket on the
frame.
SS14H011 2
4. Place the plate (4) and fasten the hood to the frame
using the two bolts (3).
5. Fasten the screw (1) of the sliding rod and the hexagon
nut (2) of the gas-operated strut to the bracket on the
frame.
6. Connect the rearview camera wire harness (if machine
is equipped with a rearview camera).
7. Remove the lifting gear and close the hood.
SS14H010 3
47829048B 15/06/2016
90.3 [90.100] / 5
Engine hood panel rear support - Remove

WARNING
Heavy objects!
W0398A
NOTE: The following description also includes removal of the fueling pump (optional).
1. Disconnect the two electrical lines (1) “XM4” and
“XM4.1” from the washer motors.
2. Pull off the hoses (2) from the washer pumps.
SS14H012 1
3. Cut the cable tie and loosen the cable clamp (3).
4. Loosen the hexagon-head screw (4) and pull the bow-
den cable out of the retainer (5).
SS14H013 2
5. Release the two connectors (6) and (7) on the right

under the cab floor and disconnect them.
SS12D544 3
47829048B 15/06/2016
90.3 [90.100] / 6
6. Release the connector (8) on the rear left of the cab

floor and disconnect it.
SS12D545 4
7. Loosen the hose clamp (9) and detach the coolant hose
from the engine.
8. Loosen the hose clamp (10) and detach the charge air
cooling hose from the turbocharger.
9. Loosen the hose clamp (11) and detach the coolant
hose from the coolant expansion reservoir.
10. Loosen the hose clamp (12).
11. Loosen the screws of the bracket that fixes the tank
filler neck to the rear panel.
SS14E246 5
12. If the fueling pump is installed:

• Detach the electrical lines from the pressure switch
(16).
• Detach the fuel filler hose (17) from the fuel tank
filler neck.
• Open the chain (18) of the suction line.
• Loosen the screws (23) and remove the bracket
(24) of the suction line.
• Loosen the screws (25) and remove the filling pump
(26).
SS14H014 6
13. Loosen the clamp (20) and remove the coolant hose.
SS12D548 7
47829048B 15/06/2016
90.3 [90.100] / 7
14. Loosen the hose clamp (21) of the air intake hose at
the turbocharger and pull off the air intake hose.
SS14F022 8
15. Secure the rear panel (22) with lifting gear.

16. Loosen the three mounting bolts on each side.
17. When raising the rear panel (22), check that it is not
catching on any cables or hoses.
SS14F021 9
47829048B 15/06/2016
90.3 [90.100] / 8
Engine hood panel rear support - Install

WARNING
Heavy objects!
W0398A
1. Using the lifting gear, lift the rear panel (22) onto the
frame and fasten it to the frame with the three mounting
bolts on both sides.
When placing the rear panel (22), check that it is not
catching on any cables or hoses.
SS14F021 1
2. Push the air intake hose of the air filter onto the tur-
bocharger.
3. Fasten the hose clamp (21) of the air intake hose at the
turbocharger.
NOTE: Attach the hose clamp.
SS14F022 2
4. Using an angle piece, check on both sides that the rear

panel is set at the correct angle to the frame.
Maximum deviation X = 4 mm (0.2 in) at the top edge.
If the gap is larger than 4 mm (0.2 in), then use shims
to even out the gap.
SS14F020 3
47829048B 15/06/2016
90.3 [90.100] / 9
5. If a fueling pump is installed:

• Install the filling pump (26) and fasten the screws
(25).
• Install the bracket (24) of the suction line and fasten
the screws (23).
• Fasten the suction line with the chain (18).
• Fasten the fuel filler hose (17) to the fuel filler neck.
• Fasten the electrical lines to the pressure switch
(16).
SS14H014 4
6. Fasten the coolant hose to the rear panel using the

clamp (20).
SS12D548 5
7. Push the coolant hose onto the engine and fasten it

with the hose clamp (9).
8. Push the charge air cooling hose onto the turbocharger
and fasten it with the hose clamp (10).
9. Push the hose onto the coolant expansion reservoir
and fasten it with the hose clamp (11).
10. Fasten the hose to the rear panel using the clamp (12).
11. Fasten the tank filler neck to the rear panel using the
bracket and the screws.
SS14E246 6
12. Insert the connector (8) into the socket at the rear
left of the cab floor and press the connector locking
mechanism down.
SS12E017 7
47829048B 15/06/2016
90.3 [90.100] / 10
13. Connect the cables to the sockets (6) and (7) on the
right under the cab floor, and lock them.
SS12D544 8
14. Loosen the hexagon head screw (4), if necessary, and

pass the bowden cable through the retainer (5).
15. Attach the cable to the release lever of the hood-lock-
ing mechanism, by using the screw (4) and addition-
ally the cable clamp (3).
SS14H013 9
16. Connect the two electrical lines (1) for the washer mo-
tors, identified by “XM4” (front washer) and “XM4.1”
(rear washer).
17. Push the hoses (2) for the spray nozzles onto the
washer pumps.
SS14H012 10
47829048B 15/06/2016
90.3 [90.100] / 11
Index

Engine hood panel rear support - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine hood panel rear support - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hood - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hood - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47829048B 15/06/2016
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47829048B 15/06/2016
90.3 [90.100] / 13
47829048B 15/06/2016
EN
SPECIAL TOOL INDEX
Genuine Reference PAGE

5870 350 000 [Assembly Car] Powershift transmission - Special tools 21.1 / 3
5870 350 063 [Holding Powershift transmission - Special tools 21.1 / 3
Fixtures]
5873 042 004 [Socket Wrench] Powershift transmission - Special tools 21.1 / 3
5873 042 002 [Socket Wrench] Powershift transmission - Special tools 21.1 / 4
5870 204 063 [Torx Adjusting Powershift transmission - Special tools 21.1 / 4
Screws (M6)]
5870 204 002 [Eye Bolt Lifting Powershift transmission - Special tools 21.1 / 4
Device]
5870 204 036 [Torx Adjusting Powershift transmission - Special tools 21.1 / 4
Screws]
5870 345 107 [Locking Plate Powershift transmission - Special tools 21.1 / 5
Assembling Aid]
5870 287 007 [HD Hand Powershift transmission - Special tools 21.1 / 5
Pump]
5870 950 101 [Mini Powershift transmission - Special tools 21.1 / 5
Measurement Coupling]
0636 804 003 [Ring Bolt M20] Powershift transmission - Special tools 21.1 / 5
0664 462 774 [Ring Nut M12] Powershift transmission - Special tools 21.1 / 6
5870 600 003 [Rolling Tool Powershift transmission - Special tools 21.1 / 6
(Suction Tube)]
5870 026 100 [Puller Insert] Powershift transmission - Special tools 21.1 / 6
5873 001 057 [Grab Sleeve] Powershift transmission - Special tools 21.1 / 6
5873 011 011 [Quick Gripper] Powershift transmission - Special tools 21.1 / 7
5870 300 028 [Idler Gear Powershift transmission - Special tools 21.1 / 7
Separator]
Assembling Aid]
5873 001 000 [Basic Set Of Powershift transmission - Special tools 21.1 / 7
Tools]
5873 001 058 [Grab Sleeve, Powershift transmission - Special tools 21.1 / 8
K3]
5873 011 014 [Quick Gripper] Powershift transmission - Special tools 21.1 / 8
5870 600 005 [Rolling Tool Powershift transmission - Special tools 21.1 / 8
(Oil Pipes)]
5870 600 006 [Housing Rear Powershift transmission - Special tools 21.1 / 8
Section Rolling Tool]
Installer]
5870 280 007 [Hand Crank] Powershift transmission - Special tools 21.1 / 9
5870 048 057 [Shaft Seal Powershift transmission - Special tools 21.1 / 9
Installer]
5870 057 011 [Seal Installer] Powershift transmission - Special tools 21.1 / 9
5870 260 002 [Handle - Driver] Powershift transmission - Special tools 21.1 / 10
5870 204 011 [Adjusting Powershift transmission - Special tools 21.1 / 10
Screws, Universal]
5870 204 007 [Adjusting Powershift transmission - Special tools 21.1 / 10
Screws (M10)]
5870 055 070 [Shaft Seal Powershift transmission - Special tools 21.1 / 10
Installer]
5870 057 010 [Locking Plate Powershift transmission - Special tools 21.1 / 11
Installer]
5870 350 000 [Assembly Car] Powershift transmission - Place on stand 21.1 / 45
5870 350 063 [Holding Powershift transmission - Place on stand 21.1 / 45
Fixtures]
5870 204 011 [Adjusting Transmission/Converter oil pump - Assemble 21.1 / 52
Screws, Universal]
47829048B 15/06/2016
5870 204 007 [Adjusting Transmission/Converter oil pump - Assemble 21.1 / 52
Screws (M10)]
5870 055 070 [Shaft Seal Transmission/Converter oil pump - Assemble 21.1 / 53
Installer]
5870 260 002 [Handle - Driver] Transmission/Converter oil pump - Assemble 21.1 / 53
5870 204 002 [Eye Bolt Lifting Input shaft coupling - Disassemble - Direct mounting 21.1 / 56
Device]
5870 204 002 [Eye Bolt Lifting Input shaft coupling - Assemble - Direct mounting 21.1 / 57
Device]
5870 204 002 [Eye Bolt Lifting Input shaft coupling - Disassemble - Separate mounting 21.1 / 58
Device]
5870 057 010 [Locking Plate Input shaft coupling - Assemble - Separate mounting 21.1 / 62
Installer]
5870 260 002 [Handle - Driver] Input shaft coupling - Assemble - Separate mounting 21.1 / 62
5870 204 002 [Eye Bolt Lifting Input shaft coupling - Assemble - Separate mounting 21.1 / 62
Device]
5870 345 107 [Locking Plate Converter oil pressure adjustment valve - Disassemble - 21.2 / 5
Assembling Aid] Temperature sensor
5870 345 107 [Locking Plate Converter oil pressure adjustment valve - Assemble - 21.2 / 7
Assembling Aid] Temperature sensor
5873 042 004 [Socket Wrench] Transmission oil filter - Remove - ZF fine filter 21.3 / 7
5870 048 057 [Shaft Seal Output shaft - Assemble - Output flange 21.4 / 13
Installer]
5870 057 011 [Seal Installer] Output shaft - Assemble - Output flange 21.4 / 13
5870 260 002 [Handle - Driver] Output shaft - Assemble - Output flange 21.4 / 13
Installer]
Installer]
5870 287 007 [HD Hand Output shaft - Assemble - Output flange 21.4 / 15
Pump]
5870 950 101 [Mini Output shaft - Assemble - Output flange 21.4 / 15
Measurement Coupling]
Installer]
5870 204 011 [Adjusting Output shaft - Assemble - Output flange 21.4 / 17
Screws, Universal]
Installer]
Installer]
Installer]
5870 506 099 [Gear Centring Output shaft - Assemble - Output flange 21.4 / 22
Sleeve]
0636 804 003 [Ring Bolt M20] Internal components - Remove - Drive shaft, output shaft and 21.4 / 25
clutches
0664 462 774 [Ring Nut M12] Internal components - Remove - Drive shaft, output shaft and 21.4 / 25
clutches
0636 804 003 [Ring Bolt M20] Internal components - Remove - Drive shaft, output shaft and 21.4 / 26
clutches
0664 462 774 [Ring Nut M12] Internal components - Remove - Drive shaft, output shaft and 21.4 / 26
clutches
5870 600 003 [Rolling Tool Internal components - Remove - Drive shaft, output shaft and 21.4 / 27
(Suction Tube)] clutches
5870 026 100 [Puller Insert] Internal components - Disassemble - Clutch KV 21.4 / 29
5873 001 057 [Grab Sleeve] Internal components - Disassemble - Clutch KV 21.4 / 29
47829048B 15/06/2016
5873 011 011 [Quick Gripper] Internal components - Disassemble - Clutch KV 21.4 / 29
5870 300 028 [Idler Gear Internal components - Disassemble - Clutch KV 21.4 / 30
Separator]
5870 026 100 [Puller Insert] Internal components - Disassemble - Clutch KV 21.4 / 31
5873 001 057 [Grab Sleeve] Internal components - Disassemble - Clutch KV 21.4 / 31
5873 011 011 [Quick Gripper] Internal components - Disassemble - Clutch KV 21.4 / 31
5870 345 088 [Idler Gear Internal components - Disassemble - Clutch KV 21.4 / 32
Assembling Aid]
5870 026 100 [Puller Insert] Internal components - Disassemble - Clutch KR 21.4 / 33
5873 001 057 [Grab Sleeve] Internal components - Disassemble - Clutch KR 21.4 / 33
5873 011 011 [Quick Gripper] Internal components - Disassemble - Clutch KR 21.4 / 33
5870 300 028 [Idler Gear Internal components - Disassemble - Clutch KR 21.4 / 34
Separator]
5870 026 100 [Puller Insert] Internal components - Disassemble - Clutch KR 21.4 / 35
5873 001 057 [Grab Sleeve] Internal components - Disassemble - Clutch KR 21.4 / 35
5873 011 011 [Quick Gripper] Internal components - Disassemble - Clutch KR 21.4 / 35
5870 345 088 [Idler Gear Internal components - Disassemble - Clutch KR 21.4 / 36
Assembling Aid]
5870 026 100 [Puller Insert] Internal components - Disassemble - Clutch K1 21.4 / 37
5873 001 057 [Grab Sleeve] Internal components - Disassemble - Clutch K1 21.4 / 37
5873 011 011 [Quick Gripper] Internal components - Disassemble - Clutch K1 21.4 / 37
5870 345 088 [Idler Gear Internal components - Disassemble - Clutch K1 21.4 / 39
Assembling Aid]
Assembling Aid]
Assembling Aid]
Assembling Aid]
5873 001 000 [Basic Set Of Internal components - Disassemble - Input shaft 21.4 / 53
Tools]
5873 001 058 [Grab Sleeve, Internal components - Disassemble - Input shaft 21.4 / 53
K3]
5873 011 014 [Quick Gripper] Internal components - Disassemble - Input shaft 21.4 / 53
5873 001 058 [Grab Sleeve, Internal components - Disassemble - Input shaft 21.4 / 53
K3]
5870 026 100 [Puller Insert] Internal components - Disassemble - Input shaft 21.4 / 53
5873 011 014 [Quick Gripper] Internal components - Disassemble - Input shaft 21.4 / 53
5873 001 000 [Basic Set Of Internal components - Disassemble - Drive shaft 21.4 / 54
Tools]
47829048B 15/06/2016
5873 001 058 [Grab Sleeve, Internal components - Disassemble - Drive shaft 21.4 / 54
K3]
5873 011 014 [Quick Gripper] Internal components - Disassemble - Drive shaft 21.4 / 54
5873 001 000 [Basic Set Of Internal components - Disassemble - Drive shaft 21.4 / 54
Tools]
5873 001 058 [Grab Sleeve, Internal components - Disassemble - Drive shaft 21.4 / 54
K3]
5873 011 014 [Quick Gripper] Internal components - Disassemble - Drive shaft 21.4 / 54
5870 345 088 [Idler Gear Internal components - Assemble - Clutch KV 21.4 / 59
Assembling Aid]
5870 345 088 [Idler Gear Internal components - Assemble - Clutch KV 21.4 / 59
Assembling Aid]
5870 345 088 [Idler Gear Internal components - Assemble - Clutch KR 21.4 / 64
Assembling Aid]
5870 345 088 [Idler Gear Internal components - Assemble - Clutch KR 21.4 / 64
Assembling Aid]
5870 345 088 [Idler Gear Internal components - Assemble - Clutch K1 21.4 / 68
Assembling Aid]
Assembling Aid]
Assembling Aid]
Assembling Aid]
Assembling Aid]
Assembling Aid]
Assembling Aid]
5870 600 003 [Rolling Tool Internal components - Install - Drive shaft, output shaft, and 21.4 / 91
(Suction Tube)] clutches
5870 600 005 [Rolling Tool Internal components - Install - Drive shaft, output shaft, and 21.4 / 91
(Oil Pipes)] clutches
5870 600 006 [Housing Rear Internal components - Install - Drive shaft, output shaft, and 21.4 / 92
Section Rolling Tool] clutches
0664 462 774 [Ring Nut M12] Internal components - Install - Drive shaft, output shaft, and 21.4 / 94
clutches
0636 804 003 [Ring Bolt M20] Internal components - Install - Drive shaft, output shaft, and 21.4 / 94
clutches
0664 462 774 [Ring Nut M12] Internal components - Install - Drive shaft, output shaft, and 21.4 / 95
clutches
0636 804 003 [Ring Bolt M20] Internal components - Install - Drive shaft, output shaft, and 21.4 / 95
clutches
5870 345 089 [Idler Gear Internal components - Install - Drive shaft, output shaft, and 21.4 / 96
Installer] clutches
5870 280 007 [Hand Crank] Internal components - Install - Drive shaft, output shaft, and 21.4 / 96
clutches
2897043 [Axle Hubs Powered front axle - Special tools 25.1 / 6
Disassembly Tool]
2897045 [Articulated Joint Powered front axle - Special tools 25.1 / 6
Bearing Extractor]
2897043 [Axle Hubs Wheel hub - Disassemble - Hub and transmission 25.2 / 19
Disassembly Tool]
2897043 [Axle Hubs Wheel hub - Disassemble - Hub and transmission 25.2 / 20
Disassembly Tool]
4A94740 [Retaining Bracket Planetary and final drives - Remove - Wheel drive and brake 27.2 / 4
For Disassembly / Assembly
Of Wheel Drive]
4A95443 [Fitting Tool For Planetary and final drives - Install - Wheel drive and brake 27.2 / 7
Shaft Seal]
47829048B 15/06/2016
4904506 [Mounting Tool For Planetary and final drives - Install - Wheel drive and brake 27.2 / 8
Spring Plate Retaining Ring]
4A94740 [Retaining Bracket Planetary and final drives - Install - Wheel drive and brake 27.2 / 10
Of Wheel Drive]
4A94740 [Retaining Bracket Planetary and final drives - Install - Wheel drive and brake 27.2 / 10
Of Wheel Drive]
4A95322 [Mounting Tool For Planetary and final drives - Install - Wheel drive and brake 27.2 / 11
Chain Master Link]
4A95322 [Mounting Tool For Planetary and final drives - Install - Wheel drive and brake 27.2 / 11
Chain Master Link]
4904506 [Mounting Tool For Tandem axle - Special tools 27.3 / 5
Spring Plate Retaining Ring]
4904506/00 [Mounting Tool] Tandem axle - Special tools 27.3 / 5
4A94740 [Retaining Bracket Tandem axle - Special tools 27.3 / 5
Of Wheel Drive]
4A95322 [Mounting Tool For Tandem axle - Special tools 27.3 / 5
Chain Master Link]
4A95443 [Fitting Tool For Tandem axle - Special tools 27.3 / 5
Shaft Seal]
4A95322 [Mounting Tool For Chain drive - Install 27.4 / 5
Chain Master Link]
4A95322 [Mounting Tool For Chain drive - Install 27.4 / 5
Chain Master Link]
5873 042 002 [Socket Wrench] Electro-hydraulic control valve - Disassemble - Control unit 35.6 / 3
5870 204 063 [Torx Adjusting Electro-hydraulic control valve - Disassemble - Control unit 35.6 / 3
Screws (M6)]
Screws (M6)]
Screws]
Screws]
5870 204 036 [Torx Adjusting Electro-hydraulic control valve - Assemble - Control unit 35.6 / 9
Screws]
5873 042 002 [Socket Wrench] Electro-hydraulic control valve - Assemble - Control unit 35.6 / 10
Screws]
Screws]
Screws (M6)]
Screws (M6)]
5870 204 063 [Torx Adjusting Electro-hydraulic control valve - Assemble - Converter coupling 35.6 / 17
Screws (M6)] valve
2897045 [Articulated Joint Cylinders - Disassemble - Wheel lean cylinder 41.3 / 7
Bearing Extractor]
2897045 [Articulated Joint Cylinders - Disassemble - Wheel lean cylinder 41.3 / 8
Bearing Extractor]
47829048B 15/06/2016
2897045 [Articulated Joint Cylinders - Assemble - Wheel lean cylinder 41.3 / 12
Bearing Extractor]
2897045 [Articulated Joint Cylinders - Assemble - Wheel lean cylinder 41.3 / 12
Bearing Extractor]
Dealer Made Reference PAGE
2897044 [Steering Cylinder Powered front axle - Special tools 25.1 / 6
Joint Disassembley Tool]
2897044 [Steering Cylinder Steering cylinder - Disassemble 41.3 / 15
Joint Disassembley Tool]
47829048B 15/06/2016
47829048B 15/06/2016
47829048B 15/06/2016
EN

Motor Grader: 836C 836C AWD 856C 856C AWD Stage IV

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Motor Grader: 836C 836C AWD 856C 856C AWD Stage IV

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SERVICE MANUAL

1/1 SERVICE MANUAL

Part number 47829048B

Product Market Product Engine

[10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

[10.501] Exhaust Gas Recirculation (EGR) exhaust treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5

[21.135] Powershift transmission external controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2

[21.105] Powershift transmission lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3

[21.155] Powershift transmission internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4

[21.700] Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5

Front axle system ....................................................................... 25

[25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2

Rear axle system........................................................................ 27

[27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2

[27.600] Tandem axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3

[27.650] Chain drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.4

[29.218] Pump and motor components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.2

Brakes and controls .................................................................... 33

[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2

[35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3

[35.102] Pump control valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4

[35.105] Charge pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5

[35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6

[35.354] Hydraulic central joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7

[35.739] Swing arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8

[35.741] Dozer blade cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9

[35.742] Ripper hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10

[35.310] Distributor and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.11

Frames and ballasting ................................................................. 39

[41.206] Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2

[41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3

[44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2

Cab climate control ..................................................................... 50

Electrical systems ....................................................................... 55

[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2

[55.988] Selective Catalytic Reduction (SCR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4

[55.989] Exhaust Gas Recirculation (EGR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5

[55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6

[55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7

[55.530] Camera. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8

[55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9

[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10

Dozer blade and arm................................................................... 86

[86.112] Moldboard blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.2

Platform, cab, bodywork, and decals ............................................. 90

[90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2

[90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3

Foreword - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(*) See content for specific models

Foreword - Important notice regarding equipment servicing

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT

Repairs have to be carried out only by authorized and in-

Not authorized persons are not allowed to repair or carry

Ask your employer about the safety instructions in force

Nobody should be allowed in the cab during machine

If it is necessary to move the equipment to carry out re-

Stop the engine and ensure that all pressure is relieved

All repair and maintenance operations should be carried

Service stairs and platforms used in a workshop or in the

Any functional disorders, especially those affecting the

Before performing any work on the machine, attach a